Spark ignition device and ground electrode therefor and methods of construction thereof

1. A spark ignition device, comprising:

a generally annular ceramic insulator;

a metal shell surrounding at least a portion of said ceramic insulator;

a center electrode received at least in part in said ceramic insulator; and

a ground electrode extending from said shell to a free end portion;

a firing tip attached to said free end portion with a spark gap provided between said center electrode and said firing tip; and

wherein said free end portion is bounded at least in by at least one “as laser cut” peripheral side extending adjacent said firing tip.

2. The spark ignition device of claim 1 wherein said at least one “as laser cut” peripheral side is substantially semicircular.

3. The spark ignition device of claim 2 wherein said “as laser cut” peripheral side extends immediately adjacent a weld pool attaching said firing tip to said ground electrode.

4. The spark ignition device of claim 2 wherein said “as laser cut” peripheral side includes a pair of flat “as laser cut” sides extending away from said substantially semicircular “as laser cut” side.

5. The spark ignition device of claim 1 wherein said at least one “as laser cut” peripheral side includes a pair of substantially flat “as laser cut” peripheral sides converging to another substantially flat “as laser cut” peripheral side to provide said free end portion with a frustroconical shape.

6. The spark ignition device of claim 1 wherein said free end portion of said ground electrode extends from an upper surface to a lower surface; said firing tip is attached to said upper surface; said at least one “as laser cut” peripheral side extends from said upper surface to said lower surface; and said at least one “as laser cut” peripheral side forms a terminal end of said free end portion.