Abstract: A spark plug is provided that includes an improved jamb nut configuration, which provides improved torque transfer and prevents inadvertent separation of the jamb nut from the remaining components of the spark plug, particularly during removal from the engine head. The spark plug is configured for axial insertion into the plug hole, and may have a non-axisymmetric ground shield that fits into the plug hole, wherein the plug hole is also provided with a complementary non-axisymmetric shape. The spark plug includes a central insulator, which has an inner end surrounding a central electrode and supporting the ground shield, which is mounted on the insulator to support a ground strap adjacent the electrode for forming a spark therebetween. The insulator and ground shield are axially slidable into the plug hole, and the jamb nut is rotatable to fix the spark plug in position in a predefined orientation.

Abstract: A spark plug is provided that ensures that a ground electrode is positioned in a predefined, precise orientation when installed in a spark plug hole of an engine head. The spark plug is configured for axial insertion into the plug hole, and has a non-axisymmetric ground shield that fits into the plug hole, wherein the ground shield has an outer shield surface with a non-axisymmetric shape and the plug hole is also provided with a complementary non-axisymmetric shape. The spark plug includes a central insulator, which has an inner end surrounding a central electrode and supporting the ground shield, which is mounted on the insulator to support a ground strap adjacent the electrode for forming a spark therebetween. The insulator and ground shield are axially slidable into the plug hole, and the spark plug includes a jamb nut which is rotatable to fix the spark plug in position in a predefined orientation.

Abstract: A spark plug is provided that ensures that a ground electrode is positioned in a predefined, precise orientation when installed in a spark plug hole of an engine head. The spark plug is configured for axial insertion into the plug hole, and has a non-axisymmetric ground shield that fits into the plug hole, wherein the ground shield has an outer shield surface with a non-axisymmetric shape and the plug hole is also provided with a complementary non-axisymmetric shape. The spark plug includes a central insulator, which has an inner end surrounding a central electrode and supporting the ground shield, which is mounted on the insulator to support a ground strap adjacent the electrode for forming a spark therebetween. The insulator and ground shield are axially slidable into the plug hole, and the spark plug includes a jamb nut which is rotatable to fix the spark plug in position in a predefined orientation.

Abstract: A spark plug is provided that includes an improved jamb nut configuration, which provides improved torque transfer and prevents inadvertent separation of the jamb nut from the remaining components of the spark plug, particularly during removal from the engine head. The spark plug is configured for axial insertion into the plug hole, and may have a non-axisymmetric ground shield that fits into the plug hole, wherein the plug hole is also provided with a complementary non-axisymmetric shape. The spark plug includes a central insulator, which has an inner end surrounding a central electrode and supporting the ground shield, which is mounted on the insulator to support a ground strap adjacent the electrode for forming a spark therebetween. The insulator and ground shield are axially slidable into the plug hole, and the jamb nut is rotatable to fix the spark plug in position in a predefined orientation.

Abstract: A system for testing an insulative material for a spark plug comprises a test spark plug having at least a center electrode and an insulator comprised of an insulative material surrounding at least a portion of the center electrode, wherein the insulator has an end that is closed, whereby the closed end of the insulator encloses an end of the center electrode. The system may further include a test engine that simulates engine conditions, wherein a conventional spark plug is installed in a first ignition port of the test engine and the test spark plug is installed in a second ignition portion of the test engine and a control system for controlling ignition signals to the test spark plug and the conventional spark plug.

Abstract: A system for testing an insulative material for a spark plug comprises a test spark plug having at least a center electrode and an insulator comprised of an insulative material surrounding at least a portion of the center electrode, wherein the insulator has an end that is closed, whereby the closed end of the insulator encloses an end of the center electrode. The system further includes a test engine that simulates engine conditions, wherein a conventional spark plug is installed in a first ignition port of the test engine and the test spark plug is installed in a second ignition portion of the test engine and a control system for controlling ignition signals to the test spark plug and the conventional spark plug.

