# US 2010/0164352 A1 · Method of producing a spark plug via flared tip attachment > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2010/0164352 A1 - Document ID: US20100164352A1 - Status: Published application - Kind: A1 - Application number: 12/650,821 - Filed: 2009-12-31 - Published: 2010-07-01 - Earliest claimed: 2008-12-31 - Assignees: Fram Group IP LLC - Inventors: Eric P. Passman; Jeffrey T. Boehler; Matthew B. Below - Web page: https://patentgrep.com/patent/US20100164352A1 ## CPC - H01T 13/32: characterised by features of the earthed electrode - H01T 21/02: of sparking plugs - H01T: SPARK GAPS; OVERVOLTAGE ARRESTERS USING SPARK GAPS; SPARKING PLUGS; CORONA DEVICES; GENERATING IONS TO BE INTRODUCED INTO NON-ENCLOSED GASES (overvoltage protection circuits H02H) ## 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. ## Claims ### Claim 1 A side electrode for a spark plug, comprising: 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. ### Claim 2 (depends on 1) The side electrode as in claim 1, wherein the electrode tip is a rivet. ### Claim 3 (depends on 1) The side electrode as in claim 1, wherein the electrode tip is a rivet with a hollow core. ### Claim 4 (depends on 1) The side electrode as in claim 1, wherein the electrode tip is a cylinder. ### Claim 5 (depends on 1) The side electrode as in claim 1, wherein the electrode tip is a cylinder with a hollow core. ### Claim 6 (depends on 1) The side electrode as in claim 1, wherein the electrode tip is formed from at least a precious metal, a precious metal alloy, a base metal or a combination thereof. ### Claim 7 (depends on 1) The side electrode as in claim 1, wherein portions of the electrode tip comprises clad. ### Claim 8 (canceled) ### Claim 9 (depends on 1) The side electrode as in claim 1, wherein the shaft portion is impacted with an impact device to engage the shaft portion to the flared portion. ### Claim 10 (depends on 9) The side electrode as in claim 9, wherein the impact device is configured to form a cross-sectional shape on the shaft portion during impact. ### Claim 11 (depends on 1) The side electrode as in claim 1, wherein the tip portion is coined on the second surface. ### Claim 12 The side electrode as in claiml, wherein the tip portion is secured to the shaft portion by a resistance welding process. ### Claim 13 A side electrode for a spark plug, comprising: 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 first member and a second member, the first member and the second member each having a tip portion and a shaft portion, wherein the tip portion of second member is located on the second surface and the tip portion of the first member is secured to the side wire by engaging the flared portion. ### Claim 14 (depends on 13) The side electrode as in claim 13, wherein the first member is secured to the second member by a resistance welding process. ### Claim 15 (depends on 13) The side electrode as in claim 13, wherein the first member is a first rivet and the second member is a second rivet. ### Claim 16 (depends on 13) The side electrode as in claim 13, wherein the first member and the second member of the electrode tip are each formed from at least a precious metal, a precious metal alloy, a base metal or a combination thereof. ### Claim 17 (depends on 13) The side electrode as in claim 13, wherein the tip portion of the first member is impacted with an impact device to engage the tip portion of the first member to the flared portion. ### Claim 18 (canceled) ### Claim 19 (canceled) ### Claim 20 (canceled) ### Claim 21 (canceled) ### Claim 22 (canceled) ### Claim 23 A spark plug, comprising: an insulator shell; a center electrode disposed in the insulator shell such that one end of the center electrode protrudes from the insulator shell; a metal shell exterior to the insulator shell; a side electrode having a side wire with a first end coupled to the metal shell and a second end facing the protruding end of the center electrode forming a spark discharge gap therebetween, an opening proximate to the first end of the side wire, 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. ### Claim 24 (depends on 23) The spark plug as in claim 23, wherein the electrode tip is a rivet. ### Claim 25 (depends on 23) The spark plug as in claim 23, wherein the electrode tip is a cylinder. ### Claim 26 (canceled) ### Claim 27 (depends on 23) The spark plug as in claim 23, wherein portions of the electrode tip comprises clad. ### Claim 28 (canceled) ### Claim 29 (canceled) ### Claim 30 (canceled)