New Spark Plugs with Innovative High-Voltage Connection Optimize Combustion for Compact Plug Top Ignition Coils

Auburn Hills, Michigan, December 7, 2011 - BorgWarner BERU Systems new double platinum spark plugs feature an innovative high-voltage connection specifically designed for the next generation of compact plug top ignition coils used in Audi’s 1.8- and 2.0-liter TFSI engines. Audi’s new four-cylinder engines will power the recently launched Audi A4 and A4 Avant series, and will replace current engines in the Audi A5, A5 Sportback and A5 Cabrio. The engine is expected to power more vehicle models for the VW group in the future.

“Our new spark plugs for plug top ignition coils offer a combination of advanced technologies engineered to help optimize combustion for better fuel economy and lower emissions,” said Brady Ericson, President and General Manager, BorgWarner BERU Systems and Emission Systems. “Once again, BorgWarner is demonstrating its reputation for innovation and product leadership. We are pleased to supply our latest ignition technology to Audi for a wide range of vehicles.”

Today’s turbocharged direct-injection gasoline engines require very high voltage ignition systems, up to 40,000 volts compared with 20,000 to 30,000 volts in a naturally aspirated engine. BorgWarner’s new spark plugs use a combination of advanced technologies to meet high voltage specifications while minimizing the risk of arcing and flashover, which can cause engine misfires. For dependable starts and efficient combustion, an innovative “bowl” contact optimizes the connection between the spark plug and the internal compression spring of the plug top ignition coil. The 8.5 mm longer insulator increases the maximum ignition voltage and reduces arcing, while the double platinum tip reduces erosion for longer service life. Featuring a new pointed shape, the ground electrode reduces quenching and improves combustion by directing the spark to optimize ignition. Both the ground and center electrodes are laser-welded for durability and feature a copper core for improved cooling.

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