Corona ignition device with improved electrical performance

1. A corona igniter for emitting a radio frequency electric field to ionize a fuel-air mixture and provide a corona discharge, comprising:

a central electrode formed of an electrically conductive material for receiving a high radio frequency voltage and emitting the radio frequency electric field;

an insulator formed of an electrically insulating material surrounding said central electrode and extending longitudinally along a center axis from an insulator upper end to an insulator nose end;

said insulator including an insulator outer surface extending from said insulator upper end to said insulator nose end;

said insulator outer surface presenting an insulator outer diameter extending across and perpendicular to said center axis;

said insulator including an insulator body region and an insulator nose region;

said insulator outer surface including a lower ledge extending outwardly away from and transverse to said center axis between said insulator body region and said insulator nose region;

said lower ledge presenting an increase in said insulator outer diameter;

a conductive component surrounding at least a portion of said insulator body region such that said insulator nose region extends outwardly of said conductive component;

said conductive component including a shell surrounding at least a portion of said insulator body region and extending from a shell upper end to a shell firing end;

said shell presenting a shell inner surface facing said center axis and extending along said insulator outer surface from said shell upper end to said shell firing end;

said conductive component including an intermediate part formed of an electrically conductive material and surrounding a portion of said insulator body region and extending longitudinally from an intermediate upper end to an intermediate firing end;

said intermediate part including an intermediate inner surface facing said center axis and extending longitudinally along said insulator surface said from said intermediate upper end to said intermediate firing end;

said intermediate inner surface presenting a conductive inner diameter extending across and perpendicular to said center axis;

said conductive inner diameter being less than said insulator outer diameter below said lower ledge of said insulator; and

said intermediate firing end engaging said lower ledge of said insulator.

2. The corona igniter of claim 1 , wherein said insulator outer surface of said insulator body region presents an upper ledge extending inwardly toward said center axis to said lower ledge to present a recess therebetween and said intermediate part is disposed in said recess.

3. The corona igniter of claim 1 , wherein said shell inner surface presents a shell inner diameter extending across and perpendicular to said center axis; and said shell inner diameter is greater than or equal to said insulator outer diameter.

4. The corona igniter of claim 1 , wherein said insulator presents a thickness between said insulator inner surface and said insulator outer surface; and said thickness increases adjacent said shell firing end and adjacent said intermediate firing end.

5. The corona igniter of claim 1 , wherein said shell inner surface extends away from said insulator outer surface adjacent said shell upper end to present a crevice between said shell inner surface and said insulator outer surface.

6. The corona igniter of claim 5 , wherein said insulator outer surface along said insulator body region presents an upper ledge extending inwardly toward said center axis to said lower ledge to present a recess therebetween; and said intermediate part is disposed in said recess.

7. The corona igniter of claim 6 , wherein said insulator outer diameter is constant from said upper ledge along a portion of said insulator body region toward said insulator upper end; said insulator outer diameter increases gradually along a portion of said insulator body region toward said insulator upper end; said insulator outer diameter is constant between said gradual increase and said insulator upper end; and said crevice extends from said gradual increase toward said insulator upper end.

8. The corona igniter of claim 6 , wherein said insulator outer diameter increases gradually from said upper ledge toward said insulator upper end and is constant from said gradual increase to said insulator upper end; and said crevice extends from said gradual increase toward said insulator upper end.

9. The corona igniter of claim 6 , wherein said insulator outer diameter is constant from said upper ledge to said insulator upper end.

10. The corona igniter of claim 6 , wherein said insulator has a length between said insulator upper end and said insulator nose end, and said intermediate part and said recess extend along not greater than one quarter of said length.

11. The corona igniter of claim 6 , wherein said insulator has a length between said insulator upper end and said insulator nose end, and said intermediate part and said recess extend along greater than one quarter of said length.

12. The corona igniter of claim 5 , wherein said crevice extends from said intermediate upper end to said shell upper end.

13. The corona igniter of claim 12 , wherein said insulator outer diameter is constant from said lower ledge to said insulator upper end.

14. The corona igniter of claim 12 , wherein said insulator outer diameter decreases between said lower ledge and said insulator upper end.

15. The corona igniter of claim 6 wherein said insulator outer diameter increases gradually along a portion of said insulator body region from said upper ledge toward said insulator upper end and is constant along a portion of said insulator body region from said gradual increase to said insulator upper end.

16. The corona igniter of claim 5 , wherein said insulator outer diameter tapers from said lower ledge along said insulator nose region to said insulator nose end.

17. The corona igniter of claim 5 including an adhesive filler material filling said crevice between said insulator outer surface and said shell inner surface adjacent said shell upper end and attaching said insulator to said shell.

18. The corona igniter of claim 1 wherein said intermediate outer surface includes an intermediate seat between said intermediate upper end and said intermediate firing end; said intermediate outer diameter decreases along said intermediate seat toward said intermediate firing end; and said shell inner surface presents a shell seat engaging said intermediate seat.

19. The corona igniter of claim 2 wherein said shell inner surface presents a shell seat facing said insulator upper ledge; said shell inner diameter decreases along said shell seat toward said shell firing end; and a gasket separates said shell seat and said insulator upper ledge.

