Abstract: A method of forming a spark plug for an internal combustion engine is provided, the method including the steps of: separately securing a ground electrode to a ground shield, the ground shield having an elongated base section being configured to substantially surround a first insulator section of an insulator configured to substantially surround a center electrode, the insulator having a substantially cylindrical body with at least the first insulator section and a second insulator section, the first and second insulator sections having first and second diameters respectively and being separated by an insulator shoulder; and the elongated center electrode having a center electrode tip at one end and a terminal proximate another end of the center electrode, wherein the ground shield has a frustoconical flange protruding from a first end of the elongated base section, the frustoconical flange being configured to engage the insulator shoulder, and wherein the ground electrode extends from a second end of the elon

Abstract: A spark plug for an internal combustion engine, the spark plug having: an elongated center electrode having a center electrode tip at one end and a terminal proximate the other end; an insulator substantially surrounding the center electrode, the insulator having a channel formed in an exterior surface of the insulator; an outer shell surrounding the insulator having: a jamb nut portion with a distal end extending thereform, the distal end being aligned with the channel such that the distal end of the outer shell is received within and engages the channel; a motor seat portion proximate to the jamb nut portion; and a threaded portion proximate to the motor seat portion, wherein the jamb nut portion, the motor seat portion, and the threaded portion are all integrally formed with the outer shell as a single component.

Abstract: A spark plug for an internal combustion engine, the spark plug having: an elongated center electrode having a center electrode tip at one end and a terminal proximate the other end; an insulator substantially surrounding the center electrode, the insulator having a channel formed in an exterior surface of the insulator; and an outer shell surrounding the insulator, the outer shell having a jamb nut portion and a distal end extending from the jamb nut portion, the distal end of the outer shell is aligned with the channel such that the distal end of the outer shell is received in and engages the channel of the outer shell.

Abstract: A method of forming a spark plug for an internal combustion engine is provided, the method including the steps of: separately securing a ground electrode to a ground shield, the ground shield having an elongated base section being configured to substantially surround a first insulator section of an insulator configured to substantially surround a center electrode, the insulator having a substantially cylindrical body with at least the first insulator section and a second insulator section, the first and second insulator sections having first and second diameters respectively and being separated by an insulator shoulder; and the elongated center electrode having a center electrode tip at one end and a terminal proximate another end of the center electrode, wherein the ground shield has a frustoconical flange protruding from a first end of the elongated base section, the frustoconical flange being configured to engage the insulator shoulder, and wherein the ground electrode extends from a second end of the elon

Abstract: Exemplary embodiments of the present invention provide a spark plug for use in conjunction with an internal combustion engine, and, more particularly, to a spark plug having a structure providing improved ignition capability. In one particular configuration, a spark plug is provided forming a gap between a center electrode and an insulator of the spark plug. However, it will become apparent that other configurations are contemplated as well, as shown and described herein.

Abstract: A small diameter spark plug configuration is provided, the configuration has been found to provide additional volume for the insulator member. That is, by limiting the overall number of threads on the intermediate portion along with a limit of the overall diameter of the spark plug, additional volume of insulator material may be achieved in an interior cavity of a metal shell of the spark plug. This additional volume enables a portion of the insulator member to have a larger diameter and hence greater material thickness. The larger diameter of the insulator provides enhanced dielectric properties and protects internal components of the spark plug from high combustion chamber temperatures while simultaneously providing a robust attachment of the spark plug with an engine 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: Exemplary embodiments of the present invention relate to methods and devices for monitoring the flow of particulate matter within an exhaust gas stream. In one exemplary embodiment, a particulate matter sensor for an exhaust system of an engine is provided. The particulate matter sensor includes a casing having an attachment feature for mounting the particulate matter sensor to the exhaust system. The particulate matter sensor also includes an insulator disposed within the casing. The particulate matter sensor further includes a sensing rod having a hollow portion extending between a first end and a second end of the sensing rod. The first end of the sensing rod is supported by the insulator and the second end of the sensing rod extending away from the insulator. The particulate matter sensor still further includes an electrical connector assembly engaging the first end of the sensing rod. The electrical connector assembly is configured to transmit a signal generated by the sensing rod.

Abstract: Exemplary embodiments of the present invention relate methods and devices for measuring flow rate of particulate matter within an exhaust gas stream. In one particular exemplary embodiment, a sensor for detecting and monitoring particulate matter within an exhaust flow path of an engine is provided. The sensor includes a housing having an attachment for mounting the sensor. The sensor also includes a sensing rod supported by an insulating base. The sensing rod is attached to the housing and includes a probe adapted to be placed within the exhaust flow path. The probe includes a section having an increased surface area per unit length as compared to at least one other section of the probe. The sensing rod is configured to detect particulate matter flowing through the exhaust component and generates a signal based thereupon. The sensor further includes an electrical connector in communication with the sensing rod.