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 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: An assembly for a spark plug, the assembly having: an insulator, the insulator having a channel formed in an exterior surface of the insulator; and a jamb nut surrounding the insulator, the jamb nut being aligned with the channel such that a distal end of the jamb nut does not contact the insulator.

Abstract: A spark plug is provided including an outer shell and an insulator having a bore extending therethrough, the bore having a first bore section and a second bore section. The first bore section and the outer shell extend along a common longitudinal axis. The second bore section extends along a second longitudinal axis offset from the common longitudinal axis. The spark plug further includes a center electrode and a ground electrode.

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 is provided providing resistance to fouling. The spark plug includes a metal shell having a first end, a second end and an intermediate portion that collectively define a central cavity. The spark plug also includes an insulator that extends through the central cavity of the metal shell. The insulator includes a first end portion extending through an intermediate portion to a stepped tip portion having a first length. The stepped tip portion includes a first section and a substantially straight second section having a second length. The substantially straight second section includes a segment that extends beyond the second end of the metal shell to a third length. The second length of substantially straight portion is based upon at least one of the first length and the third length.

Abstract: An assembly for a spark plug, the assembly having: an insulator, the insulator having a channel formed in an exterior surface of the insulator; and a jamb nut surrounding the insulator, the jamb nut being aligned with the channel such that a distal end of the jamb nut does not contact the insulator.

Abstract: A spark plug casing includes a single-piece shell having a nut portion, first and second tubular portions and a converging shell portion, which are configured to be removed from a cylinder head as an integral device. The first tubular portion extends from the nut portion and has a first cross-sectional size. The second tubular portion has a second cross-sectional size less than the first cross-sectional size. The converging shell portion is coupled between the first and second tubular portions. The casing further includes a ground strap having a third cross-sectional size less than the second cross-sectional size. The ground strap is received within an end portion of the second tubular portion opposite the converging shell portion, such that the ground strap and the cylinder head are in a spaced relationship with respect to each other for preventing carbon buildup from binding the ground strap to the cylinder head.

Abstract: An igniter for an internal combustion engine, the igniter comprising: a center electrode; an insulator disposed about the center electrode; a ground shield disposed about the insulator, the insulator having a tip portion extending past an end portion of the ground shield and a tip portion of the center electrode extending through and away from the tip portion of the insulator; and a spark gap disposed between the tip portion of the center electrode and the end portion of the ground shield.

Abstract: An internal combustion engine analysis system is provided, the system having: a spark plug having a thermocouple sensor coupled thereto, the thermocouple sensor being configured to generate a first signal according to a combustion temperature proximate to the spark plug; a current sensor configured to monitor electrical current provided to the spark plug and generate a second signal based upon current the monitored electrical current; one or more signal conditioners configured to generate a first and a second optical signals based upon the first and second signal respectively; a receiver electrically connected to the one or more signal conditioners, the receiver being configured to generate a first and a second digital signal based upon the first and second optical signals respectively; and an analysis device in signal communication with the receiver, the analysis device configured to receive the first and second digital signal and being configured to generate a visual display of the combustion temperature as

Abstract: A side electrode for a spark plug is provided. The side electrode includes a side wire having a first end and a second end; an opening proximate to the first end, the opening extending from a first surface of the side wire to a second surface of the side wire, wherein the first surface has a flared portion proximate to the opening; and an electrode tip secured to the first end of the side wire, the electrode tip having a tip portion and a shaft portion, wherein the tip portion is located on the second surface and the shaft portion is secured to the side wire by engaging the flared portion.

Abstract: A spark plug casing includes a single-piece shell having a nut portion, first and second tubular portions and a converging shell portion, which are configured to be removed from a cylinder head as an integral device. The first tubular portion extends from the nut portion and has a first cross-sectional size. The second tubular portion has a second cross-sectional size less than the first cross-sectional size. The converging shell portion is coupled between the first and second tubular portions. The casing further includes a ground strap having a third cross-sectional size less than the second cross-sectional size. The ground strap is received within an end portion of the second tubular portion opposite the converging shell portion, such that the ground strap and the cylinder head are in a spaced relationship with respect to each other for preventing carbon buildup from binding the ground strap to the cylinder head.