Abstract: A spark plug having a multilayer firing tip that minimizes the amount of precious metal used and a method of assembling a spark plug with a multilayer firing tip. The firing tip includes a discharge end and a weld end, with the weld end being connected to a center electrode, and more specifically to a base electrode on the center electrode. The weld end has a coefficient of thermal expansion, which is not between the values for the coefficients of thermal expansion for the discharge end and the base electrode. More specifically, the weld end has a coefficient of thermal expansion which is greater than the coefficients of thermal expansion for the discharge end and base electrode. The weld end is formed from Nickel and Chromium with a limited amount of additional elements. The spark plug is assembled by providing a first elongated material formed from the material used for the discharge end and a second elongated material formed from a material used for the weld end.

Abstract: An electrode for a spark ignition device, including a spark plug, which includes an alloy consisting essentially of, in weight percent, at least 15% Ni and the balance substantially Pt, and more particularly 15-45% Ni and the balance substantially Pt; 5-35% W, and the balance substantially Pd; and 5-15% Ni, 5-15% Pt, less than 10% Ir, and the balance substantially Pd.

Abstract: A spark plug circuit for, and a method of, reducing or preventing the corrosion of a spark plug electrodes in an internal combustion engine. The circuit and method provide a positive voltage across the center electrode/ground electrode gap, which repels positively charged corrosion mechanisms, such as calcium and phosphorus ions.

Abstract: A spark plug (10) having an elongated ceramic insulator (12) includes numerous design features in various strategic locations. At least the ground electrode (26) is fitted with a rimmed, hemispherical metallic sparking tip (56) which controls rogue electrical arcing (62) and facilitates attachment techniques due to increased surface contact with the ground electrode (26). The various features of the spark plug (10) cooperate with one another so that the physical dimensions of the spark plug (10) can be reduced to meet current demands of newer engines without sacrificing mechanical strength or performance.

Abstract: A spark plug having a multilayer firing tip that minimizes the amount of precious metal used and a method of assembling a spark plug with a multilayer firing tip. The firing tip includes a discharge end and a weld end, with the weld end being connected to a center electrode, and more specifically to a base electrode on the center electrode. The weld end has a coefficient of thermal expansion, which is not between the values for the coefficients of thermal expansion for the discharge end and the base electrode. More specifically, the weld end has a coefficient of thermal expansion which is greater than the coefficients of thermal expansion for the discharge end and base electrode. The weld end is formed from Nickel and Chromium with a limited amount of additional elements. The spark plug is assembled by providing a first elongated material formed from the material used for the discharge end and a second elongated material formed from a material used for the weld end.

Abstract: A spark plug (10) having an elongated ceramic insulator (12) includes numerous design features in various strategic locations. At least the ground electrode (26) is fitted with a rimmed, hemispherical metallic sparking tip (56) which controls rogue electrical arcing (62) and facilitates attachment techniques due to increased surface contact with the ground electrode (26). The various features of the spark plug (10) cooperate with one another so that the physical dimensions of the spark plug (10) can be reduced to meet current demands of newer engines without sacrificing mechanical strength or performance.

Abstract: A spark plug having a center electrode and a ground electrode wherein the spark portion of at least one of the center electrode and ground electrode includes a base material and a protective material that substantially prevents corrosion of the base material.

Abstract: A spark plug having a multilayer firing tip that minimizes the amount of precious metal used and a method of assembling a spark plug with a multilayer firing tip. The firing tip includes a discharge end and a weld end, with the weld end being connected to a center electrode, and more specifically to a base electrode on the center electrode. The weld end has a coefficient of thermal expansion, which is not between the values for the coefficients of thermal expansion for the discharge end and the base electrode. More specifically, the weld end has a coefficient of thermal expansion which is greater than the coefficients of thermal expansion for the discharge end and base electrode. The weld end is formed from Nickel and Chromium with a limited amount of additional elements. The spark plug is assembled by providing a first elongated material formed from the material used for the discharge end and a second elongated material formed from a material used for the weld end.

Abstract: An electrode for an ignition device is made from a dilute nickel alloy which has improved resistance to high temperature oxidation, sulfidation, corrosive wear, deformation and fracture and includes at least 90% by weight of nickel; zirconium; boron and at least one element from the group consisting of aluminum, magnesium, silicon, chromium, titanium and manganese. The weight ratio of Zr/B may range from about 0.5 to 150, and may include amounts of, by weight of the alloy, 0.05-0.5% zirconium and 0.001-0.01% boron. The oxidation resistance of the alloy may also be improved by the addition of hafnium to the alloy in an amount that is comparable to the amount of zirconium, which may include an amount of, by weight of the alloy, 0.005-0.2% hafnium. Electrodes of dilute nickel alloys which include aluminum and silicon, as well as those which include chromium, silicon, manganese and titanium, are particularly useful as spark plug electrodes.

Abstract: A spark plug having a multilayer firing tip that minimizes the amount of precious metal used and a method of assembling a spark plug with a multilayer firing tip. The firing tip includes a discharge end and a weld end, with the weld end being connected to a center electrode, and more specifically to a base electrode on the center electrode. The weld end has a coefficient of thermal expansion, which is not between the values for the coefficients of thermal expansion for the discharge end and the base electrode. More specifically, the weld end has a coefficient of thermal expansion which is greater than the coefficients of thermal expansion for the discharge end and base electrode. The weld end is formed from Nickel and Chromium with a limited amount of additional elements. The spark plug is assembled by providing a first elongated material formed from the material used for the discharge end and a second elongated material formed from a material used for the weld end.

