A spark plug electrode with one or more electrode tip(s) formed on one or more electrode base(s) using an additive manufacturing process, such as a powder bed fusion technique, such that each electrode tip overhangs an edge of a corresponding electrode base. The spark plug electrode may be a center electrode, a ground electrode, or an annular ground electrode and can be provided according to a number of different configurations. Each electrode tip includes a precious metal-based material, such as an iridium- or platinum-based alloy, and a plurality of laser deposition layers, and each electrode tip can be secured to an electrode base with a weldless joint. An additive manufacturing process is also provided.

A passive prechamber spark plug for use in a combustion chamber of a vehicle engine includes an upper prechamber having an upper opening where the upper prechamber is connectable to the combustion chamber via the upper opening. An air ignition spark is formable via an upper air spark gap. A central electrode is disposed in an upper region of the upper prechamber where a base of the upper prechamber opposite the upper region is an insulator. An electrically conductive element or a slot is guided by the insulator continuously from the upper prechamber into a lower region under the base and the lower region is either a lower prechamber or is arrangeable directly in the combustion chamber. An earth electrode is disposed in the lower region such that a lower air spark gap is formed between the earth electrode and the electrically conductive element or the slot.

Spark plugs are disclosed that include electrode arrangements to improve the charge flow into and out of the annular volume around the insulator nose and a pre-chamber volume of a pre-chamber device, thus directing a purge of exhaust gases trapped in the annular volume to a space formed by the exterior of the spark plug body and the interior of the pre-chamber device.

A passive prechamber spark plug for use in a combustion chamber of a vehicle engine includes an upper prechamber having an upper opening where the upper prechamber is connectable to the combustion chamber via the upper opening. An air ignition spark is formable via an upper air spark gap. A central electrode is disposed in an upper region of the upper prechamber where a base of the upper prechamber opposite the upper region is an insulator. An electrically conductive element or a slot is guided by the insulator continuously from the upper prechamber into a lower region under the base and the lower region is either a lower prechamber or is arrangeable directly in the combustion chamber. An earth electrode is disposed in the lower region such that a lower air-surface gap spark gap is formed between the earth electrode and the electrically conductive element or the slot.

A spark plug electrode with one or more electrode tip(s) formed on one or more electrode base(s) using an additive manufacturing process, such as a powder bed fusion technique, such that each electrode tip overhangs an edge of a corresponding electrode base. The spark plug electrode may be a center electrode, a ground electrode, or an annular ground electrode and can be provided according to a number of different configurations. Each electrode tip includes a precious metal-based material, such as an iridium- or platinum-based alloy, and a plurality of laser deposition layers, and each electrode tip can be secured to an electrode base with a weldless joint. An additive manufacturing process is also provided.

A spark plug includes a central electrode member and an outer electrode member. The central electrode member includes a central base and a plurality of electrode prongs extending in an axial direction from the central base. The outer electrode member surrounds the central electrode member. The outer electrode member includes a wall that is radially spaced from the plurality of electrode prongs to allow a series of electric arcs to form between the wall and the plurality of electrode prongs. The outer electrode member and the central electrode member are sized and positioned relative to one another such that a first rate of wear of the outer electrode member, along a longitudinal axis of the spark plug, is substantially equal to a second rate of wear of the central electrode member along the longitudinal axis.

A spark plug includes a central electrode member and an outer electrode member. The central electrode member includes a central base and a plurality of electrode prongs extending in an axial direction from the central base. The outer electrode member surrounds the central electrode member. The outer electrode member includes a wall that is radially spaced from the plurality of electrode prongs to allow a series of electric arcs to form between the wall and the plurality of electrode prongs. The outer electrode member and the central electrode member are sized and positioned relative to one another such that a first rate of wear of the outer electrode member, along a longitudinal axis of the spark plug, is substantially equal to a second rate of wear of the central electrode member along the longitudinal axis.

A spark plug having multiple spark gaps, where at least one of the spark gaps is located within a prechamber. The spark plug may include a first center wire assembly, a second center wire assembly, an insulator, a metallic shell, a first sparking area with a prechamber cap and a ground electrode for a prechamber spark gap, and a second sparking area with a ground electrode for a main chamber spark gap. The spark plug is designed to maximize engine performance and/or operation by utilizing the multiple spark gaps, where the prechamber spark gap may be used for certain operating conditions where such a spark gap is advantageous and the separate main chamber spark gap may be used for other conditions where a main chamber spark gap is advantageous.

A spark plug includes a central electrode member and an outer electrode member. The central electrode member includes a central base and a plurality of electrode prongs extending in an axial direction from the central base. The outer electrode member surrounds the central electrode member. The outer electrode member includes a wall that is radially spaced from the plurality of electrode prongs to allow a series of electric arcs to form between the wall and the plurality of electrode prongs. The outer electrode member and the central electrode member are sized and positioned relative to one another such that a first rate of wear of the outer electrode member, along a longitudinal axis of the spark plug, is substantially equal to a second rate of wear of the central electrode member along the longitudinal axis.

A system includes an igniter rod having a ground rod with a first tip bent at a 90-degree angle, an internal rod with a second tip, a rod cover enclosing a portion of the internal rod, and a base tube, fixed to an external surface of the rod cover, enclosing a portion of the ground rod. The base tube has a plurality of adjustment screws that hold in place and position the ground rod. The igniter system further includes an igniter body configured to enclose a portion of the igniter rod and a fuel supply. The fuel supply is configured to be brought into contact with a gap between the first tip and the second tip.