Abstract: A fuel injector includes a nozzle body to be inserted into a fuel injector receiving bore along a nozzle body axis; a valve housing; and a locating pin extending from the valve housing along a locating pin axis. The locating pin axis is eccentric to the nozzle body axis. The locating pin has a width in a first direction radially relative to the nozzle body axis and through the locating pin axis and a length in a second direction perpendicular to the width such that the width is less than the length. The locating pin includes a first crush rib and a second crush rib which are diametrically opposed at the length of the locating pin and such that the first crush rib and the second crush rib plastically deform when inserted into the locating bore, thereby preventing rotational movement of the fuel injector about the nozzle body axis.

Abstract: A fuel injector includes a nozzle body configured to be inserted into a fuel injector receiving bore of the internal combustion engine along a nozzle body axis; a valve housing held in fixed relationship to the nozzle body; and a first locating pin and a second locating pin each extending from the valve housing. The first locating pin extends from a first locating pin fixed end which is fixed to the valve housing to a first locating pin free end. The second locating pin extends from a second locating pin fixed end which is fixed to the valve housing to a second locating pin free end. The first locating pin and the second locating pin elastically deform when inserted into the bore, thereby preventing rotational movement of the fuel injector about the nozzle body axis.

Abstract: A fuel injector includes a nozzle body to be inserted into a fuel injector receiving bore along a nozzle body axis; a valve housing; and a locating pin extending from the valve housing along a locating pin axis. The locating pin axis is eccentric to the nozzle body axis. The locating pin has a width in a first direction radially relative to the nozzle body axis and through the locating pin axis and a length in a second direction perpendicular to the width such that the width is less than the length. The locating pin includes a first crush rib and a second crush rib which are diametrically opposed at the length of the locating pin and such that the first crush rib and the second crush rib plastically deform when inserted into the locating bore, thereby preventing rotational movement of the fuel injector about the nozzle body axis.

Abstract: A fuel injector includes a nozzle body configured to be inserted into a fuel injector receiving bore of the internal combustion engine along a nozzle body axis; a valve housing held in fixed relationship to the nozzle body; and a first locating pin and a second locating pin each extending from the valve housing. The first locating pin extends from a first locating pin fixed end which is fixed to the valve housing to a first locating pin free end. The second locating pin extends from a second locating pin fixed end which is fixed to the valve housing to a second locating pin free end. The first locating pin and the second locating pin elastically deform when inserted into the bore, thereby preventing rotational movement of the fuel injector about the nozzle body axis.

Abstract: A fuel injector-engine component assembly includes an engine component with a stepped bore defined along an axis and having a stepped bore stop surface facing axially upward. A fuel injector extending along the axis is disposed in the stepped bore and includes a fuel injector stop surface facing axially downward and axially opposing the stepped bore stop surface. An isolation ring is disposed between the engine component and fuel injector stop surfaces for axially isolating the fuel injector from the engine component. The isolation ring includes a rigid support member for limiting the axial motion of the engine component and fuel injector stop surfaces together. The isolation ring also includes a resilient and compliant isolation member located axially between the engine component and fuel injector stop surfaces to provide acoustic and thermal isolation between the fuel injector and the engine component below a predetermined pressure of the fuel injector.

Abstract: A method for controlling a DI fuel injector relying on measurement of a engine operating parameter, preferably fuel pressure in an associated fuel rail. Regimes of low fuel injector flow require lowered fuel rail pressure, allowing lowered peak and hold currents that afford quicker closing. Under low flow conditions, a prior art fixed peak current exceeds the current required for rapid opening of the fuel injector, and a prior art fixed hold current exceeds the current required for holding the valve open for the full duration of the open window. In the present invention, the peak and hold currents, and optionally peak and hold voltages, are varied as functions of fuel rail pressure, either continuously or stepwise. The result is full function of a fuel injector over the full range of fuel flow requirements while also providing the quickest possible response under all flow conditions.

Abstract: A coupling for suspending a fuel injector from a fuel rail assembly of an internal combustion engine includes a collar that mates with the fuel injector and a retainer clip that engages with the collar thereby mechanically connecting the fuel injector to the fuel rail assembly. The retainer clip includes windows to enable even load distribution upon the socket flange when assembled. Features are integrated in the collar to facilitate correct alignment of the injector relative to the fuel rail. Paired together, the retainer clip and the collar enable a secure, and a keyed fuel injector-to-fuel rail connection that is able to withstand high pressure separating loads.

Abstract: A coupling for suspending a fuel injector from a fuel rail assembly of an internal combustion engine includes a collar that mates with the fuel injector and a retainer clip that engages with the collar thereby mechanically connecting the fuel injector to the fuel rail assembly. The retainer clip includes windows to enable even load distribution upon the socket flange when assembled. Features are integrated in the collar to facilitate correct alignment of the injector relative to the fuel rail. Paired together, the retainer clip and the collar enable a secure, and a keyed fuel injector-to-fuel rail connection that is able to withstand high pressure separating loads.

Abstract: An upper guide system for a solenoid actuated fuel injector of an internal combustion engine includes an armature and a guide ring having a cylindrical shape and surrounding the armature and positioning the armature in a radial direction. The location of the upper guide system is substantially in the same axial location as the radial magnetic forces imposed on the armature. Features such as flutes or grooves are disposed on an outer diameter surface of the armature and/or holes through a body portion of the armature. Accordingly, the response performance of the solenoid actuated fuel injector is improved.

