Abstract: An engine cooling module includes a shroud structure 12 having a shroud hub 46 constructed and arranged to receive a portion of a motor 16. A DC electric motor 16 has first and second ends and a rotatable shaft 40. The second end of the motor is received by the shroud hub. A fan 70 is provided that has a fan hub 72. The fan is coupled with the shaft for rotation therewith. The shroud hub 46 defines a protective cover covering the second end of the motor, and the fan hub 70 defines a protective cover covering the first end of the motor. Thus, no motor housing is required.

Abstract: An engine cooling module includes a shroud structure 12. A housing 20 of a d.c. electric motor is formed integrally with the shroud structure 12. The housing has an open end 21. The motor has a drive shaft 26. A heat sink 22 is disposed opposite the open end and is insert molded with respect to the housing 20. The heat sink 22 defines a seat for a bearing 24 supporting the shaft 26. A flux ring assembly 48 is insert molded with respect to the housing. The flux ring assembly includes permanent magnets 33. An armature assembly 28 is disposed in the housing and fixed to the shaft for rotation in response to a magnetic field generated by the magnets 33. A commutator 32 is disposed in the housing and electrically connected with the armature assembly 28 and mounted for movement with the armature assembly. A brush card assembly 36 is coupled to the open end 21 of the housing to define an end cap covering the open end. The brush card assembly 36 has brushes 42 associated with the commutator 32.

Abstract: A fuel system has a fuel injector directly mounted with a fuel rail. The fuel rail has a body with interior and exterior surfaces. The interior surface defines a volume. The exterior surface surrounds the interior surface. An aperture extends between the interior and exterior surfaces in fluid communication with the volume. The fuel injector has an inlet tube with an inside surface that defines a flow path through a portion of the fuel injector, and an outside surface that surrounds the inside surface. The fuel injector is disposed so that the flow path is in fluid communication with the volume. A rigid connection is disposed between at least one of the interior and exterior surfaces of the fuel rail and the outside surface of the inlet tube, the rigid connection securing and hermetically sealing the fuel rail with the fuel injector.

Abstract: A fuel system has a fuel injector directly mounted with a fuel rail. The fuel rail includes a first portion and a second portion that form a body. The body has an interior surface defining a volume, an exterior surface surrounding the interior surface, and at least one aperture disposed between the interior and exterior surfaces in fluid communication with the volume. The at least one fuel injector has an inlet tube with an inside surface defining a flow path through a portion of the fuel injector and an outside surface surrounding the inside surface. The fuel injector is disposed such that the flow path is in fluid communication with the volume. A rigid connection is disposed between the interior surface of the fuel rail and at least one of the outside surface and the inside surface of the inlet tube. The rigid connection secures and hermetically seals the fuel rail with the at least one fuel injector.

Abstract: An engine cooling module includes a shroud structure 12. A housing 20 of a d.c. electric motor is formed integrally with the shroud structure 12. The housing has an open end 21. The motor has a drive shaft 26. A heat sink 22 is disposed opposite the open end and is insert molded with respect to the housing 20. The heat sink 22 defines a seat for a bearing 24 supporting the shaft 26. A flux ring assembly 48 is insert molded with respect to the housing. The flux ring assembly includes permanent magnets 33. An armature assembly 28 is disposed in the housing and fixed to the shaft for rotation in response to a magnetic field generated by the magnets 33. A commutator 32 is disposed in the housing and electrically connected with the armature assembly 28 and mounted for movement with the armature assembly. A brush card assembly 36 is coupled to the open end 21 of the housing to define an end cap covering the open end. The brush card assembly 36 has brushes 42 associated with the commutator 32.

