Abstract: 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.

Abstract: 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.

Abstract: An insulator for a spark plug comprises a first segment surrounding the terminal, a second segment extending from the first segment, and a third segment extending from the second segment. A gap is disposed between the third segment of the insulator and the outer shell. At least one coating having a least one layer is disposed on a surface of the third segment.

Abstract: Disclosed herein is a spark plug comprising an insulative sleeve. A glaze coating is disposed on the exterior surface of the insulative sleeve. The glaze coating comprises a silicate glass, a phosphorous glass, a borosilicate glass, or a combination of the foregoing glasses wherein the glasses are independently modified with a modifier selected from the group consisting of alkali group metals, alkali earth group metals, aluminum, and a combination of two or more of the foregoing modifiers and further wherein the glaze coating has a glass transition temperature (Tg) of 300 to 1000 degrees Celsius.

Abstract: An insulator for a spark plug comprises a first segment surrounding the terminal, a second segment extending from the first segment, and a third segment extending from the second segment. A gap is disposed between the third segment of the insulator and the outer shell. At least one coating having a least one layer is disposed on a surface of the third segment.

Abstract: A spark plug is provided. The spark plug has an insulative sleeve with a central axial bore and an exterior surface of a shaped tip portion. A coating is disposed on the exterior surface of the shaped tip portion and the coating comprises a transition metal compound or a combination of transition metal compounds, and an alkali metal compound. A center electrode extends through the central axial bore of the insulative sleeve. A metal sleeve is provided, wherein the insulating sleeve is positioned within, and secured to the metal shell. A ground electrode is coupled to the metal shell and positioned in a spaced relationship relative to the center electrode so as to define a spark gap.

Abstract: A method of applying a coating to a spark plug insulator comprises the steps of forming a slurry solution and applying the slurry solution as a first coating to an insulative sleeve configured for use in a spark plug. The method further includes the step of heat treating the insulative sleeve to a temperature of between about 500 degrees Celsius and about 1000 degrees Celsius for between about 10 minutes and about 2 hour(s). Still further, the method includes the step of applying a second coating overlying at least a portion of the first coating, wherein the second coating comprises an organic binder.

Abstract: A spark plug is provided having a resistor. The resistor is made from resistor glass material containing an alkali free barium alumino-silicate glass mixed with mullite. In one embodiment, the resistor is a 15 to 30 wt % alkali free barium alumino-silicate glass and 10 to 25 wt % mullite. The resistor material provides for a greater processing kiln temperature range with reduced resistor variability and improved durability performance.

Abstract: A method of applying a coating to a spark plug insulator comprises the steps of forming a slurry solution and applying the slurry solution as a first coating to an insulative sleeve configured for use in a spark plug. The method further includes the step of heat treating the insulative sleeve to a temperature of between about 500 degrees Celsius and about 1000 degrees Celsius for between about 10 minutes and about 2 hour(s). Still further, the method includes the step of applying a second coating overlying at least a portion of the first coating, wherein the second coating comprises an organic binder.

Abstract: A spark plug is provided. The spark plug has an insulative sleeve with a central axial bore and an exterior surface of a shaped tip portion. A coating is disposed on the exterior surface of the shaped tip portion and the coating comprises a transition metal compound or a combination of transition metal compounds, and an alkali metal compound. A center electrode extends through the central axial bore of the insulative sleeve. A metal sleeve is provided, wherein the insulating sleeve is positioned within, and secured to, the metal shell. A ground electrode is coupled to the metal shell and positioned in a spaced relationship relative to the center electrode so as to define a spark gap.

Abstract: A spark plug includes an insulator having a first end, the insulator having a center axis and a center electrode coupled to the insulator and having a center electrode tip extending beyond the first end of the insulator. The spark plug further includes a ground electrode having an end spaced from an end of the center electrode, the ground electrode having a first portion extending substantially parallel to the center axis and a second portion extending at an angle from the first portion and relative to the center axis. A ground electrode tip is disposed on the second portion of the ground electrode, wherein the ground electrode tip is spaced from the center electrode tip. A ring member is operatively connected to the center electrode proximate the center electrode tip.

