Abstract: A fuel injector has an internal heater energized during cold starting to reduce emissions, the heater being a ceramic hollow cylinder disposed within a valve body just upstream of a valve seat where fuel is injected through an orifice into the engine. Conductors for energizing the heater extend into the valve body and are sealed against the escape of pressurized fuel. In one version, the conductors extend through an O-ring to be sealed. In another version the conductors include pins extending through the valve body sidewall with glass seals fused to the valve body and the pins. The conductors may comprise flat foil strips clamped between the O-ring and an elastomeric washer. The conductors also may be molded into the magnetic coil bobbin and sealed where the conductors emerge into the fuel cavity.

Abstract: An improved atomization fuel injector for an internal combustion engine includes an armature assembly including an injector needle reciprocable between a closed position and an open position; a needle seat for receiving the injector needle in the closed position, the needle seat including a central opening therethrough; an exit orifice disk disposed downstream of the needle seat; and an impinging jet atomizer disposed upstream of the exit orifice disk. A method of improving atomization of fuel in fuel injectors includes providing a fuel injector; adding fuel to the fuel injector; passing the fuel through a central opening in a seat of the fuel injector; separating the fuel into at least two channels; and directing at least two channels of fuel towards one another such that the channels of fuel collide with each other.

Abstract: An electromagnetic actuator for an internal combustion engine includes upper and lower electromagnets each having first and second opposing sides. First and second spacers are provided. The first spacer is connected to the first sides of the electromagnets and the second spacer is connected to the second sides of the electromagnets such that the electromagnets are disposed between the spacers. The spacers are constructed and arranged with respect to the electromagnets to define a space between the electromagnets. An armature is mounted for movement in the space between the electromagnets. A stamped steel housing is connected to the first and second spacers. The housing is constructed and arranged to mount the actuator to a structure.

Abstract: An electromagnetic actuator 10 includes first and second electromagnets 12 and 18, respectively. The second electromagnet 18 is in spaced relation with respect to the first electromagnet 12. An armature 24 is mounted for movement between the first and second electromagnets. An engaged position of the armature 24 is defined when the armature contacts one of the electromagnets 12 or 18 with an electrical signal to the contacted electromagnet being turned-off. Spring structure 30 is operatively associated with the armature 24 to bias the armature 24 away from the engaged position thereof. A piezoelectric device 34 is operatively associated with the armature 24 so that when the armature is in the engaged position and a force of the spring structure 30 is insufficient to move the armature from contact with the contacted electromagnet, the piezoelectric device 34 may be energized so as to move the armature 24 from contact with the contacted electromagnet.

Abstract: An electromagnetically operable fuel injector, for a gaseous fuel injection system of an internal combustion engine is disclosed, the injector having a generally longitudinal axis, a ferromagnetic core, a magnetic coil at least partially surrounding the ferromagnetic core, and an armature magnetically coupled to the magnetic coil and being movably responsive to the magnetic coil. The armature actuates a valve closing element which interacts with a fixed valve seat of a fuel valve and is movable away from the fixed valve seat when the magnetic coil is excited, the armature having a generally elongated shape and a generally central opening for axial reception and passage of gaseous fuel from a fuel inlet connector positioned adjacent thereto. The fuel inlet connector and the armature are adapted to permit a first flow path of gaseous fuel through a working gap between the fuel inlet connector and the armature and between the armature and the magnetic coil as part of a path leading to the fuel valve.

Abstract: A mechanical rotation limiting connection, defined between the end of a rigid metal cross-over tube and the adjacent end of a fuel rail, is disclosed. The coupling comprises a fitting that is inserted into, and permanently joined to, an open end of the fuel rail. The fitting includes a body complementary in shape to the fuel rail, with an enlarged flange at its trailing end, a tapered leading section, and an axial bore of stepped configuration. The leading section of the cylindrical cross-over tube is deformed into a polygonal shape that fits into the bore of the fitting; a transition section and a round section extend inboard of the leading section, and an enlarged annular collar encircles the cross-over tube. The leading section of the cross-over tube is inserted into the fitting, and mechanical members on the fitting are deformed or crimped over the annular collar on the cross-over tube to lock the tube within the fitting, and prevent inadvertent disassembly.

Abstract: A method of joining a magnetic armature of an electromagnetic actuator to a shaft is provided. The method includes holding the armature stationary while spinning the shaft. The spinning shaft is then pressing against the stationary armature such that friction between the shaft and the armature causes a portion of the armature and a portion of the shaft to melt and define a weld joint. The weld joint is permitted to cool thereby joining the shaft to the armature.

Abstract: A method and system for determining weight and/or position of a vehicle seat occupant to be used for controlling the reaction of a safety restraint system. A plurality of spaced weight sensors are disposed between a seating surface and seat mounting surface to provide output signals indicative of an applied weight on each sensor. The sensors are spaced such that the sensors measure the weight applied to a seat back and the seating surface. A controller calculates the weight and/or position of the seat occupant in response to the output signals of the sensors. The controller sends the weight and position of the seat occupant to the safety restraint system to be used to tailor or suppress the reaction of the safety restraint system.

Abstract: An electromagnetic actuator 10 includes housing structure 12, first and second electromagnets 14 and 16 disposed in spaced relation in the housing structure, an armature 24 mounted for reciprocal movement between the electromagnets, and a spring assembly 11 operatively associated with the armature 24. The spring assembly includes a coil spring 30, a spring retainer 32 carrying the coil spring and being constructed and arranged to contact the armature 24, a spring adjusting member 38 engaged with a bore in the housing structure 12 and engaging the spring 30 so as to control compression of the spring associated with a set position of the armature 24 between the electromagnets. At least one cap screw 50 extends from a surface of the housing structure generally adjacent to the bore. A locking member 56 is engaged with the spring adjusting member 38 and with the cap screw 50.