Abstract: An engine cooling module includes a shroud structure 12. A housing 20 of a d.c. electric motor is formed integrally with the shroud structure 12. The housing has an open end 21. The motor has a drive shaft 26. A heat sink 22 is disposed opposite the open end and is insert molded with respect to the housing 20. The heat sink. 22 defines a seat for a bearing 24 supporting the shaft 26. A flux ring assembly 48 is insert molded with respect to the housing. The flux ring assembly includes permanent magnets 33. An armature assembly 28 is disposed in the housing and fixed to the shaft for rotation in response to a magnetic field generated by the magnets 33. A commutator 32 is disposed in the housing and electrically connected with the armature assembly 28 and mounted for movement with the armature assembly. A brush card assembly 36 is coupled to the open end 21 of the housing to define an end cap covering the open end. The brush card assembly 36 has brushes 42 associated with the commutator 32.

Abstract: A fuel system has a fuel injector directly mounted with a fuel rail. The fuel rail has a body with interior and exterior surfaces. The interior surface defines a volume. The exterior surface surrounds the interior surface. An aperture extends between the interior and exterior surfaces in fluid communication with the volume. The fuel injector has an inlet tube with an inside surface that defines a flow path through a portion of the fuel injector, and an outside surface that surrounds the inside surface. The fuel injector is disposed so that the flow path is in fluid communication with the volume. A rigid connection is disposed between at least one of the interior and exterior surfaces of the fuel rail and the outside surface of the inlet tube, the rigid connection securing and hermetically sealing the fuel rail with the fuel injector.

Abstract: A fuel system has a fuel injector directly mounted with a fuel rail. The fuel rail includes a first portion and a second portion that form a body. The body has an interior surface defining a volume, an exterior surface surrounding the interior surface, and at least one aperture disposed between the interior and exterior surfaces in fluid communication with the volume. The at least one fuel injector has an inlet tube with an inside surface defining a flow path through a portion of the fuel injector and an outside surface surrounding the inside surface. The fuel injector is disposed such that the flow path is in fluid communication with the volume. A rigid connection is disposed between the interior surface of the fuel rail and at least one of the outside surface and the inside surface of the inlet tube. The rigid connection secures and hermetically seals the fuel rail with the at least one fuel injector.

Abstract: An engine cooling module includes a shroud structure, and a brushless dc electric motor having an armature assembly and a rotor carrying permanent magnets. Mounting structure is provided having first and second opposing surfaces. The armature assembly is fixedly coupled with respect to the first surface. The mounting structure is fixed to the shroud structure. A fan has a plurality of blades and a hub. The rotor is fixed with respect to the hub. A shaft is associated with the rotor and the armature assembly permitting rotation of the rotor with resect to the armature assembly. An electronic control unit is coupled to the second surface of the mounting structure and is electrically connected with the armature assembly to control operation of the motor.

Abstract: A fuel injector has a metal housing with grooves formed adjacent the interface of the metal housing and a plastic overmold. By extending the overmold around the grooves, fluid migration past the interface of the overmold and metal housing is prevented. Fluid migration is also prevented in the calibration hole of the injector by forming a thin layer of plastic material at the base of the hole which, when compressed during staking and calibration, remains as a layer overlying the metal portions of the inlet connector. The terminal boss for the windings of the injector also has a plurality of grooves which during the plastic encapsulation process, are filled with plastic materials, hence also inhibiting fluid migration past the interface.

Abstract: A generally frusto-conical contaminant particle deflector is mounted within a valve body of an automotive engine fuel injector, surrounding a fuel injector valve element. An inner clearance space between the valve element and an open end of the deflector receives fuel flow when the injector valve element is moved to allow fuel flow. Contaminant particles are caused to move along a path extending radially out of the fuel stream and into a dead zone outside the perimeter of the deflector where they tend to remain so as to avoid any effects on the performance of the fuel injector.

Abstract: A filter-retainer assembly performs both the function of filtering the inlet fuel flow and retaining the inlet tube O-ring of a top-feed fuel injector of the type commonly used in fuel injection systems of internal combustion engines. The assembly has a snap-on, snap-off feature.