Abstract: A ground electrode is provided having a ground electrode body, the ground electrode body having an anchored end and a non-anchored end opposite the anchored end. The ground electrode includes a plateau extending from a surface of the ground electrode body adjacent the non-anchored end. In illustrative embodiments, the plateau is formed by removing a portion of the ground electrode body near the non-anchored end. The plateau is configured to be exposed around its periphery. A noble metal tip is fixably attached to the plateau.

Abstract: An insulator for a spark plug is provided having an insulator tip. The insulator tip includes a feature extending radially inward from an exterior surface of the insulator tip.

Abstract: A spark plug is provided having a resistor. The resistor is made from resistor glass material containing an alkali free barium alumino-silicate glass mixed with mullite. In one embodiment, the resistor is a 15 to 30 wt % alkali free barium alumino-silicate glass and 10 to 25 wt % mullite. The resistor material provides for a greater processing kiln temperature range with reduced resistor variability and improved durability performance.

Abstract: A spark plug is provided. The spark plug has an insulative sleeve with a central axial bore and an exterior surface of a shaped tip portion. A coating is disposed on the exterior surface of the shaped tip portion and the coating comprises a transition metal compound or a combination of transition metal compounds, and an alkali metal compound. A center electrode extends through the central axial bore of the insulative sleeve. A metal sleeve is provided, wherein the insulating sleeve is positioned within, and secured to the metal shell. A ground electrode is coupled to the metal shell and positioned in a spaced relationship relative to the center electrode so as to define a spark gap.

Abstract: An electrode for a spark plug includes an electrode tip end. A first weld affixes at least a portion of the noble metal tip to the tip end of the electrode. The noble metal tip has a fold around its periphery. A second weld joins the fold of the noble metal tip to the tip end of the electrode and creates a seal over the first weld.

Abstract: Disclosed herein is a spark plug comprising an insulative sleeve. A glaze coating is disposed on the exterior surface of the insulative sleeve. The glaze coating comprises a silicate glass, a phosphorous glass, a borosilicate glass, or a combination of the foregoing glasses wherein the glasses are independently modified with a modifier selected from the group consisting of alkali group metals, alkali earth group metals, aluminum, and a combination of two or more of the foregoing modifiers and further wherein the glaze coating has a glass transition temperature (Tg) of 300 to 1000 degrees Celsius.

Abstract: A ground electrode is provided having a ground electrode body, the ground electrode body having an anchored end and a non-anchored end opposite the anchored end. The ground electrode includes a plateau extending from a surface of the ground electrode body adjacent the non-anchored end. In illustrative embodiments, the plateau is formed by removing a portion of the ground electrode body near the non-anchored end. The plateau is configured to be exposed around its periphery. A noble metal tip is fixably attached to the plateau.

Abstract: A method of manufacturing a center electrode for a spark plug, the method including the steps of: resistance welding a sphere of a noble metal to a center electrode of a spark plug to provide a center electrode with an electrode tip that has a tip portion of a first configuration, the first configuration having a first height and a first width; and shaping the tip portion after the sphere is welded to the center electrode by a process wherein the tip portion will have a second configuration having a second height and a second width, the second height being greater than the first height and the second width being less than the first width wherein a peripheral edge of the noble metal is flush with a peripheral edge of the material it is secured to.

Abstract: A spark plug comprises a shell having a substantially cylindrical threaded portion for threadable engagement in a cylinder head of an internal combustion engine, an insulator disposed coaxially in the shell, a center electrode disposed coaxially in the insulator, a side ground electrode having a first end coupled to the shell and a second end facing an end of the center electrode to define a spark discharge gap therebetween, and an electrode tip portion secured to either the side ground electrode or the center electrode proximate the spark discharge gap. The tip portion is formed from an alloy comprising from about 60 to about 70 percent by weight iridium, from about 30 to about 35 percent by weight rhodium, from 0 to about 10 percent by weight nickel, from about 3500 to about 4500 parts per million tantalum, and from about 100 to about 200 parts per million zirconium.