Igniter assembly including arcing reduction features

1. A method of forming an igniter for receiving a voltage from a power source and emitting an electrical field that forms a corona to ionize a mixture of fuel and air of an internal combustion engine comprising the steps of:

providing a shell extending longitudinally from an upper shell end to a lower shell end;

disposing an insulator in the shell;

disposing an electrode including an electrode body portion extending longitudinally from an electrode terminal end to an electrode firing end in the insulator such that the electrode firing end faces toward the lower shell end; and

forming a corona reducing lip at the upper shell end to be free of sharp edges, wherein the corona reducing lip includes a lip outer surface presenting a plurality of spherical lip radii therealong, and each of the spherical lip radii is not less than 0.004 inches.

2. A method as set forth in claim 1 wherein the forming the corona reducing lip includes removing sharp edges at the upper shell end.

3. A method as set forth in claim 1 including forming the shell to include a shell inner surface adjacent the corona reducing lip and facing the insulator to be free of sharp edges.

4. A method as set forth in claim 1 including forming the insulator to include an insulator outer surface facing the shell and being free of sharp edges.

5. A method as set forth in claim 1 including moving the upper shell end radially inwardly.

6. A method as set forth in claim 1 wherein each of the spherical lip radii is at least 0.005 inches.

7. A method as set forth in claim 1 wherein the lip outer surface is round.

8. A method as set forth in claim 1 wherein the corona reducing lip presents smooth transitions between different sections of the lip outer surface.

9. A method as set forth in claim 1 wherein the upper shell end is distal and the corona reducing lip is spaced from the insulator at the upper shell end.

10. A method as set forth in claim 1 wherein the corona reducing lip includes a stem extending radially inwardly toward the insulator and a bulb at the upper shell end and wherein lip thicknesses t 1 of the bulb is greater than lip thicknesses t 1 of the stem and wherein the lip outer surface of the bulb is rounded.

11. A method as set forth in claim 1 wherein the shell presents a shell inner surface extending from the corona reducing lip to the lower shell end, the shell inner surface facing the insulator and being free of sharp edges.

12. A method as set forth in claim 11 , wherein the shell inner surface presents a plurality of spherical shell radii therealong and each of the spherical shell radii is at least 0.004 inches.

13. A method as set forth in claim 1 wherein the insulator presents an insulator outer surface facing the shell and being free of sharp edges.

14. A method as set forth in claim 13 wherein the insulator outer surface presents a plurality of spherical insulator radii therealong and each of the spherical insulator radii is at least 0.004 inches.

15. A method as set forth in claim 1 including a shell sealing gasket being free of sharp edges disposed between the shell and the insulator.

16. A method of forming an igniter for receiving a voltage from a power source and emitting an electrical field that forms a corona to ionize a mixture of fuel and air of an internal combustion engine comprising the steps of:

providing a shell extending longitudinally from an upper shell end to a lower shell end;

disposing an insulator in the shell;

disposing an electrode including an electrode body portion extending longitudinally from an electrode terminal end to an electrode firing end in the insulator such that the electrode firing end faces toward the lower shell end;

forming a corona reducing lip at the upper shell end to be free of sharp edges, wherein the corona reducing lip includes a lip outer surface presenting a plurality of spherical lip radii therealong, and each of the spherical lip radii is at least 0.004 inches; and

wherein the electrode body portion has an electrode diameter generally perpendicular to the longitudinal electrode body portion; the electrode includes a corona enhancing tip at the electrode firing end having a tip diameter generally perpendicular to the longitudinal electrode body portion; the tip diameter is greater than the electrode diameter; and the corona enhancing tip including a plurality of branches each extending away from the shell to a distal end.

17. A method as set forth in claim 16 wherein the insulator includes an insulator nose region presenting an insulator nose diameter generally perpendicular to the longitudinal electrode body portion and tapering to an insulator nose end; and the insulator nose diameter at the insulator nose end is less than the tip diameter of the corona enhancing tip.

18. A method of forming an igniter for receiving a voltage from a power source and emitting an electrical field that forms a corona to ionize a mixture of fuel and air of an internal combustion engine comprising the steps of:

providing a shell extending longitudinally from an upper shell end to a lower shell end;

disposing an insulator in the shell;

disposing an electrode including an electrode body portion extending longitudinally from an electrode terminal end to an electrode firing end in the insulator such that the electrode firing end faces toward the lower shell end;

forming a corona reducing lip at the upper shell end to be free of sharp edges, wherein the corona reducing lip includes a lip outer surface presenting a plurality of spherical lip radii therealong, and each of the spherical lip radii is at least 0.004 inches; and

wherein the electrode is formed of an electrically conductive material; the electrode body portion has an electrode diameter generally perpendicular to the longitudinal electrode body portion; the electrode including a corona enhancing tip at the electrode firing end having a tip diameter extending generally perpendicular to the longitudinal electrode body portion; the tip diameter being greater than the electrode diameter; the insulator is disposed annularly around and longitudinally along the electrode body portion from an insulator upper end to an insulator nose end adjacent the electrode firing end such that the insulator nose end abuts the corona enhancing tip; the insulator including an insulator nose region presenting an insulator nose diameter generally perpendicular to the longitudinal electrode body portion and tapering to the insulator nose end; the insulator nose diameter at the insulator nose end being less than the tip diameter; a terminal received in the insulator and in electrical communication with the electrode terminal end; the terminal extending from a first terminal end to a second terminal end being in electrical communication with the electrode terminal end; the terminal formed of an electrically conductive material; a resistor layer disposed between and electrically connecting the second terminal end and the electrode terminal end; the resistor layer formed of an electrically conductive material; the shell is disposed annularly around the insulator; the shell is formed of a metal material; the shell extends longitudinally along the insulator such that the insulator nose region projects outwardly of the lower shell end; and the corona reducing lip presents a lip outer surfaces having a plurality of sections with smooth transitions therebetween.