Spark plug with undercut insulator and one piece shell

1. A spark plug for an internal combustion engine, the spark plug comprising:

an elongated center electrode having a center electrode tip at one end and a terminal proximate the other end;

an insulator substantially surrounding the center electrode, the insulator having a channel formed in an exterior surface of the insulator;

an outer shell surrounding the insulator having: a jamb nut portion with a distal end extending thereform, the distal end being aligned with the channel such that the distal end of the outer shell is received within and engages the insulator within the channel;

a motor seat portion proximate to the jamb nut portion; and

a threaded portion proximate to the motor seat portion, wherein the jamb nut portion, the motor seat portion, and the threaded portion are all integrally formed with the outer shell such that the outer shell comprises the jamb nut portion, the motor seat portion, and the threaded portion, which are formed as a single component.

2. The spark plug as in claim 1 , wherein the insulator has a first portion, a second portion and a third portion, the first portion being located at one end of the insulator and the third portion being located at an opposite end of the insulator, wherein the channel is located in the third portion and the second portion has a larger thickness than the first portion and the third portion has a larger thickness than the first portion.

3. The spark plug as in claim 2 , wherein the insulator further comprises a shoulder portion configured to engage a portion of the distal end of the outer shell as it is crimped into the channel.

4. The spark plug as in claim 1 , wherein the insulator further comprises a shoulder portion configured to engage a portion of the distal end of the outer shell as it is crimped into the channel.

5. The spark plug as in claim 4 , wherein the insulator further comprises another shoulder portion located in the first portion, the another shoulder portion being configured to engage a portion of the outer shell having the threaded portion.

6. The spark plug as in claim 1 , wherein the insulator is made from a non-conducting ceramic material.

7. The spark plug as in claim 6 , wherein the center electrode extends form one end of the insulator and the terminal extends from an opposite end of the insulator.

8. A method of forming a spark plug, comprising:

inserting an insulator into an outer shell of the spark plug, the insulator having a first portion, a second portion and a third portion, the first portion being located at one end of the insulator and the third portion being located at an opposite end of the insulator, wherein a channel is located in the third portion and the second portion has a larger thickness than the first portion and the third portion;

contacting the insulator within the channel with a portion of the outer shell proximate to a distal end of the outer shell, the distal end extending from a jamb nut portion of the outer shell; and

wherein the outer shell has a motor seat portion and a threaded portion integrally formed with the jamb nut portion and the motor seat portion is located between the jamb nut portion and the threaded portion.

9. The method a in claim 8 wherein the insulator has a first portion, a second portion and a third portion, the first portion being located at one end of the insulator and the third portion being located at an opposite end of the insulator, wherein the channel is located in the third portion and the second portion has a larger thickness than the first portion and the third portion has a larger thickness than the first portion.

10. The method as in claim 9 , wherein the insulator further comprises a shoulder portion configured to engage a portion of the distal end of the outer shell as it is crimped into the channel.

11. The method as in claim 8 , wherein the insulator further comprises a shoulder portion configured to engage a portion of the distal end of the outer shell as it is crimped into the channel.

12. The method as in claim 11 , wherein the insulator further comprises another shoulder portion located in the first portion, the another shoulder portion being configured to engage a portion of the outer shell having the threaded portion.

13. The method as in claim 8 , wherein the insulator is made from a non-conducting ceramic material.

14. The method as in claim 13 , wherein the center electrode extends form one end of the insulator and the terminal extends from an opposite end of the insulator.

15. A spark plug for an internal combustion engine, the spark plug comprising:

an elongated center electrode having a center electrode tip at one end and a terminal proximate the other end;

an insulator substantially surrounding the center electrode, the insulator having a channel formed in an exterior surface of the insulator, wherein the channel has a thickness that is less than thicknesses of portions of the insulator on opposing sides of the channel;

an outer shell surrounding the insulator having: a jamb nut portion with a distal end extending therefrom, the distal end being aligned with the channel such that the distal end of the outer shell is received within and engages the insulator within the channel;

a motor seat portion proximate to the jamb nut portion; and

a threaded portion proximate to the motor seat portion, wherein the jamb nut portion, the motor seat portion, and the threaded portion are all integrally formed with the outer shell such that the outer shell comprises the jamb nut portion, the motor seat portion, and the threaded portion, which are formed as a single component.