Federal-Mogul Ignition Gmbh

Daniel Konig

Werner Niessner

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.

Method of manufacturing spark plug electrode with electrode tip directly thermally coupled to heat dissipating core

A spark plug electrode with an electrode tip formed on an electrode base using an additive manufacturing process, such as a powder bed fusion technique. The spark plug electrode includes an intermediate layer located between the electrode tip and the electrode base, where the intermediate layer has a coefficient of thermal expansion (CTE) that is between that of the electrode base and the electrode tip and includes a whole area connection. In some examples, the whole area connection is non-uniform in thickness so that it is thicker in one section than it is in another section.

Spark plug electrode and method of manufacturing the same

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

A spark plug electrode with an electrode tip formed on an electrode base using an additive manufacturing process, such as a powder bed fusion technique. The spark plug electrode includes an electrode base that at least partially surrounds a heat dissipating core, an electrode tip that is formed on the electrode base and includes a precious metal-based material, and a thermal coupling zone that directly thermally couples the electrode tip to the heat dissipating core. In some examples, the electrode tip is formed on an electrode base that has been cut or severed to expose a portion of the heat dissipating core, such that the electrode tip is formed directly on the heat dissipating core using additive manufacturing.

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Rodental, Germany

Daniel Konig