Spark Plug Ground Electrode X-Position Regulation

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Solution Overview

Problem

Conventional methods for manufacturing internal combustion spark plugs struggle to maintain a constant X-directional position of the ground electrode's front end surface with respect to the center electrode, leading to deviations in ignition timing and reduced combustion efficiency.

Innovation Solution

A method involving a cylindrical insulator, center electrode, and metal shell with a regulation member that measures and adjusts the X-directional position of the ground electrode's front end surface during the manufacturing process to ensure precise positioning and minimize deviations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the ground electrode is pressed and bent without regulating the X-directional position, then the manufacturing process is simple, but the X-directional position of the front end surface of the ground electrode deviates from the predetermined position

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidX-directional position accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The regulation member is positioned in advance at a predetermined X-directional position before the ground electrode is pressed and bent. This preliminary positioning ensures that when the ground electrode is formed, its front end surface automatically achieves the correct X-directional position relative to the center electrode, eliminating the need for post-assembly adjustments and maintaining manufacturing simplicity while ensuring precision.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A regulation member is introduced as an intermediary tool during the gap forming process. This regulation member contacts the ground electrode and constrains its X-directional position during bending, serving as a mediator between the pressing force and the ground electrode to ensure accurate positioning without complicating the overall manufacturing process.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If the X-directional position of the ground electrode is regulated during assembly, then the ignition timing accuracy is improved, but the assembly complexity increases

Engineering Contradiction:

Improveignition timing accuracyVSAvoidassembly process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The regulation member is positioned in advance at the correct X-directional location before the ground electrode bending operation. This preliminary setup ensures that the ground electrode is formed with the correct position relative to the center electrode, achieving accurate ignition timing without requiring complex post-assembly adjustments or additional positioning mechanisms.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The positioning function and the gap forming function are merged into a single operation. The regulation member simultaneously serves as both a positioning constraint and a forming tool during the ground electrode bending process, eliminating the need for separate positioning and assembly steps, thus improving ignition timing accuracy without significantly increasing assembly complexity.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If the ground electrode is pressed and bent to form the spark gap, then the spark gap is formed, but the X-directional position of the front end surface of the ground electrode cannot be controlled

Engineering Contradiction:

Improvegap forming capabilityVSAvoidX-directional position control

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The regulation member acts as an intermediary constraint during the gap forming process. It contacts the ground electrode and prevents it from moving in the X-direction during bending, thereby controlling the X-directional position of the front end surface while still allowing the spark gap to be formed between the ground electrode and center electrode.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The regulation member is positioned in advance at the predetermined X-directional position before the pressing and bending operation begins. This preliminary positioning ensures that as the ground electrode is formed into the spark gap, its front end surface automatically achieves the correct X-directional position, maintaining both gap forming capability and position control.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS7581998B2Method for regulating aground electrode position in spark plug

Publication Date: 2009.09.01 NITERRA CO LTD

AI summary

A method and apparatus for manufacturing a spark plug, the spark plug being defined herein, the method including a center electrode position measuring step of measuring an X-directional position of the front end of the center electrode; a regulation member positioning step of positioning an X-directional position of a regulation member based on the X-directional position of the front end of the center electrode measured in the center electrode position measuring step, the regulation member regulating an X-directional position of a front end surface of the ground electrode when the ground electrode is pressed and bent in a Y direction; and a gap forming step of using the regulation member to regulate the X-directional position of the front end surface of the ground electrode while pressing and bending the ground electrode in the Y direction so as to form the spark discharge gap; wherein: the X direction and the Y direction are as defined herein.