Spark Plug Center Electrode Coupling for Heat Dissipation

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Solution Overview

Problem

Existing spark plugs with large center electrode heads made from non-precious metals face thermal issues, leading to physical failure and shortened lifetimes, while precious metal spark plugs are costly and do not provide optimal engine performance.

Innovation Solution

A spark plug design featuring a large center electrode head formed from nickel-alloys, with a circumferential edge that forms a spark gap with a circumferentially extending side electrode, utilizing a threaded connection and conductive glass powder to secure the electrode head to the wire, enhancing heat dissipation and durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a large center electrode head made from non-precious metals is used, then cost is reduced and engine performance is improved, but thermal issues occur leading to physical failure and shortened lifetime

Engineering Contradiction:

ImprovecostVSAvoidoperational lifetime

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The center electrode is divided into two distinct segments: a large center electrode head made from cost-effective nickel-alloys for optimal engine performance, and a center electrode wire made from heat-resistant iridium. This segmentation allows each component to be optimized for its specific function while managing thermal loads appropriately.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The spark plug employs a composite structure combining nickel-alloy material for the electrode head with iridium material for the wire. This composite approach leverages the high thermal conductivity and cost advantages of nickel-alloys in the head while using iridium's superior heat resistance in the wire portion subjected to highest thermal stress.

Inventive Principle:

Principle #40Composite materials

2Power

If a large center electrode head is used, then engine performance is improved, but thermal issues lead to physical failure

Engineering Contradiction:

Improveengine performanceVSAvoidheat dissipation

Core Design Contradiction:

PowerVSTemperature

Solution Approach 1:

Different materials with appropriate thermal properties are applied to different locations: nickel-alloy with high thermal conductivity is used in the electrode head where heat generation occurs and needs rapid dissipation, while iridium with superior heat resistance is used in the wire portion exposed to the highest combustion temperatures.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The composite structure combines nickel-alloy and iridium materials to achieve optimal thermal management, allowing the electrode head to efficiently dissipate heat while the wire withstands extreme thermal conditions.

Inventive Principle:

Principle #40Composite materials

3Reliability

If precious metal spark plugs are used, then operational lifetime is extended, but cost increases and engine performance is reduced

Engineering Contradiction:

Improveoperational lifetimeVSAvoidengine performance

Core Design Contradiction:

ReliabilityVSPower

Solution Approach 1:

The electrode structure is segmented to concentrate the precious iridium material only in the wire portion where it is most needed for heat resistance and durability, while the electrode head is made from affordable nickel-alloy to maintain optimal engine performance and enable cost-effective replacement of the more expensive wire component if needed.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention changes the material composition parameters by using nickel-alloy instead of precious metals in the electrode head, fundamentally altering the cost-performance-thermal management balance while maintaining operational lifetime through the iridium wire.

Inventive Principle:

Principle #35Parameter changes

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

The design achieves a longer operational life comparable to iridium spark plugs while maintaining improved engine performance and reduced costs, with enhanced heat dissipation and structural integrity.

Implementation Method 1

utilizing a threaded connection and conductive glass powder to secure the electrode head to the wire, enhancing heat dissipation and durability

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

enhancing heat dissipation and durability

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11916357B2Spark plug with mechanically and thermally coupled center electrode

Publication Date: 2024.02.27 ECOPOWER SPARK LLC

AI summary

A spark plug including a terminal end, a firing end, an axial centerline extending between the terminal end and the firing end, and an insulative core extending between the terminal end and the firing end. The insulative core includes a central bore coincident with the axial centerline extending through the insulative core, and an insulative nose extending along the axial centerline at the firing end of the insulative core, the insulative nose having an axial length and defining an end surface of the insulative core, wherein a cross-sectional area of the insulative nose perpendicular to the axial centerline varies along the axial length of the insulative nose with a cross-sectional area along at least a portion of the axial length being less than a surface area of the end surface so that a perimeter surface along the portion of the axial length of the insulative nose has a concave profile.