Abstract: An electrode tip assembly for a spark plug includes an electrode tip that is formed on an electrode base using an additive manufacturing process, such as a powder bed fusion technique, after which the electrode base is welded to an electrode body. The electrode base includes a welding side and an additive manufacturing side, and the electrode tip includes a plurality of laser deposition layers built on the additive manufacturing side of the electrode base.

Abstract: An electrode tip assembly for a spark plug includes an electrode tip that is formed on an electrode base using an additive manufacturing process, such as a powder bed fusion technique, after which the electrode base is welded to an electrode body. The electrode base includes a welding side and an additive manufacturing side, and the electrode tip includes a plurality of laser deposition layers built on the additive manufacturing side of the electrode base.

Abstract: A composite sparking component for a spark plug that has a thin precious metal layer with a series of grooves attached to an underlying base layer. The grooves allow the precious metal layer, and hence the entire composite sparking component, to be more easily bent or formed into a desired shape, while at the same time minimizing the amount of precious metal and providing enhanced sparking sites along the edges of the grooves. In one example, the composite sparking component is a sleeve-shaped component attached to a center electrode. In a different example, the composite sparking component is a ring-shaped component attached to a ground electrode. The precious metal layer may be bonded to the base layer in the form of a bimetal laminate structure, or the precious metal layer can be built on the base layer with the use of additive manufacturing, to cite several possibilities.

Abstract: A composite sparking component for a spark plug that has a thin precious metal layer with a series of grooves attached to an underlying base layer. The grooves allow the precious metal layer, and hence the entire composite sparking component, to be more easily bent or formed into a desired shape, while at the same time minimizing the amount of precious metal and providing enhanced sparking sites along the edges of the grooves. In one example, the composite sparking component is a sleeve-shaped component attached to a center electrode. In a different example, the composite sparking component is a ring-shaped component attached to a ground electrode. The precious metal layer may be bonded to the base layer in the form of a bimetal laminate structure, or the precious metal layer can be built on the base layer with the use of additive manufacturing, to cite several possibilities.

Abstract: A spark plug having a shell with a ground electrode recess. A ground electrode having an insertion end, a firing end, and a round cross-sectional profile toward the insertion end is inserted into the ground electrode recess of the shell. An attachment portion surrounds at least a portion of the ground electrode and includes a solidified bonding material at a connection interface between the ground electrode and the shell. In some implementations, the ground electrode can have a copper core that extends further into the shell, past the distal end of the insulator. In some embodiments, the ground electrode has a sheath surrounding the copper core that has aluminum and a high weight percentage of nickel.

Abstract: A spark plug electrode assembly and method of manufacturing a spark plug assembly having an inner and outer electrode component, one of which or both being formed using metal injection molding (MIM). Forming at least one of the inner or outer electrode components with MIM allows for the creation of a mechanical lock and a metallurgical bond at an interface between the components such that the components may be joined without a weld.

Abstract: A spark plug electrode assembly and method of manufacturing a spark plug assembly having an inner and outer electrode component, one of which or both being formed using metal injection molding (MIM). Forming at least one of the inner or outer electrode components with MIM allows for the creation of a mechanical lock and a metallurgical bond at an interface between the components such that the components may be joined without a weld.

Abstract: A prechamber spark plug for a gas-powered internal combustion engine, having a metallic body, an insulator, a center electrode, at least one ground electrode, a cap, and a sleeve. The cap is arranged at a front end of the spark plug and shields the center and ground electrodes from a combustion chamber after the prechamber spark plug is installed in the internal combustion engine, and the cap delimits a prechamber in which the center electrode and the ground electrode are located from the combustion chamber. The cap has at least one opening that permits gas exchange between the prechamber and the space outside of the prechamber. The cap is mounted on the sleeve, which surrounds a section of the body, contains external threads for screwing into the internal combustion engine, and is joined to the body. In addition, a method for manufacturing the aforementioned spark plug is described.

Abstract: A prechamber spark plug for a gas-powered internal combustion engine, having a metallic body, an insulator, a center electrode, at least one ground electrode, a cap, and a sleeve. The cap is arranged at a front end of the spark plug and shields the center and ground electrodes from a combustion chamber after the prechamber spark plug is installed in the internal combustion engine, and the cap delimits a prechamber in which the center electrode and the ground electrode are located from the combustion chamber. The cap has at least one opening that permits gas exchange between the prechamber and the space outside of the prechamber. The cap is mounted on the sleeve, which surrounds a section of the body, contains external threads for screwing into the internal combustion engine, and is joined to the body. In addition, a method for manufacturing the aforementioned spark plug is described.

Abstract: A spark plug for a gas-powered internal combustion engine having: a spark plug body; an insulator; a center electrode; a ground electrode support that is attached to the spark plug body and supports at least one ground electrode that forms a spark gap with the center electrode; a swirl chamber located at the front end of the spark plug whose wall surrounds the center and ground electrodes; the wall of the swirl chamber is formed by a cylindrical sleeve which has an open front face and radial perforations; the ground electrode support includes an annular base part and at least one arm that supports the ground electrode; the arm starts at the base part and extends within the swirl chamber. The arm of the ground electrode support increases in cross-section starting from the ground electrode it supports toward the annular base part of the ground electrode support.

Abstract: A spark plug for a gas-powered internal combustion engine having: a spark plug body; an insulator; a center electrode; a ground electrode support that is attached to the spark plug body and supports at least one ground electrode that forms a spark gap with the center electrode; a swirl chamber located at the front end of the spark plug whose wall surrounds the center and ground electrodes; the wall of the swirl chamber is formed by a cylindrical sleeve which has an open front face and radial perforations; the ground electrode support includes an annular base part and at least one arm that supports the ground electrode; the arm starts at the base part and extends within the swirl chamber. The arm of the ground electrode support increases in cross-section starting from the ground electrode it supports toward the annular base part of the ground electrode support.