An insulator for a corona igniter, referred to as a barrier discharge ignition (BDI) device, for use in an internal combustion engine, is provided. A central electrode is disposed in a slot of the insulator and an electrode tip is spaced from a round insulator tip by insulating material. A shell formed of metal surrounds a portion of the insulator. The insulator has a thickness tapering between a shell firing surface and the insulator tip. The tapering insulator thickness is unidirectional and thus does not increase between a start of the taper and the insulator tip. A method of manufacturing an insulator for a corona igniter is also provided. Equations can be used to determine if a taper in the insulator thickness is needed to encourage corona propagation along a core nose projection of the insulator, and if so, the location and size of the taper.

In a method for manufacturing a spark plug, a space on a proximal end side of a center electrode in a shaft hole of an insulator is filled with first electrically conductive glass powder. A space on the proximal end side of the first electrically conductive glass powder in the shaft hole is filled with resistor composition powder. A space on the proximal end side of the resistor composition powder in the shaft hole is filled with second electrically conductive glass powder. The first electrically conductive glass powder, the resistor composition powder, and the second electrically conductive glass powder are sintered in the shaft hole. Prior to filling of the resistor composition powder, at least one of the insulator and the first electrically conductive glass powder is placed in an uncharged state, or the insulator and the first electrically conductive glass powder are placed in the same charged state.

In a method for manufacturing a spark plug, a space on a proximal end side of a center electrode in a shaft hole of an insulator is filled with first electrically conductive glass powder. A space on the proximal end side of the first electrically conductive glass powder in the shaft hole is filled with resistor composition powder. A space on the proximal end side of the resistor composition powder in the shaft hole is filled with second electrically conductive glass powder. The first electrically conductive glass powder, the resistor composition powder, and the second electrically conductive glass powder are sintered in the shaft hole. Prior to filling of the resistor composition powder, at least one of the insulator and the first electrically conductive glass powder is placed in an uncharged state, or the insulator and the first electrically conductive glass powder are placed in the same charged state.

A spark plug that improves the heat resistance performance of an ignition plug.

A spark plug that improves the heat resistance performance of an ignition plug.

An ignition plug comprising: an insulator having a through hole extending from a rear-end side toward a forward-end side; a center electrode inserted at least partially into a portion of the through hole on the forward-end side; a metal terminal member inserted at least partially into a portion of the through hole on the rear-end side; and a seal disposed within the through hole and in contact with the center electrode and an inner circumferential surface of the insulator. The seal contains a glass and an electrically conductive substance, and the glass contained in the seal contains Si in an amount of 50 mass % or more as reduced to SiO.sub.2 and Na in an amount of 0.1 mass % or more and less than 1 mass % as reduced to Na.sub.2O.

An ignition plug comprising: an insulator having a through hole extending from a rear-end side toward a forward-end side; a center electrode inserted at least partially into a portion of the through hole on the forward-end side; a metal terminal member inserted at least partially into a portion of the through hole on the rear-end side; and a seal disposed within the through hole and in contact with the center electrode and an inner circumferential surface of the insulator. The seal contains a glass and an electrically conductive substance, and the glass contained in the seal contains Si in an amount of 50 mass % or more as reduced to SiO.sub.2 and Na in an amount of 0.1 mass % or more and less than 1 mass % as reduced to Na.sub.2O.

An ignition plug includes a tubular insulator, a metallic shell disposed around the outer circumference of the insulator, a center electrode disposed in an axial hole of the insulator, and a ground electrode connected to the forward end of the metallic shell and facing the center electrode. The metallic shell has a threaded portion to be engaged with an internal combustion engine. The relational expression Ss/(Sa+Sb)2.6 is satisfied, where Ss is the surface area of an outer circumferential surface of the metallic shell extending from the rear end of the threaded portion to the forward end of the threaded portion, Sa is the surface area of that portion of the metallic shell which is to be exposed to combustion gas of the internal combustion engine, and Sb is the surface area of that portion of the insulator which is to be exposed to the combustion gas.

An ignition plug includes a tubular insulator, a metallic shell disposed around the outer circumference of the insulator, a center electrode disposed in an axial hole of the insulator, and a ground electrode connected to the forward end of the metallic shell and facing the center electrode. The metallic shell has a threaded portion to be engaged with an internal combustion engine. The relational expression Ss/(Sa+Sb)2.6 is satisfied, where Ss is the surface area of an outer circumferential surface of the metallic shell extending from the rear end of the threaded portion to the forward end of the threaded portion, Sa is the surface area of that portion of the metallic shell which is to be exposed to combustion gas of the internal combustion engine, and Sb is the surface area of that portion of the insulator which is to be exposed to the combustion gas.

A spark plug includes a housing, an insulator, a center electrode, and an earth electrode. The earth electrode has a gap-forming surface which forms a discharge gap between the gap-forming surface and a tip surface of the center electrode. The insulator includes an insulator protrusion protruding on the tip side of the housing in a plug axial direction. At least one of cross-sections passing through a plug center axis and parallel to the plug axial direction is referred to as an axial parallel cross-section. The outer peripheral surface of the insulator protrusion includes an insulator inclined surface extending inward toward the tip in the plug axial direction, in a straight line or a curve that is convex inward, in the axial parallel cross-section. In the axial parallel cross-section, a virtual straight line passing through both ends of the insulator inclined surface passes through the gap-forming surface.