Spark plug having firing pad

1. A spark plug, comprising:

a shell having an axial bore;

an insulator having an axial bore and being disposed at least partially within the axial bore of the shell;

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

a ground electrode attached to the shell and composed of a nickel-based alloy material; and

a firing pad attached to the ground electrode and composed of a platinum-based alloy material containing at least 25 wt. % of nickel, the firing pad having a protrusion projecting from a bottom side of the firing pad that concentrates current flow therethrough amid a resistance welding process, wherein the attachment between the firing pad and the ground electrode includes a resistance-welded weldment and lacks a laser-welded weldment, the protrusion facilitates the absence of a laser-welded weldment in the attachment between the firing pad and the nickel-based alloy material of the ground electrode.

2. A spark plug as defined in claim 1 , wherein the platinum-based alloy material of the firing pad includes nickel from about 25 wt. % to about 35 wt. %, inclusive, and platinum from about 65 wt. % to about 75 wt. %, inclusive.

3. A spark plug as defined in claim 2 , wherein the platinum-based alloy material of the firing pad includes about 30 wt. % of nickel and about 70 wt. % of platinum.

4. A spark plug as defined in claim 1 , wherein the platinum-based alloy material of the firing pad further comprises at least one element selected from the group consisting of: tungsten (W), palladium (Pd), rhodium (Rh), iridium (Ir), or rhenium (Re).

5. A spark plug as defined in claim 1 , wherein the protrusion is a single protrusion spanning across the bottom side between a first side of the firing pad and a second side of the firing pad.

6. A spark plug as defined in claim 5 , wherein the protrusion has a crest, the crest spanning across the side surface between a third side of the firing pad and a fourth side of the firing pad, the protrusion tapering in thickness from the crest toward the first side of the firing pad, the protrusion tapering in thickness from the crest toward the second side of the firing pad.

7. A spark plug as defined in claim 1 , wherein, once the firing pad is attached to the ground electrode, the ground electrode has a depression located in a working surface of the ground electrode, the depression receiving the protrusion.

8. A spark plug as defined in claim 1 , further comprising a resistance-welded expulsion situated at least partly around a peripheral edge (P) of the firing pad, the resistance-welded expulsion having a top surface generally in-line with a sparking surface of the firing pad.

9. A spark plug as defined in claim 8 , further comprising a heat-affected zone located in the ground electrode, the heat-affected zone resulting from the resistance welding process, and the heat-affected zone situated largely underneath the firing pad and generally confined within an interface boundary between the firing pad the resistance-welded expulsion.

10. A spark plug as defined in claim 1 , wherein the firing pad is a thin pad with a greatest width dimension across its sparking surface that is at least several times larger than a greatest thickness dimension (T).

11. A spark plug as defined in claim 1 , wherein the firing pad is a multi-layer firing pad with a base metal layer and a precious metal layer, the base metal layer composed of a nickel-based alloy material and attached to the ground electrode via the resistance-welded weldment, and the precious metal layer composed of the platinum-based alloy material containing at least 25 wt. % of nickel.

12. A spark plug as defined in claim 1 , wherein the protrusion includes multiple protrusions projecting from the bottom side of the firing pad, the protrusions concentrating current flow therethrough amid the resistance welding process.

13. A method of preparing a ground electrode and firing pad assembly, the method comprising the steps of:

locating a firing pad on a ground electrode, the firing pad having a protrusion projecting from a bottom side of the firing pad, the protrusion making line-to-surface contact with the ground electrode; and

passing electrical current through the line-to-surface contact between the protrusion and the ground electrode while pressing the firing pad and the ground electrode together, the firing pad at least partially sinking into the ground electrode amid the passing of the electrical current and producing a surface-to-surface contact between the protrusion and the ground electrode, the firing pad thereafter attached to the ground electrode and establishing the ground electrode and firing pad assembly.

14. A method as defined in claim 13 , wherein the line-to-surface contact made between the protrusion and the ground electrode constitutes the sole contact made between the firing pad and the ground electrode when the firing pad is located on the ground electrode and when electrical current is initiated.

15. A method as defined in claim 13 , wherein the step of passing electrical current comprises passing electrical current at a first occurrence to form a first resistance-welded weldment, and passing electrical current at a second occurrence to form a second resistance-welded weldment, the second resistance-welded weldment constituting the final attachment between the firing pad and the ground electrode.

16. A method as defined in claim 13 , wherein the surface-to-surface contact produced between the protrusion and the ground electrode is established via the protrusion and a depression of the ground electrode formed in a working surface of the ground electrode when the firing pad is at least partially sunk into the ground electrode.

17. A method as defined in claim 13 , wherein, when the firing pad is at least partially sunk into the ground electrode, material is displaced from therebetween and to a peripheral edge (P) of the firing pad, the displaced material making an expulsion at the peripheral edge (P), the expulsion having a sparking surface to exchange sparks during use of the ground electrode and firing pad assembly.

18. A method as defined in claim 17 , further comprising the step of trimming the ground electrode and firing pad assembly along a trim line spanning through the expulsion and through the ground electrode.

19. A method as defined in claim 13 , further comprising the step of pressing a resistance weld arbor against a sparking surface of the firing pad in order to pass electrical current through the line-to-surface contact between the protrusion and the ground electrode, and wherein, when the firing pad is at least partially sunk into the ground electrode, material is displaced from therebetween and to a peripheral edge (P) of the firing pad, the displaced material abuts against a confronting surface of the resistance weld arbor and a top surface of the displaced material is thereby maintained generally in-line with the sparking surface of the firing pad.

20. A spark plug, comprising:

a shell having an axial bore;

an insulator having an axial bore and being disposed at least partially within the axial bore of the shell;

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

a ground electrode attached to the shell;

a firing pad attached to the ground electrode, the firing pad having a single protrusion projecting from a bottom side of the firing pad, the single protrusion spanning across the bottom side and being received in a depression of the ground electrode upon attachment between the firing pad and ground electrode, the firing pad having a first sparking surface that exchanges sparks during use of the spark plug; and

a resistance-welded expulsion at least partly surrounding a peripheral edge (P) of the firing pad, the resistance-welded expulsion having a second sparking surface generally in-line with the first sparking surface of the firing pad, the second sparking surface exchanging sparks during use of the spark plug.

21. A spark plug as defined in claim 20 , wherein the attachment between the firing pad and the ground electrode includes at least one resistance-welded weldment and lacks a laser-welded weldment.