20. The corona igniter of claim 19 , wherein said insulator outer diameter at said upper ledge is greater than said insulator outer diameter at said lower ledge.

21. The corona igniter of claim 19 , wherein said shell has a thickness extending from said shell inner surface to said shell outer surface and said thickness increases at said shell seat.

22. The corona igniter of claim 1 wherein said shell firing end is disposed on said intermediate upper end.

23. The corona igniter of claim 22 , wherein said conductive inner diameter from said intermediate upper end to said intermediate firing end is constant and said intermediate outer diameter tapers from said intermediate upper end to said intermediate firing end.

24. The corona igniter of claim 1 wherein said intermediate firing end is longitudinally aligned with said shell firing end.

25. The corona igniter of claim 1 , wherein said shell inner surface presents a shell inner diameter extending across and perpendicular to said center axis; and said shell inner diameter is less than or equal to said insulator outer diameter along a portion of said insulator.

26. A method of forming a corona igniter, comprising the steps of:

providing an insulator formed of an electrically insulating material extending along a center axis from an insulator upper end to an insulator nose end, the insulator including an insulator outer surface extending from the insulator upper end to the insulator nose end and presenting an insulator outer diameter, the insulator outer surface including a lower ledge extending outwardly away from and transverse to the center axis between an insulator body region and an insulator nose region;

disposing an intermediate part formed of an electrically conductive material on the lower ledge of the insulator; and

disposing a shell formed of an electrically conductive material around the intermediate part and the insulator.

27. The method of claim 26 , including inserting the insulator nose end through a shell upper end into a shell bore until the insulator nose end extends outwardly of a shell firing end.

28. The method of claim 27 , including attaching the intermediate part to the insulator outer surface before inserting the insulator into the shell, and wherein the attaching step includes at least one of the following steps: casting, sintering, brazing, soldering, diffusion bonding, and by an adhesive.

29. The method of claim 26 including inserting the insulator through a shell lower end into a shell bore.

30. The method of claim 26 , wherein the intermediate part extends from an intermediate upper end to an intermediate firing end, and including the step of disposing intermediate upper end along a shell firing end.

31. The method of claim 26 , including attaching the intermediate part to the insulator outer surface after disposing the shell around the insulator, and wherein the attaching step includes at least one of the following steps: casting, sintering, brazing, soldering, diffusion bonding, and by an adhesive.

32. The method of claim 26 , including hermetically sealing the intermediate part to the insulator.

33. A corona igniter for emitting a radio frequency electric field to ionize a fuel-air mixture and provide a corona discharge, comprising:

a central electrode formed of an electrically conductive material for receiving a high radio frequency voltage and emitting the radio frequency electric;

said central electrode extending longitudinally along a center axis from a terminal end to an electrode firing end;

an insulator formed of an electrically insulating material and extending longitudinally along said center axis from an insulator upper end to an insulator nose end;

said electrode firing end disposed outwardly of said insulator nose end;

a corona enhancing tip disposed at said firing end of said central electrode;

said insulator including an insulator inner surface surrounding said central electrode and presenting an insulator inner diameter extending across and perpendicular to said center axis;

said insulator inner surface surrounding an insulator bore receiving said central electrode;

said insulator including an insulator outer surface extending from said insulator upper end to said insulator nose end;

said insulator outer surface presenting an insulator outer diameter extending across and perpendicular to said center axis;

said insulator inner diameter being 15 to 25% of said insulator outer diameter;

said insulator including an insulator body region and an insulator nose region;

said insulator outer surface including a lower ledge extending outwardly away from and transverse to said center axis between said insulator body region and said insulator nose region;

said lower ledge presenting an increase in said insulator outer diameter;

a conductive component formed of electrically conductive material surrounding at least a portion of said insulator body region such that said insulator nose region extends outwardly of said conductive component;

said conductive component including a shell surrounding at least a portion of said insulator body region and extending from a shell upper end to a shell firing end;

said shell presenting a shell inner surface facing said center axis and extending along said insulator outer surface from said shell upper end to said shell firing end;

said shell inner surface presenting a shell bore surrounding said center axis and a shell inner diameter extending across and perpendicular to said center axis;

said shell inner diameter being greater than or equal to said insulator outer diameter from said insulator upper end to said insulator nose end;

said shell including a shell outer surface facing opposite said shell inner surface and presenting a shell outer diameter;

said conductive component including an intermediate part surrounding a portion of said insulator body region and extending longitudinally from an intermediate upper end to an intermediate firing end;

said intermediate part including an intermediate inner surface facing said center axis and extending longitudinally along said insulator surface said from said intermediate upper end to said intermediate firing end;

said intermediate inner surface being hermetically sealed to said insulator outer surface;

said intermediate inner surface presenting a conductive inner diameter extending across and perpendicular to said center axis;

said conductive inner diameter being less than said insulator outer diameter below said lower ledge of said insulator;

said conductive inner diameter being 80 to 90% of said insulator outer diameter below said lower ledge and being 75 to 90% of said shell inner diameter along said intermediate part;

said intermediate firing end engaging said lower ledge of said insulator and being longitudinally aligned with said shell firing end.