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.

A spark plug is provided that includes an improved jamb nut configuration, which provides improved torque transfer and prevents inadvertent separation of the jamb nut from the remaining components of the spark plug, particularly during removal from the engine head. The spark plug is configured for axial insertion into the plug hole, and may have a non-axisymmetric ground shield that fits into the plug hole, wherein the plug hole is also provided with a complementary non-axisymmetric shape. The spark plug includes a central insulator, which has an inner end surrounding a central electrode and supporting the ground shield, which is mounted on the insulator to support a ground strap adjacent the electrode for forming a spark therebetween. The insulator and ground shield are axially slidable into the plug hole, and the jamb nut is rotatable to fix the spark plug in position in a predefined orientation. The insulator includes a retaining clip outwardly of the jamb nut that permits rotation of the jamb nut relative to the insulator but prevents axial separation of the jamb nut during removal of the spark plug from the engine head. An improved tool is also provided which better distributes torque transfer to the jamb nut and includes a catch to facilitate pulling of the spark plug from the engine head.

A spark plug is provided that includes an improved jamb nut configuration, which provides improved torque transfer and prevents inadvertent separation of the jamb nut from the remaining components of the spark plug, particularly during removal from the engine head. The spark plug is configured for axial insertion into the plug hole, and may have a non-axisymmetric ground shield that fits into the plug hole, wherein the plug hole is also provided with a complementary non-axisymmetric shape. The spark plug includes a central insulator, which has an inner end surrounding a central electrode and supporting the ground shield, which is mounted on the insulator to support a ground strap adjacent the electrode for forming a spark therebetween. The insulator and ground shield are axially slidable into the plug hole, and the jamb nut is rotatable to fix the spark plug in position in a predefined orientation. The insulator includes a retaining clip outwardly of the jamb nut that permits rotation of the jamb nut relative to the insulator but prevents axial separation of the jamb nut during removal of the spark plug from the engine head. An improved tool is also provided which better distributes torque transfer to the jamb nut and includes a catch to facilitate pulling of the spark plug from the engine head.

A spark plug is provided that ensures that a ground electrode is positioned in a predefined, precise orientation when installed in a spark plug hole of an engine head. The spark plug is configured for axial insertion into the plug hole, and has a non-axisymmetric ground shield that fits into the plug hole, wherein the ground shield has an outer shield surface with a non-axisymmetric shape and the plug hole is also provided with a complementary non-axisymmetric shape. The spark plug includes a central insulator, which has an inner end surrounding a central electrode and supporting the ground shield, which is mounted on the insulator to support a ground strap adjacent the electrode for forming a spark therebetween. The insulator and ground shield are axially slidable into the plug hole, and the spark plug includes a jamb nut which is rotatable to fix the spark plug in position in a predefined orientation. Preferably, an outer surface of the insulator and an inner surface of the ground shield have complementary shapes wherein the ground shield fits closely on the insulator. For example, the outer insulator surface and the inner shield surface may have a complementary axisymmetric shape, such as cylindrical, or a non-axisymmetric shape, which may conform to the non-axisymmetric shape of the outer shield surface.

A spark plug is provided that ensures that a ground electrode is positioned in a predefined, precise orientation when installed in a spark plug hole of an engine head. The spark plug is configured for axial insertion into the plug hole, and has a non-axisymmetric ground shield that fits into the plug hole, wherein the ground shield has an outer shield surface with a non-axisymmetric shape and the plug hole is also provided with a complementary non-axisymmetric shape. The spark plug includes a central insulator, which has an inner end surrounding a central electrode and supporting the ground shield, which is mounted on the insulator to support a ground strap adjacent the electrode for forming a spark therebetween. The insulator and ground shield are axially slidable into the plug hole, and the spark plug includes a jamb nut which is rotatable to fix the spark plug in position in a predefined orientation. Preferably, an outer surface of the insulator and an inner surface of the ground shield have complementary shapes wherein the ground shield fits closely on the insulator. For example, the outer insulator surface and the inner shield surface may have a complementary axisymmetric shape, such as cylindrical, or a non-axisymmetric shape, which may conform to the non-axisymmetric shape of the outer shield surface.

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.

A spark plug has a housing, an insulator, a central electrode and a ground electrode. A projection part is formed projecting radially from the housing. The spark plug has a structure which satisfies a relationship of t2/t10.85, s10.5, and s11.05t2/t1. A leg part of the insulator has a first end and a second end in an axial direction thereof. The second end is located opposite to the first end in the axial direction. In the relationship, t1 represents a first radial thickness of the first end in a radial direction of the leg part, t2 represents a center radial thickness in the radial direction at a middle position of the leg part, and s1 represents a first gap width in the radial direction of the housing between the projection part of the housing and the first end of the leg part.

A spark plug has a housing, an insulator, a central electrode and a ground electrode. A projection part is formed projecting radially from the housing. The spark plug has a structure which satisfies a relationship of t2/t10.85, s10.5, and s11.05t2/t1. A leg part of the insulator has a first end and a second end in an axial direction thereof. The second end is located opposite to the first end in the axial direction. In the relationship, t1 represents a first radial thickness of the first end in a radial direction of the leg part, t2 represents a center radial thickness in the radial direction at a middle position of the leg part, and s1 represents a first gap width in the radial direction of the housing between the projection part of the housing and the first end of the leg part.

A spark plug including a cylindrical insulator having a step portion; a center electrode provided in an axial hole of the insulator; and a cylindrical metal shell having a ledge portion, the metal shell holding the insulator from an outer circumferential side in a state in which the step portion is engaged with the ledge portion via a packing, wherein a recess is formed on a part contacting with the packing, of one of the step portion and the ledge portion, and a projection which at least partially overlaps the recess in the axial-line direction is formed on a part contacting with the packing, of the other of the step portion and the ledge portion.