# US 8,348,709 B1 · Method of making a spark plug

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- Number: US 8,348,709 B1
- Document ID: US8348709B1
- Status: Granted
- Kind: B1
- Application number: 13/315,886
- Filed: 2011-12-09
- Granted: 2013-01-08
- Earliest claimed: 2011-12-09
- Assignees: Fram Group IP LLC
- Inventors: Eric Passman; Martin Carlin Baker; Jeffrey Boehler
- Web page: https://patentgrep.com/patent/US8348709B1

## CPC

- 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 method of making a spark plug includes providing a metal shell, an insulator at least partially disposed in the metal shell, a ground electrode coupled to the metal shell, and a center electrode disposed within the insulator. The method also includes depositing a tip substance on the spark plug to form an electrode tip.

## Claims

### Claim 1

A method of making a spark plug comprising:
providing a metal shell; an insulator at least partially disposed in the metal shell; a ground electrode coupled to the metal shell; and a center electrode disposed within the insulator; and
depositing a tip substance on the spark plug, melting the tip substance, and laser deposition welding the tip substance to the spark plug to form an electrode tip, wherein the steps of depositing the tip substance, melting the tip substance, and laser deposition welding the tip substance to the spark plug are performed in a single operation.

### Claim 2 (depends on 1)

The method of making a spark plug of claim 1, wherein the tip substance comprises a powder mixture of individual metals.

### Claim 3 (depends on 2)

The method of making a spark plug of claim 2, wherein the step of melting the tip substance forms an alloy material.

### Claim 4 (depends on 1)

The method of making a spark plug of claim 1, wherein the step of melting the tip substance is performed using coherent light.

### Claim 5 (depends on 1)

The method of making a spark plug of claim 1, wherein the step of depositing the tip substance on the spark plug comprises depositing the tip substance on the center electrode to form a center electrode tip.

### Claim 6 (depends on 5)

The method of making a spark plug of claim 5, wherein the step of depositing the tip substance on the spark plug further comprises depositing the tip substance on the ground electrode to form a ground electrode tip proximate the center electrode tip, thereby forming a spark gap.

### Claim 7 (depends on 1)

The method of making a spark plug of claim 1, wherein the tip substance comprises a noble metal or noble metal combination.

### Claim 8 (depends on 7)

The method of making a spark plug of claim 7, wherein the noble metal combination comprises platinum and nickel.

### Claim 9 (depends on 7)

The method of making a spark plug of claim 7, wherein the noble metal combination comprises platinum, iridium and tungsten.

### Claim 10 (depends on 7)

The method of making a spark plug of claim 7, wherein the noble metal combination comprises platinum, palladium and iridium.

### Claim 11 (depends on 7)

The method of making a spark plug of claim 7, wherein the noble metal combination comprises iridium and rhodium.

### Claim 12 (depends on 7)

The method of making a spark plug of claim 7, wherein the noble metal combination comprises platinum and rhodium.

### Claim 13

A method of making a spark plug comprising:
providing a metal shell; an insulator at least partially disposed in the metal shell; a ground electrode coupled to the metal shell; and a center electrode disposed within the insulator;
laser depositing a tip substance on the center electrode; and
melting the tip substance to form an electrode tip, wherein the step of depositing the tip substance and the step of melting the tip substance are performed in a single operation.

### Claim 14 (depends on 13)

The method of making a spark plug of claim 13, wherein the tip substance comprises a powder mixture of individual metals.

### Claim 15 (depends on 13)

The method of making a spark plug of claim 13, wherein the tip substance comprises a noble metal or noble metal combination.

### Claim 16 (depends on 15)

The method of making a spark plug of claim 15, wherein the noble metal combination comprises platinum and nickel.

### Claim 17 (depends on 15)

The method of making a spark plug of claim 15, wherein the noble metal combination comprises platinum, iridium and tungsten.

### Claim 18 (depends on 15)

The method of making a spark plug of claim 15, wherein the noble metal combination comprises platinum, palladium and iridium.

### Claim 19 (depends on 15)

The method of making a spark plug of claim 15, wherein the noble metal combination comprises iridium and rhodium.