Patent ID: 8388396

Claim:
A method of manufacturing a spark plug, the method comprising the steps of: a) forming an insulator having a first end portion, an opposing second end portion, and an opening extending longitudinally through the insulator from the first end portion to the second end portion; b) forming an electrode and a complimentary electrode cap, the electrode having an electrode body and an electrode shaft having a first end portion and an opposing second end portion, the electrode body being disposed adjacent the first end portion of the electrode shaft, the electrode cap and the second end portion of the electrode shaft being configured to be cooperatively engageable with each other; c) forming a shell having a first end portion defining a transverse end face, an opposing second end portion, and an opening extending longitudinally between the first end portion and the second end portion, the shell opening being sized to partially receive the insulator, the shell further including a plurality of bores extending longitudinally into the shell from the transverse end face; d) forming a cage including a plurality of arcuate members, each arcuate member defining an end face; e) assembling a first subassembly by connecting the electrode to the insulator, the electrode shaft being disposed within the insulator opening to dispose the electrode body adjacent the insulator first end portion, the electrode cap being connected to the electrode shaft adjacent the insulator second end portion; f) heating the shell to cause the plurality of bores to expand; g) inserting the plurality of arcuate members into respective ones of the plurality of bores in their expanded state; h) cooling the shell causing the plurality of bores to contract to secure the cage to the shell to define a second subassembly; and i) connecting the first subassembly to the second subassembly, the electrode body being disposed in close proximity to the cage to enable electrical communication therebetween.