Spark plug having improved ground electrode orientation and method of forming

A method of forming a spark plug for being threaded into a cylinder head and extending into a combustion chamber for providing a spark to ignite a combustible mixture of fuel and air in the combustion chamber, comprising the steps of:

• providing a shell formed of metal extending from a shell upper surface to a shell lower surface and including a shell outer surface between said shell upper surface and said shell lower surface,
• providing a ground electrode formed of an electrically conductive material,
• attaching the ground electrode to the shell lower surface,
• predetermining an angle of threads to be formed in the shell outer surface relative to the ground electrode and providing a thread forming apparatus for forming the threads at the predetermined angle relative to the ground electrode when the ground electrode is disposed in a predetermined position relative to the thread forming apparatus,
• using an orientation tool to dispose the ground electrode in the predetermined position relative to the thread forming apparatus, wherein the orientation tool includes a tool outer surface extending longitudinally along a tool central axis from first end to a second end and includes a thread orientation feature extending transverse to the tool outer surface and wherein the step of using the orientation tool includes:
• disposing the orientation tool in a predetermined location relative to the thread forming apparatus such that when the ground electrode contacts the thread orientation feature the ground electrode is disposed in the predetermined position relative to the thread forming apparatus,
• aligning an igniter central axis of the shell with the tool central axis,
• disposing the ground electrode along the tool outer surface,
• rotating the shell relative to the orientation tool until the ground electrode contacts the thread orientation feature, and
• forming the threads in the shell outer surface at the predetermined angle relative to the ground electrode by the thread forming apparatus while the ground electrode contacts the thread orientation feature for allowing the ground electrode to be disposed in a predetermined position in the combustion chamber when the shell is threaded into the cylinder head.

A method of forming an ignition system including a spark plug threaded into a cylinder head and extending into a combustion chamber for providing a spark to ignite a combustible mixture of fuel and air in the combustion chamber, comprising the steps of:

• providing a shell formed of a metal material extending longitudinally along an igniter central axis from a shell upper surface to a shell lower surface and including a shell inner surface facing the igniter central axis and a shell outer surface facing opposite the shell inner surface each extending longitudinally between the shell upper surface and the shell lower surface, wherein the shell outer surface presents a shell outer diameter and the shell inner surface presents a shell inner diameter each extending across the igniter central axis and wherein the shell lower surface is planar and perpendicular to the igniter central axis and extends annularly around the igniter central axis,
• providing a ground electrode formed of an electrically conductive material having a side surface extending longitudinally and straight from an attachment surface to a ground firing surface, wherein the attachment surface and the ground firing surface are planar and present an electrode thickness,
• attaching the attachment surface of the ground electrode to the shell lower surface at a predetermined circumferential location along the shell lower surface,
• predetermining an angle of threads to be formed in the shell outer surface relative to the side surface of the ground electrode,
• providing an orientation tool extending longitudinally along a tool central axis from a first end to a second end and including a tool outer surface between the first end and the second end and including a thread orientation feature disposed in a predetermined location along the tool outer surface and extending transverse to the tool outer surface,
• providing a thread forming apparatus for forming the threads at the predetermined angle relative to the ground electrode when the ground electrode is disposed in a predetermined position relative to the thread forming apparatus, wherein the thread forming apparatus receives the receptacle with the thread orientation feature located in a predetermined position relative to the thread forming apparatus when the ground electrode is contacting the thread orientation feature of the receptacle, such that the ground electrode is disposed in the predetermined position relative to the thread forming apparatus,
• aligning the tool central axis of the orientation tool with the igniter central axis of the shell,
• disposing the shell on the first end of the orientation tool such that the ground electrode engages the tool outer surface,
• rotating the shell relative to the orientation tool such that the ground firing surface slides along the tool outer surface circumferentially around the central axes until the side surface of the ground electrode contacts the thread orientation feature and is disposed in a predetermined position relative to the thread orientation feature,
• sensing the contact between the side surface of the ground electrode and the thread orientation feature,
• forming the threads in the shell outer surface at a predetermined angle relative to the side surface of the ground electrode after sensing the contact between the side surface and the thread orientation feature,
• maintaining the ground electrode in contact with the thread orientation feature while forming the threads,
• disengaging the orientation tool from the ground electrode,
• bending the ground firing surface of the ground electrode inwardly and past the igniter central axis such that the side surface of the ground electrode crosses the igniter central axis,
• sliding an insulator into the shell,
• sliding a central electrode into the insulator,
• disposing a resistor layer in the insulator along the central electrode,
• disposing a terminal in the insulator on the resistor layer,
• providing a cylinder head including threads mating the threads of the shell,
• engaging the threads of the shell and the threads of the cylinder head, and
• rotating the shell relative to the cylinder head to screw the shell into the cylinder head such that the ground electrode is disposed in the predetermined location relative to the threads of the shell and in a predetermined location relative to the cylinder head.