Ignition device having an electrode with a platinum firing tip and method of construction

1. An ignition device for an internal combustion engine, comprising:

a housing having an opening;

an insulator secured within the housing with an end of the insulator exposed through said opening in the housing;

a center electrode mounted within the insulator and having a free end extending beyond the insulator;

a ground electrode extending from the housing with a portion of the ground electrode being located opposite the free end of the center electrode to define a spark gap therebetween;

at least a selected one of said center electrode or ground electrode having a platinum-based firing tip;

a resistance weld joint bonding said firing tip to said selected electrode, said resistance weld joint defining a lower surface of said firing tip embedded a first distance beneath an outer surface of said selected electrode; and

a continuous bead of overlapping laser weld pools formed over an outer periphery of said firing tip further bonding said firing tip to said selected electrode, said overlapping weld pools extending a second distance beneath said outer surface of said selected electrode, wherein said second distance is greater than said first distance and said firing tip is free from undercuts from said laser weld pools.

2. The ignition device of claim 1 wherein said selected electrode is free from undercuts from said laser weld pools.

3. The ignition device of claim 1 wherein said laser weld pools have a sidewall bonded to said firing tip, said firing tip having a central axis wherein said sidewall extends radially outwardly from said axis.

4. The ignition device of claim 1 wherein said center electrode has a side surface extending along a longitudinal axis and said laser weld pools abut said side surface.

5. The ignition device of claim 4 wherein said laser weld pools define a surface that is oblique to said side.

6. The ignition device of claim 4 wherein said laser weld pools define a generally conical surface.

7. The ignition device of claim 1 wherein said lower surface of said firing tip is generally convex.

8. The ignition device of claim 1 wherein said center electrode has a sidewall extending along a longitudinal axis and said laser weld pools are formed radially inwardly from said sidewall and out of abutment with said side.

9. The ignition device of claim 8 wherein said center electrode has a generally annular surface free of said laser weld pools extending from said laser weld pools to said side.

10. The ignition device of claim 9 wherein said annular surface is formed in a conical shape.

11. An electrode assembly for an ignition device, comprising:

an electrode body having an outer surface;

a firing tip having a lower surface and an outer periphery;

a resistance weld joint bonding said firing tip lower surface to said electrode body, said lower surface being embedded a first distance beneath said outer surface; and

a continuous bead of overlapping laser weld pools formed over said firing tip outer periphery, said laser weld pools extending a second distance beneath said electrode body outer surface, said second distance being greater than said first distance, wherein said firing tip is free from undercuts from said laser weld pools.

12. The electrode assembly of claim 11 wherein said electrode assembly is a center electrode.

13. The electrode assembly of claim 12 wherein said laser weld pools define a conical surface extending radially outwardly from said firing tip.

14. The electrode assembly of claim 13 wherein said conical surface extends to a sidewall of said electrode body.

15. The electrode assembly of claim 12 wherein said electrode body has a sidewall and said laser weld pools are spaced radially inwardly from said sidewall.

16. The electrode assembly of claim 15 wherein a conical surface extends radially outwardly from adjacent said laser weld pools to said sidewall.

17. The electrode assembly of claim 11 wherein said firing tip has a central axis and said laser weld pools have an annular sidewall bonded to said firing tip, said sidewall extending radially outwardly from said central axis.

18. The electrode assembly of claim 11 wherein said firing tip is platinum-based.

19. A method of construction for an ignition device, comprising:

providing an electrode body having an outer surface;

providing a preformed piece of noble metal firing tip material;

resistance welding said firing tip material to said body to at least partially form a firing tip and defining a lower surface of said firing tip a first distance beneath said outer surface;

laser welding a continuous bead of overlapping laser weld pools over an outer periphery of said firing tip so that said weld pools extending a second distance beneath said outer surface, wherein said second distance is greater than said first distance; and

forming said weld pools so that said firing tip is free from undercuts from said laser weld pools.

20. The method of claim 19 further including constructing said ignition device as a center electrode for a spark plug.

21. The method of claim 20 further including forming a conical surface extending radially outwardly from said firing tip via said laser weld pools.

22. The method of claim 21 further including forming said conical surface so that it extends radially outwardly from said firing tip to a sidewall of said electrode body.

23. The method of claim 20 further including forming said laser weld pools so that they are spaced radially inwardly from a sidewall of said electrode body by an non-welded annular portion of said electrode body.

24. The method of claim 23 further including forming a conical surface on said non-welded annular portion.

25. The method of claim 19 further including defining said lower surface having a convex shape.

26. A method of constructing an ignition device for an internal combustion engine, comprising:

providing a housing;

securing an insulator within the housing with an end of the insulator exposed through an opening in the housing;

mounting a center electrode body having an outer surface within the insulator with a firing tip region of the center electrode body extending beyond the insulator;

extending a ground electrode body having an outer surface from the housing with a firing tip region of the ground electrode body being located opposite the firing tip region of the center electrode body to define a spark gap therebetween;

providing at least one preformed piece of firing tip material formed from noble metal;

resistance welding said at least one piece of firing tip material to at least one of said center electrode body or said ground electrode body to at least partially form a firing tip and defining a lower surface of said firing tip a first distance beneath said outer surface;

laser welding a continuous bead of overlapping laser weld pools over an outer periphery of said firing tip so that said weld pools extending a second distance beneath said outer surface, wherein said second distance is greater than said first distance; and

forming said weld pools so that said firing tip is free from undercuts from said laser weld pools.

27. The method of claim 26 wherein said firing tip material is welded to said center electrode body and further including forming a conical surface extending radially outwardly from said firing tip via said laser weld pools.

28. The method of claim 27 further including forming said conical surface so that it extends radially outwardly from said firing tip to a sidewall of said center electrode body.

29. The method of claim 26 wherein said firing tip material is welded to said center electrode body and further including forming said laser weld pools so that they are spaced radially inwardly from a sidewall of said electrode body by an non-welded annular portion of said electrode body.

30. The method of claim 29 further including forming a conical surface on said non-welded annular portion.

31. The method of claim 26 further including defining said lower surface having a convex shape.