Abstract: A fuel injector comprising a pumping chamber pressurized by an actuator responsive to an engine controller for delivering pressurized fuel from the pumping chamber to a control valve module to control pressure applied at the outlet of an injector nozzle. The control valve module includes at least one control valve. Valve actuators are in a stator core plate that is independent of the control valve module. Machining operations during manufacture of the injector are simplified by a separation of the stator core plate and the control valve module. Mating, juxtaposed surfaces of the control valve module and the stator core plate are fixed by an indexer.

Abstract: Fluid in a chamber, through which a fuel control armature is moving, is used to dampen armature vibrations. This dampening effect is achieved by forming a passage through which the fluid flows as the actuator moves to a steady state position. This passage may be implemented in a control module for controlling fuel delivery in a fuel injector. The control module includes a control module housing defining the cavity. The armature is disposed at least partially within the cavity. The armature affects the flow of fuel in the injector by changing the area of a fuel port through which fuel passes. The fluid passage is formed as the armature moves towards a contact wall defining the cavity.

Abstract: A fuel injector for an internal combustion engine has multiple control valves with a single valve actuator. The valves may be packaged in an injector assembly with an economy of space and a simplified assembly procedure during manufacture. The valves are sequenced using calibrated force balance relationships as fuel injection rate shaping is established.

Abstract: A solenoid stator assembly and manufacturing method for an electro-mechanically actuated fuel injector. The solenoid stator assembly comprises a permeable stator core and a stator coil. A housing formed of an electrically insulating material is located about the stator core and stator coil such that a distal end of the stator core is oriented proximate to an armature of the fuel injector. A pair of terminals extends into the housing to a pair of leads for the stator coil to energize the stator coil and generate a magnetic field for actuating the fuel injector armature. A reinforcement structure is disposed generally about the stator core within the housing to improve the robustness of the stator assembly.

Abstract: An electromagnetic actuator for a fluid pressure control valve in a fuel injector for an internal combustion engine is disclosed. The fuel injector comprises a control module including a fuel pressure control valve; an armature connected to the fuel pressure control valve; and a stator assembly including a magnetic core comprising of at least two segments and a bobbin. The stator assembly, when it is energized by a power source, produces a magnetic field to draw the armature towards the stator assembly.

Abstract: Fluid in a chamber, through which a fuel control armature is moving, is used to dampen armature vibrations. This dampening effect is achieved by forming a passage through which the fluid flows as the actuator moves to a steady state position. This passage may be implemented in a control module for controlling fuel delivery in a fuel injector. The control module includes a control module housing defining the cavity. The armature is disposed at least partially within the cavity. The armature affects the flow of fuel in the injector by changing the area of a fuel port through which fuel passes. The fluid passage is formed as the armature moves towards a wall defining the cavity.

Abstract: A fuel injector unit comprises a follower assembly that includes a sleeve having an internal groove that receives a spring clip. The clip is made with a spring ring stock having a diameter less then the width of the groove so that the sleeve may be freely rotated around the retainer clip held in the groove. The retainer clip has linear portions aligned along the flat walls of a follower subassembly that receives a plunger carried by the follower assembly. The flat walls terminate at an expanded shoulder that limits displacement of the retainer clip to a fixed height of the follower assembly for shipping and handling, while permitting controlled axial movement of the follower assembly and the plunger along the aligned flat surfaces of the follower subassembly.