A spark plug combustion ionization sensor for measuring ion current inside the cylinder of an internal combustion engine. The sensor measures ion current which flows when the energy released during combustion ionizes the air inside the cylinder, and thus can detect combustion and emission parameters. The spark plug combustion ionization sensor generally includes an insulated, dedicated sensing electrode, separate from the sparking electrode of a spark plug. The sensing electrode may also be shielded to further reduce interference such as electromagnetic interference (EMI). The use of a dedicated electrode allows for ion current measurement with less electromagnetic noise from the ignition process, and also eliminates the need for circuitry that is typically necessary when the sparking electrode is also used to sense ion current.

A spark plug includes an insulative sleeve. A glaze coating is disposed on an exterior surface of the insulative sleeve. The glaze coating includes a boric acid, a borosilicate glass, a barium borate glass, a phosphorous glass, a silicate glass, or a combination thereof. The glasses are independently modified with a modifier selected from the group consisting of alkali group metals, alkali earth group metals, aluminum, silicon, a halogen, or a combination thereof. The glaze coating has a softening point between about 650° C. and about 1100° C.

A spark plug includes an insulative sleeve. A glaze coating is disposed on an exterior surface of the insulative sleeve. The glaze coating includes a boric acid, a borosilicate glass, a barium borate glass, a phosphorous glass, a silicate glass, or a combination thereof. The glasses are independently modified with a modifier selected from the group consisting of alkali group metals, alkali earth group metals, aluminum, silicon, a halogen, or a combination thereof. The glaze coating has a softening point between about 650° C. and about 1100° C.

Provided are a molding step (A) of preparing an alumina molded body 11 from a molding raw material which contains an alumina raw material powder having an average particle size of 2 m to 5 m and a molding additive, and a sintering step (B) of preparing an alumina molded body 12, which becomes a spark plug insulator 1, by sintering the alumina molded body 11. At the sintering step (B), the alumina molded body 11 is conveyed to a continuous furnace 100 provided with a heating zone Z1 which is heated to 700 C. to 1600 C. by a heating means 401, followed by introducing oxygen gas to control the heating zone Z1 to have a high oxygen atmosphere with an oxygen concentration exceeding 20 mol %.

Provided are a molding step (A) of preparing an alumina molded body 11 from a molding raw material which contains an alumina raw material powder having an average particle size of 2 m to 5 m and a molding additive, and a sintering step (B) of preparing an alumina molded body 12, which becomes a spark plug insulator 1, by sintering the alumina molded body 11. At the sintering step (B), the alumina molded body 11 is conveyed to a continuous furnace 100 provided with a heating zone Z1 which is heated to 700 C. to 1600 C. by a heating means 401, followed by introducing oxygen gas to control the heating zone Z1 to have a high oxygen atmosphere with an oxygen concentration exceeding 20 mol %.

A method of producing a cylindrical insulator for a spark plug includes a molding step of forming ceramic powder filled in a cavity defined by a mold and a molding pin into a compact. In a first removal step of removing the compact from the mold, the compact has at least one protrusion formed in at least one recess of the molding pin formed in an outer cylindrical surface of the molding pin, and the at least one protrusion is locked in the at least one recess, thereby allowing the compact to be removed with the molding pin from the mold. In a second removal step of removing the molding pin from the compact, the molding pin is turned or rotated in the circumferential direction about the compact, causing the at least one recess to cut the at least one protrusion from the compact, and thereafter the molding pin is removed from the compact.

A method for manufacturing a spark plug that includes preparing an assembly fitted with a cylindrical insulator, and a main metal fitting disposed on an outer periphery of the insulator; photographing the assembly by using a camera disposed on the axis while turning on a first lighting equipment disposed; photographing the assembly by using the camera while turning on a second lighting equipment; specifying a position of an outer peripheral surface of the insulator by using one of photographed images; specifying a position of an inner peripheral surface of the main metal fitting by using the other of the photographed images; and specifying a size of a clearance between the insulator and the main metal fitting by using the position of the outer peripheral surface of the insulator and the position of the inner peripheral surface of the main metal fitting.

A method for manufacturing a spark plug that includes preparing an assembly fitted with a cylindrical insulator, and a main metal fitting disposed on an outer periphery of the insulator; photographing the assembly by using a camera disposed on the axis while turning on a first lighting equipment disposed; photographing the assembly by using the camera while turning on a second lighting equipment; specifying a position of an outer peripheral surface of the insulator by using one of photographed images; specifying a position of an inner peripheral surface of the main metal fitting by using the other of the photographed images; and specifying a size of a clearance between the insulator and the main metal fitting by using the position of the outer peripheral surface of the insulator and the position of the inner peripheral surface of the main metal fitting.

A spark plug having an insulator with a leg portion whose outer circumferential surface has an arithmetic mean roughness Ra of 0.5 m or less. The leg portion has a first section, a second section, and a third section. The first section has an outer diameter that decreases toward the forward end of the first section. The second section is located forward of and adjacent to the first section and its outer diameter decreases toward the forward end of the second section. The outer circumferential surface of the second section is located inward of a first straight line passing through the base and forward ends of the outer circumferential surface of the first section. The third section is located forward of and adjacent to the second section. The outer diameter of the third section is equal to or less than a forward end outer diameter Ds of the second section over the entire third section.

A spark plug having an insulator with a leg portion whose outer circumferential surface has an arithmetic mean roughness Ra of 0.5 m or less. The leg portion has a first section, a second section, and a third section. The first section has an outer diameter that decreases toward the forward end of the first section. The second section is located forward of and adjacent to the first section and its outer diameter decreases toward the forward end of the second section. The outer circumferential surface of the second section is located inward of a first straight line passing through the base and forward ends of the outer circumferential surface of the first section. The third section is located forward of and adjacent to the second section. The outer diameter of the third section is equal to or less than a forward end outer diameter Ds of the second section over the entire third section.