High-Strength Ceramic Insulators for Miniaturized Spark Plugs
Here’s PatSnap Eureka !
Summary
Problems
Current spark plug insulators struggle to meet increasing voltage requirements while maintaining a smaller size, as they often have limitations in dielectric strength and mechanical strength due to poor consolidation of ceramic materials, leading to issues with thinner cross-sections and crescent-shaped voids.
Innovation solutions
The development of high purity alumina ceramic bodies with a single-phase crystal structure and reduced porosity, manufactured using injection molding or specialized pressing methods, which enhance dielectric strength and allow for thinner cross-sections while maintaining mechanical integrity, enabling proportional increases in other components' thicknesses.
TRIZ Analysis
Specific contradictions:
General conflict description:
Principle concept:
If the radial thickness of the insulator is reduced to enable smaller spark plug sizes (M10), then the size requirement is met, but the dielectric strength and mechanical strength deteriorate due to poor consolidation of ceramic materials
Why choose this principle:
The patent changes the physical and chemical parameters of the ceramic material by using high purity alumina with controlled grain size (less than 10 microns, preferably less than 5 microns) and density (greater than 98% of theoretical density). These parameter changes enable the ceramic body to achieve sufficient dielectric strength even at reduced thicknesses, resolving the contradiction between miniaturization and reliability.
Principle concept:
If the radial thickness of the insulator is reduced to enable smaller spark plug sizes (M10), then the size requirement is met, but the dielectric strength and mechanical strength deteriorate due to poor consolidation of ceramic materials
Why choose this principle:
The patent employs a composite ceramic material system consisting of high purity alumina with specific grain size distribution and density characteristics. This composite material structure provides both the mechanical integrity needed for thin sections and the dielectric properties required for high voltage operation, enabling smaller spark plug sizes without sacrificing reliability.
Application Domain
Data Source
AI summary:
The development of high purity alumina ceramic bodies with a single-phase crystal structure and reduced porosity, manufactured using injection molding or specialized pressing methods, which enhance dielectric strength and allow for thinner cross-sections while maintaining mechanical integrity, enabling proportional increases in other components' thicknesses.
Abstract
A spark plug and method of manufacturing, where the spark plug meets particular geometric relationships to maintain and potentially improve dielectric performance while downsizing other plug dimensions. The spark plug includes an insulator that can withstand higher voltages while having areas with a reduced cross-sectional thickness. In some embodiments, the insulator has a dielectric strength of 42 kV/mm or more with a radial thickness at the internal seal of 1.5 to 1.6 mm, inclusive, and a radial thickness at a gasket of 0.6 to 0.9 mm, inclusive.