A spark plug electrode with one or more electrode tip(s) formed on one or more electrode base(s) using an additive manufacturing process, such as a powder bed fusion technique, such that each electrode tip overhangs an edge of a corresponding electrode base. The spark plug electrode may be a center electrode, a ground electrode, or an annular ground electrode and can be provided according to a number of different configurations. Each electrode tip includes a precious metal-based material, such as an iridium- or platinum-based alloy, and a plurality of laser deposition layers, and each electrode tip can be secured to an electrode base with a weldless joint. An additive manufacturing process is also provided.

A passive prechamber spark plug for use in a combustion chamber of a vehicle engine includes an upper prechamber having an upper opening where the upper prechamber is connectable to the combustion chamber via the upper opening. An air ignition spark is formable via an upper air spark gap. A central electrode is disposed in an upper region of the upper prechamber where a base of the upper prechamber opposite the upper region is an insulator. An electrically conductive element or a slot is guided by the insulator continuously from the upper prechamber into a lower region under the base and the lower region is either a lower prechamber or is arrangeable directly in the combustion chamber. An earth electrode is disposed in the lower region such that a lower air spark gap is formed between the earth electrode and the electrically conductive element or the slot.

A passive prechamber spark plug for use in a combustion chamber of a vehicle engine includes an upper prechamber having an upper opening where the upper prechamber is connectable to the combustion chamber via the upper opening. An air ignition spark is formable via an upper air spark gap. A central electrode is disposed in an upper region of the upper prechamber where a base of the upper prechamber opposite the upper region is an insulator. An electrically conductive element or a slot is guided by the insulator continuously from the upper prechamber into a lower region under the base and the lower region is either a lower prechamber or is arrangeable directly in the combustion chamber. An earth electrode is disposed in the lower region such that a lower air-surface gap spark gap is formed between the earth electrode and the electrically conductive element or the slot.

A spark plug electrode with one or more electrode tip(s) formed on one or more electrode base(s) using an additive manufacturing process, such as a powder bed fusion technique, such that each electrode tip overhangs an edge of a corresponding electrode base. The spark plug electrode may be a center electrode, a ground electrode, or an annular ground electrode and can be provided according to a number of different configurations. Each electrode tip includes a precious metal-based material, such as an iridium- or platinum-based alloy, and a plurality of laser deposition layers, and each electrode tip can be secured to an electrode base with a weldless joint. An additive manufacturing process is also provided.

A spark plug includes a central electrode member and an outer electrode member. The central electrode member includes a central base and a plurality of electrode prongs extending in an axial direction from the central base. The outer electrode member surrounds the central electrode member. The outer electrode member includes a wall that is radially spaced from the plurality of electrode prongs to allow a series of electric arcs to form between the wall and the plurality of electrode prongs. The outer electrode member and the central electrode member are sized and positioned relative to one another such that a first rate of wear of the outer electrode member, along a longitudinal axis of the spark plug, is substantially equal to a second rate of wear of the central electrode member along the longitudinal axis.

Methods and systems are provided for operating a cylinder with a series gap igniter coupled to an ion sensing module. In one example, a method may include determining a location of an initial combustion in a cylinder from a series gap igniter based on a pressure rise rate in the cylinder, the ignition spark initiating combustion in the cylinder; and adjusting at least one setting of the cylinder based on the determined location. In this way, combustion stability and efficiency may be increased without increasing a cost and complexity of the engine.

Methods and systems are provided for operating an engine with a series gap igniter. In one example, a system may include a series gap igniter coupled to a cylinder head of a cylinder, the series gap igniter including a first spark gap in an internal volume of the series gap igniter and a second spark gap of the series gap igniter external to the internal volume of the series gap igniter and within a clearance volume of the cylinder. In this way, a cylinder with a series gap igniter may be operated to efficiently and reliably initiate combustion over a range of engine operating conditions.

The invention relates to a spark plug (100) for an internal combustion engine, in particular having a high frequency ignition system, having a central electrode (28; 128), a ground electrode (12; 112) and an electrical insulator (18; 118) arranged between the central electrode (28; 128) and the ground electrode (12; 112), wherein a central electrode connecting point (26; 126) for electrically connecting the central electrode (28; 128) to an ignition system is provided on the insulator (18; 118), wherein the central electrode (28; 128) and the ground electrode (12; 112) project beyond the insulator (18; 118) at an axial end (114) of the spark plug (100) and each form, with a part projecting axially beyond the insulator (18; 118), a central electrode end (140) and a ground electrode end (142), wherein the central electrode end (140) and the ground electrode end (142) are arranged and embodied in such a way that an axial region (170) of a gap (146) is formed between them in an axial direction, wherein the axial region (170) of the gap (146) is spaced apart from the insulator (18; 118), wherein at least one additional electrode (150) is provided which projects beyond the insulator (118) at the axial end (114) of the spark plug (100) and forms, with a part which projects axially beyond the insulator (118), an additional electrode end (154). In this case the additional electrode (150) is arranged electrically insulated from the ground electrode (112) and the central electrode (128), on the spark plug (100), wherein the additional electrode end (154) projects into the axial region (170) of the gap (146) between the central electrode end (140) and the ground electrode end (142) or is arranged into a region (170) of the gap (146) which is radially adjacent to the axial region (170) of the gap (146), and as a result divides the gap (146) into two ignition spark end gaps (156, 166).

The invention relates to a spark plug (100) for an internal combustion engine, in particular having a high frequency ignition system, having a central electrode (28; 128), a ground electrode (12; 112) and an electrical insulator (18; 118) arranged between the central electrode (28; 128) and the ground electrode (12; 112), wherein a central electrode connecting point (26; 126) for electrically connecting the central electrode (28; 128) to an ignition system is provided on the insulator (18; 118), wherein the central electrode (28; 128) and the ground electrode (12; 112) project beyond the insulator (18; 118) at an axial end (114) of the spark plug (100) and each form, with a part projecting axially beyond the insulator (18; 118), a central electrode end (140) and a ground electrode end (142), wherein the central electrode end (140) and the ground electrode end (142) are arranged and embodied in such a way that an axial region (170) of a gap (146) is formed between them in an axial direction, wherein the axial region (170) of the gap (146) is spaced apart from the insulator (18; 118), wherein at least one additional electrode (150) is provided which projects beyond the insulator (118) at the axial end (114) of the spark plug (100) and forms, with a part which projects axially beyond the insulator (118), an additional electrode end (154). In this case the additional electrode (150) is arranged electrically insulated from the ground electrode (112) and the central electrode (128), on the spark plug (100), wherein the additional electrode end (154) projects into the axial region (170) of the gap (146) between the central electrode end (140) and the ground electrode end (142) or is arranged into a region (170) of the gap (146) which is radially adjacent to the axial region (170) of the gap (146), and as a result divides the gap (146) into two ignition spark end gaps (156, 166).

A spark plug electrode with one or more electrode tip(s) formed on one or more electrode base(s) using an additive manufacturing process, such as a powder bed fusion technique, such that each electrode tip overhangs an edge of a corresponding electrode base. The spark plug electrode may be a center electrode, a ground electrode, or an annular ground electrode and can be provided according to a number of different configurations. Each electrode tip includes a precious metal-based material, such as an iridium- or platinum-based alloy, and a plurality of laser deposition layers, and each electrode tip can be secured to an electrode base with a weldless joint. An additive manufacturing process is also provided.