Abstract: An unencapsulated bobbin-mounted coil is associated with a stator wherein the stator, in cooperation with other parts of a mold, define a mold cavity. Encapsulating material is injected through gates in one of the other mold parts into the defined mold cavity to encapsulate the coil and bobbin in their entirety, including attachments of the finish lead ends of the coil wire to bobbin-mounted electrical terminals that extend axially away from the bobbin and coil, except for distal end portions of the terminals. The process simultaneously joins the encapsulated coil and bobbin with the stator.

Abstract: Audible noise emission from a solenoid-operated fuel injector is reduced by providing a groove around the armature spaced from the end of the armature that impacts the end to the pole piece/fuel inlet tube so as to leave a radial flange at the end of the armature. In one form of the invention, the groove extends around the outside diameter of the armature. In another form, the groove extends around the inside diameter of the armature. The groove is located and sized to optimize energy absorption during impact of the armature against the pole fuel inlet tube piece.

Abstract: The fuel pressure regulator is disposed in an off-engine mounting that is fastened to a wall of the engine compartment. The mounting is a body of synthetic material having a socket within which the fuel pressure regulator is disposed. Nipples for fluid-connecting flexible fuel conduits to the body are integral formations of the body. Protective walls that are also integral formations of the body circumferentially surround the nipples. Levers are pivotally connected with the protective walls, and when operated to force-applying positions, they pinch the sides of the conduits against the nipples.

Abstract: A length of wire is toroidally wound, and then the toroid is encapsulated and cut in two along a plane that is perpendicular to the toroidal axis. The resulting portions are used as stator and/or armature of a solenoid, and in the solenoid the cut face of each forms one side of the solenoid's working gap so that the faces move toward and away from each other as the solenoid operates.

Abstract: A press metering device enables internal flow measurements to be made while press fitting components together. The press metering device comprises a press means for press fitting the components and a manifold for controlling flow path dimensions during the press fitting. The manifold has a first upper port and a second upper port for apportioning flow into a differential air flow gauge and metering the flow. A bottom port holds the components to be press fitted and may be sealed to the manifold by one or more o-rings.

Abstract: Each swirl passages of the needle guide and fuel swirl member of a fuel injector has a longer and wider entrance portion and a shorter and narrower exit portion to allow only the latter portion, not the former portion, to perform a metering function. Production of swirl passages is facilitated and more consistent metering results.

Abstract: Keys on legs of a U-shaped stator are in keyed engagement with keyways on diametrically opposite sides of the O.D. of the sidewall of a valve seat member to axially and circumferentially locate the seat member.

Abstract: An attachment clip for connecting a top-feed fuel injector to a socket on a fuel rail has a cylindrical wall that is coaxial with the fuel inlet tube of the injector and contains a pattern of circumferentially spaced apertures. At each aperture there is at least one catch that extends from the margin of a circumferentially extending edge of the aperture radially inwardly and axially toward the fuel injector body to terminate at a distal end that is axially within the axial span of the aperture. The circumferential span of each catch is less than that of the aperture. As the fuel inlet tube is pushed into the socket, the catches are resiliently flexed by engagement with the socket rim until the distal ends of the catches clear a lip extending around the outside of the rim at which point they relax to lodge behind the lip thereby attaching the fuel injector to the socket.

Abstract: A small axial lost motion connection between an armature disk and a needle valve allows armature disk to snub rebound of needle valve upon impacting a valve seat.

Abstract: An apparatus is used to align, burnish, and secure an upper needle guide for a fuel injector valve body. The apparatus includes a lower portion having a fixture containing a spring-loaded plunger and a spring-loaded centering pin, and an upper portion having a burnishing tool, a spring-loaded stripper, and a crimping ram. The fixture aligns the needle guide and the valve body, and as the two portions are operated closed, the inside diameter of the upper needle guide is first burnished, and then the valve body is crimped onto the needle guide. The stripper holds the crimped parts against the lower portion of the apparatus while the upper and lower portions are operated open to withdraw the burnishing tool from the inside diameter of the needle guide.