Abstract: A spark plug (10) having an elongated ceramic insulator (12) includes numerous design features in various strategic locations. At least the ground electrode (26) is fitted with a rimmed, hemispherical metallic sparking tip (56) which controls rogue electrical arcing (62) and facilitates attachment techniques due to increased surface contact with the ground electrode (26). The various features of the spark plug (10) cooperate with one another so that the physical dimensions of the spark plug (10) can be reduced to meet current demands of newer engines without sacrificing mechanical strength or performance.

Abstract: An electrode for an ignition device is made from a dilute nickel alloy which has improved resistance to high temperature oxidation, sulfidation, corrosive wear, deformation and fracture and includes at least 90% by weight of nickel; zirconium; boron and at least one element from the group consisting of aluminum, magnesium, silicon, chromium, titanium and manganese. The weight ratio of Zr/B may range from about 0.5 to 150, and may include amounts of, by weight of the alloy, 0.05-0.5% zirconium and 0.001-0.01% boron. The oxidation resistance of the alloy may also be improved by the addition of hafnium to the alloy in an amount that is comparable to the amount of zirconium, which may include an amount of, by weight of the alloy, 0.005-0.2% hafnium. Electrodes of dilute nickel alloys which include aluminum and silicon, as well as those which include chromium, silicon, manganese and titanium, are particularly useful as spark plug electrodes.

Abstract: A spark plug (10) for a spark ignited internal combustion engine includes a suppressor seal pack (54) interposed between an upper terminal stud (46) and a lower center electrode (60). The suppressor seal pack (54) includes a top layer of conductive glass (52) surrounding the bottom end (50) of the terminal stud (46) and a lower glass seal layer (58) surrounding a head (62) of the center electrode (60). A resistor layer (56) fills the space between the conductive glass layers (52, 58). The resistor layer (56) has a larger first cross-sectional area (76) at its upper end and a smaller second cross-sectional area (78) at its lower end. A reducing taper (80) establishes a progressive transition between the greater and lesser cross-sectional areas (76, 78). The reducing taper (80) is located in a large shoulder region (LS) which is defined as the longitudinal dimension between the theoretical reference point (70) at the filleted transition (26) and the theoretical reference point (68) at the upper seat (17).

Abstract: A spark plug having a pair of independent spark gaps includes a shell, inner and outer insulators, a cylindrical electrode assembly, a center wire assembly, and a pair of ground electrodes. The cylindrical electrode assembly is generally located between the two insulators and delivers a first high voltage ignition pulse to a first spark gap. The center wire assembly is located in an axial bore of the inner insulator and delivers a second high voltage ignition pulse to a second spark gap. The two insulators and two electrode assemblies are all coaxially aligned within the shell so that both insulators can be rotationally symmetrical. The first spark gap is radially oriented while the second spark gap is axially oriented, and the first and second spark gaps are located at different axial positions and can fire independently of one another. A method of assembling the spark plug is also disclosed.

Abstract: A sparkplug having ground and center electrodes that include a firing tip formed from a noble metal or noble metal alloy by reflowing of a noble metal preform. The present invention also includes a method of manufacturing a metal electrode having an ignition tip for an ignition device, including forming a metal electrode having a firing tip portion; applying a noble metal preform to the firing tip portion; and reflowing the noble metal preform to form a noble metal firing tip.

Abstract: An ignition device includes a ground electrode, center electrode, or both composed of a cobalt-based alloy including: Ni in an amount between about 20 and 24% by weight; Cr in an amount between about 20 and 24% by weight; W in an amount between about 10 and 16% by weight; and Co in an amount between about 32 and 47% by weight or alternately an iron-based alloy comprising: Cr in an amount between about 18 and 24% by weight; Al in an amount between about 4 and 7% by weight; and Fe in an amount between about 67 and 78% by weight. It is believed that the electrode alloys may also include Zr and B in an amount, by weight, of 0.005-0.5% Zr and 0.001-0.10% B. Center or ground electrodes of the invention may also include firing tips attached at a sparking end thereof. The firing tips may be formed of at least one of gold, a gold alloy, a platinum group metal or a tungsten alloy.

Abstract: A spark plug (10) having an elongated ceramic insulator (12) includes numerous design features in various strategic locations. At least the ground electrode (26) is fitted with a rimmed, hemispherical metallic sparking tip (56) which controls rogue electrical arcing (62) and facilitates attachment techniques due to increased surface contact with the ground electrode (26). The various features of the spark plug (10) cooperate with one another so that the physical dimensions of the spark plug (10) can be reduced to meet current demands of newer engines without sacrificing mechanical strength or performance.

Abstract: A spark plug (10) for a spark ignited internal combustion engine includes a suppressor seal pack (54) interposed between an upper terminal stud (46) and a lower center electrode (60). The suppressor seal pack (54) includes a top layer of conductive glass (52) surrounding the bottom end (50) of the terminal stud (46) and a lower glass seal layer (58) surrounding a head (62) of the center electrode (60). A resistor layer (56) fills the space between the conductive glass layers (52, 58). The resistor layer (56) has a larger first cross-sectional area (76) at its upper end and a smaller second cross-sectional area (78) at its lower end. A reducing taper (80) establishes a progressive transition between the greater and lesser cross-sectional areas (76, 78). The reducing taper (80) is located in a large shoulder region (LS) which is defined as the longitudinal dimension between the theoretical reference point (70) at the filleted transition (26) and the theoretical reference point (68) at the upper seat (17).

Abstract: A spark plug circuit for, and a method of, reducing or preventing the corrosion of a spark plug electrodes in an internal combustion engine. The circuit and method provide a positive voltage across the center electrode/ground electrode gap, which repels positively charged corrosion mechanisms, such as calcium and phosphorus ions.

Abstract: A spark plug having a center electrode and/or a ground electrode with an attached spark portion. The spark portion has a base material and a protective material wherein the base material is highly resistant to spark erosion and the protective material is highly resistant to corrosion.