Abstract: A protection device for a lower guide system of a fuel injector includes a debris shield deflecting a fuel flow around a lower guide system and a particle trap collecting particles contained within the fuel flow. By deflecting the fuel flow towards flow passages around the lower guide system, the particles contained in the fuel flow are prevented from entering a lower guide area, such as a radial gap between the stationary components of the lower guide system and the moving component of the valve assembly. The particle trap may be defined in a lower housing of the fuel injector or may be integrated in the debris shield. The debris shield may be integral with a valve assembly or may be a separate component. A permeable area may be integrated in the debris shield to enable partial flow therethrough.

Abstract: An internal pulse damper for use in a fuel rail for an internal combustion engine. The damper is formed from a length of tubular metal stock having a flat oval cross-section and ends flattened by crimping to form a captive-air pillow. The end crimps are improved through use of tooling to eliminate a creased sidewall area vulnerable to stress failure in prior art pulse dampers. Such tooling includes constraints to prevent the tubing sides from flaring out and forming a longitudinal crease adjacent the end crimp during squeezing-shut of the tube end.

Abstract: Several embodiments of noise reduction apparatus for a fuel injector are disclosed and include perforated tubes, side branch filters and expansion chambers strategically located between a respective injector and the fuel rail to target and reduce high frequency noise generated by the mechanical movement of the fuel injector.

Abstract: An internal pulse damper for a fuel rail. The damper has an increased captive air volume and consequent improved damping and stress characteristics. The improved damper is a pillow having a modified flat oval cross-sectional profile, with two long diaphragm sides and rigid short sides connecting the two long sides. At least one of the short sides, and preferably both, is strengthened by being provided with a longitudinal reverse bend or inwardly-extending longitudinal rib generally parallel with the long sides. Preferably, the short sides are somewhat higher than the comparable short sides of similar prior art dampers, to increase the captive air volume, yet are not high enough to preclude installation of the improved damper within an existing fuel rail configuration.

Abstract: A fluid pulse damper having increased dynamic range and sensitivity, being especially useful in suppressing pulsations in the fuel supply rail of an internal combustion engine. The damper is a longitudinal gas-filled plastic pillow having walls formed by opposed flexible short sides and opposed flexible long sides, and includes at least one internal self-contact element, and preferably a plurality of such elements. As the short sides flex, the elements make contact internally, shifting the damper into a different compression regime and extending the pressure/response over an increased range of pressures. A feature of some embodiments is that the inner surface within the contact elements is shifted into tension after the elements make contact, thereby stiffening the damper and increasing the damper's resistance to further deformation. The damper is formed of a plastic such as ultra-high molecular weight polyethylenes, high flow polyetherimides, or tubing grade polyphthalamides.

Abstract: A fuel pressure regulator including a valve head having a centerline offset from the centerline of a corresponding fuel orifice. The valve head may be offset with respect to the valve seat and orifice, the orifice may be offset within the seat with respect to the head and diaphragm assembly, or the axes of the head and seat may be non-coaxially biased. Because the vector of the valve closing force does not align with the centerline of the valve head and diaphragm assembly, a resulting torque on the valve head keeps the head in a stable, pivoted position at all flow rates. The valve head always makes contact with the valve seat at a predetermined point during regulator operation, eliminating pressure instabilities and noise experienced in prior art pressure regulators.

Abstract: A fuel rail damper includes a hollow member having a first end and a second end, opposing first and second sides, a first face and a second face interconnecting and spacing apart the first and second sides, and a width. Each of the first and second ends are sealed in an air tight manner to thereby define a chamber in conjunction with the first and second sides and the first and second faces and wherein the widths of the ends do not substantially exceed the hollow member width.

Abstract: An anti-rotation clip for joining a fuel injector body to a fuel rail socket. A C-shaped base is formed to slide into an annular groove in the injector body. A pair of tangs extend from the base to straddle a rib on the injector body to prevent rotation between the clip and the injector. Opposed sidewalls extending from the base include windows for receiving a radial flange of the fuel rail socket to correctly position the fuel injector axially within the socket. Each window is divided by a locking bar for reception in a notch in the socket flange to prevent rotation between the clip and the socket. The radial positions of the injector rib and flange notch are selected such that the injector will be properly oriented with respect to the engine after installation therein.

Abstract: A fuel rail damper, which includes a hollow member having a first end and a second end, and at least one active portion. The hollow member being open to atmospheric pressure, thereby defining a chamber in conjunction with the at least one active portion.

Abstract: A fuel pressure regulator including a valve head having a centerline offset from the centerline of a corresponding fuel orifice. The valve head may be offset with respect to the valve seat and orifice, the orifice may be offset within the seat with respect to the head and diaphragm assembly, or the axes of the head and seat may be non-coaxially biased. Because the vector of the valve closing force does not align with the centerline of the valve head and diaphragm assembly, a resulting torque on the valve head keeps the head in a stable, pivoted position at all flow rates. The valve head always makes contact with the valve seat at a predetermined point during regulator operation, eliminating pressure instabilities and noise experienced in prior art pressure regulators.

Abstract: A fuel rail damper, which includes a hollow member having a first end and a second end, and at least one active portion. The hollow member being open to atmospheric pressure, thereby defining a chamber in conjunction with the at least one active portion.