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: A spark plug for an internal combustion engine, the spark plug having an elongated center electrode having a center electrode tip at one end and a terminal proximate to another end of the center electrode; an insulator surrounding a portion of the center electrode, 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 for an internal combustion engine, the spark plug having an elongated center electrode having a center electrode tip at one end and a terminal proximate to another end of the center electrode; an insulator surrounding a portion of the center electrode, 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 method of real-time analysis of an engine, comprising sensing a temperature within a chamber of the engine with a thermocouple sensor disposed on a spark plug operating within the chamber, the thermocouple sensor generating a first signal based upon the temperature within the chamber; detecting current on a wire coupled to the sparkplug with a sensor, the sensor generating a second signal based upon current detected on the wire; converting the first and second signal into a first and second optical signal respectively utilizing one or more signal conditioners; generating a first and second digital signal based upon the first and second optical signal respectively with a receiver; and transmitting the first and second digital signal to an analysis device to generate a display of the temperature as it relates to engine speed at a first time in response to the receipt of the first and second digital signal.

Abstract: A spark plug for an internal combustion engine comprises an elongated center electrode having a center electrode tip at one end and a terminal proximate the other end, an insulator substantially surrounding the center electrode, and a ground shield. The insulator has a substantially cylindrical body with at least a first insulator section and a second insulator section. The first and second insulator sections having first and second diameters respectively and are separated by an insulator shoulder. The ground shield has an elongated base section substantially surrounding the first insulator section, a frustoconical flange protruding from one end of the base section to engage the insulator shoulder, and a ground electrode extending from the other end of the base section to define an axial spark gap with respect to the center electrode tip. The base section and the ground electrode are formed as separate components and secured together to form the ground shield.

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 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: Exemplary embodiments of the present invention relate to methods and devices for monitoring the flow of particulate matter within an exhaust gas stream. In one exemplary embodiment, a particulate matter sensor for an exhaust system of an engine is provided. The particulate matter sensor includes a casing having an attachment feature for mounting the particulate matter sensor to the exhaust system. The particulate matter sensor also includes an insulator disposed within the casing. The particulate matter sensor further includes a sensing rod having a hollow portion extending between a first end and a second end of the sensing rod. The first end of the sensing rod is supported by the insulator and the second end of the sensing rod extending away from the insulator. The particulate matter sensor still further includes an electrical connector assembly engaging the first end of the sensing rod. The electrical connector assembly is configured to transmit a signal generated by the sensing rod.

Abstract: Exemplary embodiments of the present invention relate to methods and devices for monitoring the flow of particulate matter within an exhaust gas stream. In one exemplary embodiment, a particulate matter sensor for an exhaust system of an engine is provided. The sensor includes a casing having an attachment feature for mounting the particulate matter sensor to the exhaust system. The sensor also includes an insulator disposed within the casing. The insulator has a first end located proximate to an electrical connector of the particulate matter sensor and a second end located opposite thereof The sensor further includes a sensing rod having a first end and a second end. The first end of the sensing rod is supported by the insulator and spaced from the second end of the insulator to form a gap therebetween.

Abstract: Exemplary embodiments of the present invention relate methods and devices for measuring flow rate of particulate matter within an exhaust gas stream. In one particular exemplary embodiment, a sensor for detecting and monitoring particulate matter within an exhaust flow path of an engine is provided. The sensor includes a housing having an attachment for mounting the sensor. The sensor also includes a sensing rod supported by an insulating base. The sensing rod is attached to the housing and includes a probe adapted to be placed within the exhaust flow path. The probe includes a section having an increased surface area per unit length as compared to at least one other section of the probe. The sensing rod is configured to detect particulate matter flowing through the exhaust component and generates a signal based thereupon. The sensor further includes an electrical connector in communication with the sensing rod.

Abstract: A method of real-time analysis of an engine, comprising sensing a temperature within a chamber of the engine with a thermocouple sensor disposed on a spark plug operating within the chamber, the thermocouple sensor generating a first signal based upon the temperature within the chamber; detecting current on a wire coupled to the sparkplug with a sensor, the sensor generating a second signal based upon current detected on the wire; converting the first and second signal into a first and second optical signal respectively utilizing one or more signal conditioners; generating a first and second digital signal based upon the first and second optical signal respectively with a receiver; and transmitting the first and second digital signal to an analysis device to generate a display of the temperature as it relates to engine speed at a first time in response to the receipt of the first and second digital signal.