Abstract: Nozzle structures for fuel injectors are fabricated from silicon wafers assembled together to accurately control valve lift so that a separate step of setting valve lift is unnecessary. Sealing surfaces are P+ silicon.

Abstract: The vacuum control port at the control chamber of a fuel pressure regulator is an injection molded plastic member that can be formed with an angle. A flange is provided as a seating surface for an annular seal ring. The member extends into a tube formed in the regulator control chamber and is secured thereto.

Abstract: Lead-in of a valve seat member being pressed into a valve body bore has larger angle initial lead-in portion followed by smaller angle transition lead-in portion leading to press-fit outside diameter. This prevents a maximally misaligned valve seat member from shaving a silver as the lead-in passes across the shoulder of a counterbore at the entrance of the press-fit inside diameter of the bore.

Abstract: A structure for mounting electronic valve timing control system components wherein any bubbles or other air carrying obstructions are purged from the system. The inlet and outlet passageways (14, 18) to and from the actuator (16) are displaced either a predetermined vertical distance ("H") or are in-line and inclined along the same passageway axis.

Abstract: A combustion seal for sealing the nozzle end of a direct injection fuel injector to the combustion chamber. The seal is an imperforate metal ring, much like an eyelet, fitted onto the nozzle end. In radial cross section the ring has a semi-circular shape that is compressed between respective shoulders on the nozzle end and a through-hole in a cylinder head in which the fuel injector is mounted. The ring is a ferrous metal that is plated with a softer metal, such as zinc.

Abstract: The solenoid portion of a solenoid-operated valve is resiliently biased by a pre-loader against an internal shoulder on the valve body to maintain precision of the stator-armature working gap during the useful life of the valve. Several embodiments of pre-loader are disclosed, including a Belleville spring, a wave spring, and an elastomeric ring.

Abstract: An electromagnetically operated fuel injector has a dynamic flow calibration mechanism in which a control rod that extends between and enters holes in both the stator and the armature is selectively positioned to divert some of the magnetic flux from the axial working gap between the stator and the armature such that the diverted magnetic flux passes through the control rod directly between the stator and the armature without passing through the working gap. A non-magnetic tube is disposed between the control rod and the stator and armature holes. The portion of that tube which is within the stator hole is joined to the stator while the portion which is within the armature hole provides guidance for the armature. In a bottom-feed version of fuel injector the tube also serves to prevent fuel within the injector from wetting the control rod.

Abstract: That portion of the body of a bottom-feed solenoid operated fuel injector which is placed in communication with pressurized liquid fuel when the injector is mounted in an injector-receiving socket of a fuel rail contains a circumferentially continuous stepped groove in a radially outer portion of which a frameless circular fine mesh filter screen is disposed to cover a radially inner portion and through-holes via which liquid fuel enters the fuel injector. In one embodiment, the margins of the screen are welded to shoulders of the groove against which they are disposed. In another, they are crimped into slots adjacent the groove. In still another, at least one shoulder has a taper so that the corresponding screen margin wedges onto the shoulder. In yet another, a retaining ring is used.

Abstract: Two discrete self-heating elements are provided in a silicon based sensor structure. The first, "transfer" self-heating element receives constant current and elevates the temperature of the sensor structure to a desired initial temperature above ambient. The second, "sensor" self-heating element is thermally coupled to the first element and receives a current adjusted based on the difference between ambient temperature and the sensor structure temperature so as to maintain a constant temperature difference. Most of the current flowing through the sensor heating element is thus attributable to fluid flow, and this current can therefore be conveniently used to determine fluid flow parameters (e.g., mass air flow). The elements may comprise thin films which may be interlaced or stacked vertically.

Abstract: An accelerator control apparatus for mounting in a motor vehicle for a "drive-by-wire" system. The apparatus provides a bias spring means to generate the "feel" of an accelerator pedal to the vehicle operator, a compression spring means provides frictional forces preventing extraneous pedal actuation and pedal sensor switch means for indicating the rotation position of the accelerator pedal from a first or normal position to any second position.