High thread ground shield

1. A method of forming a spark plug for an internal combustion engine, the method comprising:

separately securing a ground electrode to a ground shield, the ground shield having an elongated base section being configured to substantially surround a first insulator section of an insulator configured to substantially surround a center electrode, the insulator having a substantially cylindrical body with at least the first insulator section and a second insulator section, the first and second insulator sections having first and second diameters respectively and being separated by an insulator shoulder; and the elongated center electrode having a center electrode tip at one end and a terminal proximate another end of the center electrode, wherein the ground shield has a frustoconical flange protruding from a first end of the elongated base section, the frustoconical flange being configured to engage the insulator shoulder, and wherein the ground electrode extends from a second end of the elongated base section to define a spark gap with respect to the center electrode tip; and

securing the ground shield to the spark plug after the ground electrode has been separately secured to the ground shield.

2. The method as in claim 1 , wherein the ground electrode is formed from a first material and the electrode base section is formed from a second material, the second material being different from the first material and wherein only the first material is suitable for maintaining the spark gap between the center electrode tip and ground electrode.

3. The method as in claim 1 , wherein the elongated base section and the ground electrode are secured together using a joining technique selected from brazing, laser welding, resistance welding, plasma welding, and combinations thereof.

4. The method as in claim 1 , wherein the ground electrode is formed as a generally U-shaped strap having pair of axially extending legs and a free end extending between the legs in a spaced relationship with the center electrode tip to define the spark gap, wherein the elongated base section is formed with a pair of axially extending slots proximate the second end, and wherein the pair of legs are welded to the elongated base section within the pair of axially extending slots to form the ground shield.

5. The method as in claim 4 , wherein the free end of the generally U-shaped strap has an annular opening therein, and wherein the center electrode tip ends proximate the annular opening to define the spark gap.

6. The method as in claim 1 , wherein the ground electrode is formed as a generally J-shaped strap having an axially extending leg and a free end extending from the leg in a spaced relationship with the center electrode tip to define the spark gap, wherein the elongated base section is formed with an axially extending slot proximate the second end, and wherein the leg is welded to the elongated base section within the axially extending slot to form the ground shield.

7. The method as in claim 1 , wherein the ground electrode is formed with a plurality of axially extending legs and a free end extending from the legs in a spaced relationship with the center electrode tip to define the spark gap, wherein the elongated base section is formed with a plurality of axially extending slots proximate the second end, and wherein the plurality of axially extending legs are welded to the elongated base section within the plurality of axially extending slots to form the ground shield.

8. The method as in claim 1 , wherein the ground electrode is manufactured from a nickel-based alloy material and the elongated base section is manufactured from a steel-based alloy material.

9. The method as in claim 1 , wherein the center electrode tip has a first noble metal chip joined thereto facing the free end of the ground electrode, and wherein the free end has a second noble metal chip joined thereto axially facing the first noble metal chip to define the spark gap, the first and second noble metal chips serving as sparking surfaces of the spark plug.

10. The method as in claim 9 , wherein the first and second noble metal chips are joined to the center electrode and the ground electrode respectively by a joining technique selected from brazing, laser welding, resistance welding, plasma welding, and combinations thereof.

11. The method as in claim 1 , wherein the insulator has a third diameter section separated from the second diameter section by a second insulator shoulder, the second diameter section being located intermediate the first and third diameter sections and being greater in diameter than the first and third diameter sections.

12. The method as in claim 11 , wherein an annular retainer substantially surrounds the second insulator section and partially surrounds the third insulator section, the annular retainer having a frustoconical end portion, and end nut portion, and a threaded portion therebetween, the annular retainer further including an internal frustoconical portion engaging the second insulator shoulder, the frustoconical end portion overlapping the frustoconical flange of the ground shield to secure the ground shield and the annular retainer together and capture the insulator therewithin.

13. The method as in claim 12 , wherein the threaded portion of the annular retainer is configured to fit the spark plug into a threaded portion of a generally cylindrical opening communicating with a combustion chamber of an internal combustion engine, and wherein the frustoconical end portion of the annular retainer is configured to engage a frustoconical seat portion of the opening to establish an electrical ground between the ground shield and the engine while at the same time sealing the combustion chamber from the surrounding environment.

14. The method as in claim 13 , wherein the threaded portion of the annular retainer has an outer diameter that is less than or equal to about 16 mm.

15. The method as in claim 1 , wherein the center electrode includes an elongated firing electrode, a terminal electrode, and a resistive element situated therebetween, the firing electrode being connected to a first end of the resistive element through an electrically conductive glass seal that surrounds the resistive element, the terminal electrode being connected to a second end of the resistive element opposing the first end of the resistive element through the electrically conductive glass seal.

16. The method as in claim 14 , wherein the firing electrode has an inner core comprising a highly heat conductive metal material and an insulating outer clad comprising a heat-resistant, corrosion-resistant metal material.

17. The method as in claim 1 , wherein the annular retainer is made from a nickel-plated steel-based alloy material.

18. The method as in claim 1 , wherein the insulator is made from a non-conducting ceramic material.