Spark Plug Electrode Core Coupling for Tip Heat Dissipation

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Solution Overview

Problem

Spark plug electrodes face erosion and corrosion due to harsh engine environments, leading to performance degradation, particularly at the joint where precious metal tips are attached to ground electrodes, causing thermal and mechanical stresses.

Innovation Solution

A spark plug electrode design featuring a heat dissipating core within the electrode base, with the electrode tip directly thermally coupled to the core through an opening, using nickel-based materials for the base, copper-based materials for the core, and precious metals for the tip, to manage thermal stresses and extend the service life.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If precious metals are used for the entire electrode body, then erosion and corrosion resistance is improved, but manufacturing cost increases significantly

Engineering Contradiction:

Improveerosion and corrosion resistanceVSAvoidquantity of precious metals

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent applies local quality by using precious metals only at the electrode tip where the spark occurs, rather than throughout the entire electrode body. This localized application of precious material provides erosion and corrosion resistance exactly where it is needed for spark generation, while minimizing the total quantity of expensive precious metals required.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The electrode is segmented into different material zones: a precious metal tip for spark generation and durability, a nickel-based intermediate layer for thermal management, and a copper-based core for heat dissipation. This segmentation allows each section to be optimized for its specific function while reducing overall precious metal consumption.

Inventive Principle:

Principle #1Segmentation

2Quantity of substance

If precious metal tip is used without adequate cooling, then manufacturing cost is reduced, but thermal stresses and electrode wear increase

Engineering Contradiction:

Improvequantity of precious metalsVSAvoidthermal stress resistance

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The patent employs a composite material structure consisting of a precious metal tip, nickel-based intermediate layer, and copper-based heat dissipating core. This composite construction provides adequate cooling to the precious metal tip through the thermally conductive copper core, reducing thermal stresses and electrode wear while maintaining cost efficiency by limiting precious metal usage to the tip region.

Inventive Principle:

Principle #40Composite materials

3Temperature

If heat dissipating core is added to the electrode structure, then thermal energy dissipation is improved, but device complexity increases

Engineering Contradiction:

Improvethermal energy dissipationVSAvoidelectrode structure complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The heat dissipating core is merged with the electrode base structure, creating an integrated component rather than a separate assembly. The copper-based core is positioned within the nickel-based intermediate layer and extends to the electrode tip, forming a unified thermal management system that dissipates heat effectively while maintaining structural integrity and minimizing overall complexity.

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This design effectively dissipates thermal energy, reducing stress and wear on the electrode tip, allowing for the use of less expensive precious metal-based materials and improving the electrode's resistance to erosion and corrosion.

Implementation Method 1

the electrode tip is directly thermally coupled to the core extension of the heat dissipating core through the opening

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11837852B1Spark plug electrode with electrode tip directly thermally coupled to heat dissipating core and method of manufacturing the same

Publication Date: 2023.12.05 FEDERAL MOGUL IGNITION GMBH

AI summary

A spark plug electrode includes an electrode tip that is attached to or formed on an electrode base so that the electrode tip is directly thermally coupled to a heat dissipating core through an opening in the electrode base. This direct thermal coupling may take place on a side surface of a ground electrode or a center electrode and removes thermal energy away from the electrode tip in order to reduce thermal and/or other stresses. The heat dissipating core may have one or more core extensions that diverge or branch off of a core main body and extend into the opening in the electrode base for better thermal coupling to the electrode tip. The electrode tip can be attached to the electrode base via welding or it can be formed on the electrode base using a suitable additive manufacturing process, such as a powder bed fusion technique.