Spark plug having multi-layer sparking component attached to ground electrode

1. A spark plug, comprising:

a metal shell having an axial bore;

an insulator at least partially disposed in the metal shell axial bore and having an axial bore;

a center electrode at least partially disposed in the insulator axial bore;

a ground electrode attached to the metal shell and having a spark-gap facing surface and a distal end surface; and

a multi-layer sparking component attached to the spark-gap facing surface of the ground electrode with a resistance welded weldment and having a precious metal layer that is precious metal based and a base metal layer that is non-precious metal based, wherein a greatest thickness dimension of the precious metal layer ranges between approximately 0.05 mm and 0.25 mm, inclusive, the multi-layer sparking component includes an intermetallic layer formed between the precious metal layer and the base metal layer before the multi-layer sparking component is resistance welded to the spark-gap facing surface of the ground electrode, and a portion of the multi-layer sparking component overhangs the distal end surface of the ground electrode.

2. The spark plug of claim 1 , wherein the precious metal layer is a thin layer with the greatest width dimension across a sparking surface that is at least several times larger than a greatest thickness dimension through the precious metal layer.

3. The spark plug of claim 1 , wherein the precious metal layer has a greatest thickness dimension that is less than the greatest thickness dimension of the base metal layer.

4. The spark plug of claim 1 , wherein the multi-layer sparking component is a pre-manufactured bi-metal ribbon with the precious metal layer and base metal layer joined together prior to attachment of the multi-layer sparking component to the ground electrode.

5. The spark plug of claim 4 , wherein the pre-manufactured bi-metal ribbon has a cladded joint between the precious metal layer and the base metal layer.

6. The spark plug of claim 1 , wherein a greatest width dimension and a greatest length dimension of the precious metal layer is the same as a greatest width dimension and a greatest length dimension of the base metal layer.

7. The spark plug of claim 1 , wherein the base metal layer is attached directly to the ground electrode via a weldment located between the base metal layer and the ground electrode.

8. The spark plug of claim 7 , wherein the base metal layer and the ground electrode are made from nickel or a nickel-based alloy, and the base metal layer is attached directly to the ground electrode via a resistance welded weldment located between the base metal layer and the ground electrode.

9. The spark plug of claim 7 , wherein the base metal layer is attached directly to the ground electrode via a surface-to-surface attachment between a bottom surface of the base metal layer and the spark-gap facing surface of the ground electrode.

10. The spark plug of claim 9 , wherein a volume of the portion of the multi-layer sparking component that overhangs the distal end surface is less than a volume of the multi-layer sparking component that does not overhang the distal end surface and is supported by the ground electrode.

11. The spark plug of claim 1 , wherein the precious metal layer is made from platinum or a platinum-based alloy.

12. A spark plug, comprising:

a metal shell having an axial bore;

an insulator at least partially disposed in the metal shell axial bore and having an axial bore;

a center electrode at least partially disposed in the insulator axial bore;

a ground electrode attached to the metal shell; and

a pre-manufactured multi-layer sparking component formed from a bi-metal ribbon prior to attachment of the pre-manufactured multi-layer sparking component to the ground electrode, the pre-manufactured multi-layer sparking component comprising:

a precious metal layer that is platinum-based and has a greatest width dimension across a sparking surface of the precious metal layer that is at least several times larger than a greatest thickness dimension through the precious metal layer, wherein the greatest thickness dimension of the precious metal layer ranges between approximately 0.05 mm and 0.25 mm, inclusive;

a base metal layer that is nickel-based and has a greatest width dimension across a bottom surface of the base metal layer that is at least several times larger than a greatest thickness dimension through the base metal layer, wherein the greatest thickness dimension of the precious metal layer is less than or equal to the greatest thickness dimension of the base metal layer; and

an intermetallic layer having platinum and nickel that is formed at the interface between the precious metal layer and the base metal layer.

13. The spark plug of claim 12 , wherein the greatest thickness dimension of the base metal layer ranges between approximately 0.05 mm and 0.75 mm, inclusive.

14. The spark plug of claim 12 , wherein a joint between the precious metal layer and base metal layer of the pre-manufactured multi-layer sparking component is a cladded joint formed at the time the bi-metal ribbon was formed.

15. A method of manufacturing a spark plug, the method comprising:

providing a metal shell, an insulator, a center electrode, and a ground electrode with a distal end surface and a spark-gap facing surface;

providing a pre-manufactured bi-metal ribbon including a precious metal layer that is precious metal based and a base metal layer that is non-precious metal based, wherein a greatest thickness dimension of the precious metal layer ranges between approximately 0.05 mm and 0.25 mm, inclusive, and the precious metal layer and the base metal layer are joined together so that an intermetallic layer is formed between the precious metal layer and the base metal layer;

severing the pre-manufactured bi-metal ribbon into an individual multi-layer sparking component, the precious metal layer and the base metal layer of the multi-layer sparking component are both thin layers; and

resistance welding the multi-layer sparking component to the spark-gap facing surface of the ground electrode with the base metal layer attached directly to the ground electrode, a portion of the multi-layer sparking component overhanging the distal end surface of the ground electrode.

16. The method of claim 15 , wherein the multi-layer sparking component is attached to the ground electrode via a surface-to-surface attachment between a bottom surface of the base metal layer and the spark-gap facing surface of the ground electrode.

17. A spark plug, comprising:

a metal shell having an axial bore;

an insulator at least partially disposed in the metal shell axial bore and having an axial bore;

a center electrode at least partially disposed in the insulator axial bore;

a ground electrode attached to the metal shell and having a distal end surface, a spark-gap facing surface, and a plurality of trimmed side surfaces; and

a multi-layer sparking component attached to the spark-gap facing surface of the ground electrode and having a precious metal layer and a base metal layer, wherein a portion of the multi-layer sparking component overhangs the distal end surface of the ground electrode and the trimmed side surfaces of the ground electrode terminate into one or more sides of the multi-layer sparking component in a flush manner.

18. A spark plug, comprising:

a metal shell having an axial bore;

an insulator at least partially disposed in the metal shell axial bore and having an axial bore;

a center electrode at least partially disposed in the insulator axial bore;

a ground electrode attached to the metal shell and having a distal end surface and a spark-gap facing surface; and

a multi-layer sparking component having a precious metal layer and a base metal layer, wherein the multi-layer sparking component is attached to the distal end surface of the ground electrode so that the precious metal layer of the multi-layer sparking component is generally aligned with the spark-gap facing surface of the ground electrode and a portion of the base metal layer of the multi-layer sparking component extends beyond the distal end surface of the ground electrode.