Abstract: A solenoid actuated fuel injector includes a valve body having a longitudinal axis. A valve seat subassembly is mounted in one end of the valve body. The valve seat subassembly includes a valve seat having a seating surface and a circumferential sealing surface surrounding the seating surface. The valve seat subassembly also includes a lower needle guide and swirl disk laser welded to the valve seat. The subassembly includes a radially extending flange that axially positions the subassembly in the nose of the injector and eliminates the tolerances associated with the stack up height of conventional valve seat subassembly components.

Abstract: A fuel injector having pressure equalization passages is provided to equalize the pressure differential across an armature in high vapor pressure fuels. At least one through passage is included that extends from a chamber beneath the armature to a chamber atop the armature to prevent differential pressure buildup when the injector is closed. The passages enable communication between the areas above and below the armature to rapidly equalize the pressure acting on the armature as the boiling bubbles burst and the fuel "explodes".

Abstract: A clip retention arrangement for a fuel injector inserted in a fuel rail seat, in which a U-shaped clip has tabs engaging an injector groove and also has slots captured on ears projecting from opposite sides of the socket. Each of the ears are configured to engage their associated slot to restrain relative rotation and to assist in properly orienting the fuel injector in the seat.

Abstract: A core assembly for an electromagnet includes a plurality of stacked laminations extending along a stacking axis. The laminations each having generally the same thickness in a direction along the stacking axis. A solid core member has opposing ends. The core member is disposed generally centrally with respect to the plurality of stacked laminations such that each end of the core member contacts a lamination of the plurality of laminations. The core member has a thickness in a direction along the stacking axis substantially greater than the thickness of a lamination. The core member also has an aperture therethrough disposed generally perpendicular to the stacking axis for receiving a shaft of an armature assembly.

Abstract: A solenoid actuated fuel injector includes a valve body, a valve seat at one end of the valve body and having a seating surface facing the interior of the valve body and including a fuel outlet opening, a fuel tube for conducting pressurized fuel into the valve body against the seating surface, a spherical valve ball moveable between a seated position against the seating surface to close the outlet opening against fuel flow, and an open position spaced from the seating surface to allow fuel flow through the outlet opening, a spring in the valve body and biasing the valve ball toward the seated position, an armature axially moveable in the valve body and including a valve ball capturing member at an end proximate the seating surface, the valve ball capturing member being engageable with the ball outer surface adjacent the seating surface, and a solenoid coil operable to draw the armature away from the seating surface, thereby moving the valve ball to the open position and allowing fuel to pass through the fuel

Abstract: A fuel injector for a spark ignition internal combustion engine includes a fuel injector having inlet and discharge ends. The discharge end includes a fuel injection port for supplying a fuel stream directed along an axis. An air shroud supplies assist air. The air shroud includes a first end mountable over the injector discharge end. The air shroud also includes a second end having an air assist passageway coaxially aligned with the fuel injection port for directing the fuel stream through the passageway along a common axis and guiding a flow of assist air through the passageway. The air flowing through the passageway coaxially surrounds the fuel stream to mix with the fuel upon discharge from the passageway, thereby providing a precisely targeted atomized fuel spray.

Abstract: An electromagnetic actuator is provided for mounting to a cylinder head of an engine. The actuator includes an actuator assembly including housing structure and an armature. A pair of electromagnets are disposed in the housing structure. An alignment collar is detached from the actuator assembly. The alignment collar has a first end constructed and arranged to be received in a bore of the cylinder head and a second end opposite the first end. The second end of the alignment collar is cooperable with an end of the actuator assembly. The detached alignment collar facilitates assembly of the electromagnetic actuator to a cylinder head. A method of securing an electromagnetic actuator to a cylinder head is also provided.

Abstract: A high pressure fuel injector has a swirl generator with a metering disk upstream of the valve seat. The disks function to redirect the axially flowing fuel through the injector into a tangential fuel flow. As the fuel moves past the needle valve and the valve seat, the narrow cross section imparts a higher velocity to the fuel to atomize the fuel. As the fuel leaves the swirl generator and is ejected from the injector, the fuel forms a hollow conical sheet containing atomized fuel.

Abstract: A fuel or air system component for a motor vehicle, constructed with shape memory alloys, to control fuel flow as a function of temperature or electrical means. The shape memory alloy changes shape at a defined temperature, or in a particular temperature range, thereby affecting a control feature internal to a component in the fuel system, and as a result, changing the fuel flow and/or pressure characteristic. The component may be a biasing spring. The shape memory alloy is an intermetallic compound or alloy which exhibits a shape transformation when heated or cooled through its transformation temperature.

Abstract: A method of manufacturing a conical valve seat, wherein the valve seat surface is placed in alignment with a cutting edge of a pattern impression pin, a predetermined amount of pressure is applied to the valve seat to move the seat surface relative to the cutting edge of a pattern impression pin to form a groove in the seat surface, hardening the seat member, and then grinding a conical surface on the seat surface to finish it.

Abstract: A bi-fuel injection system includes a source of first liquid fuel; a source of second liquid fuel; at least one variable vapor pressure fuel injector; a common fuel rail for supplying first or second fuels to the fuel injector; a first valve structure in selective communication with the source of first or second fuels and in communication with an inlet of the fuel rail to selectively control supply of one of the first and second fuels to the fuel rail; and a second valve structure in communication with an outlet of the fuel rail and in selective communication with the source of first or second fuels to return fuel exiting the fuel rail to the source of first or second fuels. The second valve structure may be in selective communication with a vapor purge system to receive fuel vapors exiting the fuel rail.