Low-Temperature Cured Spark Plug Suppressor for EMI Reduction
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Solution Overview
Problem
Existing spark plug technologies fail to effectively suppress electromagnetic interference (EMI) and radio frequency interference (RFI) generated by ignition sparks, which can interfere with engine control systems and other electronic devices, and often require high-temperature manufacturing processes that are costly and inefficient.
Innovation Solution
A spark plug design incorporating a suppressor precursor liquid with dispersed particles or grains in a matrix of conducting, semiconducting, or non-conducting materials, cured at a low temperature below 300°C, which forms a resistive component embedded in a glass seal within the insulator bore to minimize EMI and RFI, while providing a hermetic seal and improved manufacturing consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional high-temperature manufacturing processes are used for spark plug suppressors, then the suppressor can effectively seal components, but the manufacturing cost increases and manufacturing complexity increases
Solution Approach 1:
The patent changes the temperature parameter from traditional high-temperature firing (above 800°C) to low-temperature curing (below 300°C). This parameter change allows the suppressor to achieve adequate sealing effectiveness while dramatically reducing manufacturing cost and complexity, as low-temperature curing does not require expensive high-temperature furnaces and can be performed using simpler heating equipment
Solution Approach 2:
The patent employs composite materials consisting of ceramic particles (such as alumina, silica, or zirconia) dispersed in a glass matrix. This composite structure provides both the sealing effectiveness traditionally associated with high-temperature fired materials and the low-temperature processability needed for cost-effective manufacturing. The glass matrix binds the ceramic particles together at low temperatures while maintaining the sealing properties
2Reliability
If traditional high-temperature manufacturing processes are used for spark plug suppressors, then the suppressor can achieve adequate sealing, but the manufacturing time increases and productivity decreases
Solution Approach 1:
The patent changes the temperature parameter from traditional high-temperature firing (above 800°C) to low-temperature curing (below 300°C). This parameter change significantly reduces the manufacturing time required, as low-temperature curing can be completed much faster than high-temperature firing cycles, thereby increasing overall productivity and manufacturing efficiency
Solution Approach 2:
The suppressor precursor liquid is prepared in advance with the ceramic particles and glass matrix pre-mixed in the correct proportions. This preliminary preparation allows the suppressor to be quickly applied and cured without requiring time-consuming on-site mixing or preparation steps, further enhancing manufacturing efficiency
3Manufacturing precision
If suppressor precursor liquid with dispersed particles is used, then manufacturing consistency improves, but the formulation complexity increases
Solution Approach 1:
The patent uses a liquid precursor formulation where ceramic particles are suspended in a glass matrix liquid. This liquid state allows for easy mixing, pouring, and filling of the suppressor into the spark plug insulator bore. The liquid formulation ensures uniform distribution of ceramic particles throughout the suppressor volume, improving manufacturing consistency and reducing variability between batches
Solution Approach 2:
The patent changes the physical state of the suppressor material from solid (traditional powder or rod) to liquid (precursor liquid). This parameter change simplifies the manufacturing process by allowing the suppressor to be easily formed and shaped during the liquid state, then cured to the final solid form. The liquid state enables better wetting and adhesion to surrounding components while ensuring uniform particle distribution
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 solution effectively reduces EMI and RFI, offers improved manufacturing efficiency and cost reduction by eliminating high-temperature processes, and ensures uniformity and consistency in suppressor production, suitable for various ignition devices including automotive and industrial spark plugs.
Implementation Method 1
curing the suppressor precursor liquid at a temperature below 300° C.
Implementation Method 2
the suppressor is designed to reduce the amount of electromagnetic interference (EMI) produced by the spark plug when it is used in an engine... absorbing interfering electromagnetic waves
Data Source
AI summary
A spark plug suppressor and a method of producing a spark plug suppressor from a suppressor precursor liquid that may be cured at a temperature below 300° C. The spark plug suppressor may include particles or grains dispersed in a matrix of electrically conducting material, electrically semiconducting material, or electrically non-conducting material. The suppressor may include a conductive glass seal component and a resistive suppressor component. The resistive suppressor component may be at least partially embedded in the glass seal component, and the glass seal component may seal a center electrode of the spark plug, a terminal of the spark plug, or both the center electrode and the terminal.