Abstract: A fuel injector having a fuel flow rate set by injector stroke is disclosed. The fuel injector includes a housing having a hollow passage and a seat disposed at one end of the hollow passage. A needle is slidably mounted in the hollow passage. The needle is operable between a first position wherein the needle engages the seat and a second position wherein the needle is disposed away from the seat. A first flow area is formed by a minimum frusto-conical area between the seat and the needle when the needle is disposed away from the seat. The fuel injector also includes an opening at the one end of the hollow passage proximate to the seat. The opening has a second flow area larger than the first flow area. A method for setting a gaseous fuel injector flow rate with injector stroke is also disclosed.

Abstract: A fuel injector has a fuel inlet, a fuel outlet, and a fuel passageway extending along an axis between the fuel inlet and the fuel outlet. The fuel injector comprises a body, an armature, a spring, and a spring stop. The body has an inlet portion, an outlet portion, and a passage disposed between the inlet portion and the outlet portion. The armature is disposed within the passage and is displaceable along the axis relative to the body. The spring is disposed within the passage and applies a biasing force to the armature. The spring has a first end disposed proximate the armature and a second end opposite from the first end. The spring stop is disposed within the passage and has a first and second portion. The first portion includes at least one projection engaging the passage. The at least one projection extends obliquely with respect to the axis and in a direction general toward the inlet portion.

Abstract: The present invention provides an apparatus that can form a plurality of orifices where the orifices are consistent dimensionally, such as, for example, the diameter, the surface roughness or the entry and exit configurations. Preferably, the invention provides a laser machining apparatus. The apparatus includes a laser light source that provides a generally coherent light beam along the beam's axis. The apparatus also includes a light directing device to direct a first portion of light from the light beam to a work piece at a first angle of incidence relative to the axis of the light beam during a first time interval to form at least one of an orifice and a chamfer. The apparatus further includes an adjustable beam splitter assembly to direct another portion of the light beam to form the other of the at least one of an orifice and a chamfer in the work piece during a second time interval that overlaps a portion of the first time interval.

Abstract: A method of selecting at least one optimal combination of engine or fuel injector characteristics that minimize injector tip deposit formation of one or more selected internal combustion engine and fuel injector. The combination can be different engines with different injectors or the same engine or the same injector but with different characteristics for the engine and injector. For each combination selected, the method involves generating at least two maps different maps that are analyzed to determine whether a particular engine with the particular fuel injector has a tendency to promote injector tip deposits formation. The first map is a map of the range of injector tip temperatures of a particular engine and injector combination. The first map is a rough indicator of a tendency towards combustion deposits. The second map is an engine characterization map that correlates testing conditions to actual combustion deposits formation.

Abstract: An apparatus and method for actuating a valve using magnetostrictive transduction is provided. A ferro-magnetic rod having giant magnetostrictive properties is operatively coupled with a hydraulic chamber. Application of a magnetic field to the ferro-magnetic rod generates strain in the rod and corresponding movement in a first piston, causing the fluid in the hydraulic chamber to become pressurized. The pressurized fluid forces a second piston to move, thereby actuating the valve.

Abstract: A fuel injector has a fuel inlet, a fuel outlet, and a fuel passageway extending along an axis between the fuel inlet and the fuel outlet. The fuel injector comprises a body, an armature, a spring, and a spring stop. The body has an inlet portion, an outlet portion, and a passage disposed between the inlet portion and the outlet portion. The armature is disposed within the passage and is displaceable along the axis relative to the body. The spring is disposed within the passage and applies a biasing force to the armature. The spring has a first end disposed proximate the armature and a second end opposite from the first end. The spring stop is disposed within the passage and has a first and second portion. The first portion includes at least one projection engaging the passage. The at least one projection extends obliquely with respect to the axis and in a direction general toward the inlet portion.

Abstract: A fuel rail that forms a conduit for pressurized fuel to be delivered to at least one fuel injector. The fuel rail includes an elongated member that is corrugated such that the fuel rail acts as a pressure damper. A method of reducing pressure pulsation in a fuel system is achieved by configuring a fuel of a second configuration from an initial configuration, the second configuration having a first portion and a second portion, the first portion having at least three points defining a virtual plane, the first portion including a continuous surface that intersects the virtual plane at a plurality of positions.

Abstract: An internal damper element that is usable in a fuel rail of a fuel system, the fuel system having a pressurized fuel source coupled to the fuel rail that has at least one fuel injector. The damper element includes an elongated member having a longitudinal damper element axis generally parallel to the longitudinal rail axis, the damper element having a first portion and a second portion, the first portion having at least three points defining a virtual plane, the first portion including a continuous surface that intersects the virtual plane at a plurality of positions.

Abstract: An apparatus and method for actuating a valve using magnetostrictive transduction is provided. A ferro-magnetic rod having giant magnetostrictive properties is operatively coupled with a hydraulic chamber. Application of a magnetic field to the ferro-magnetic rod generates strain in the rod and corresponding movement in a first piston, causing the fluid in the hydraulic chamber to become pressurized. The pressurized fluid forces a second piston to move, thereby actuating the valve.

Abstract: A fuel injector for use with an internal combustion engine. The fuel injector comprises a valve group subassembly and a coil group subassembly. The valve group subassembly includes a tube assembly having a longitudinal axis that extends between a first end and a second end; a seat that is secured at the second end of the tube assembly and that defines an opening; an armature assembly that is disposed within the tube assembly; a member that biases the armature assembly toward the seat; an adjusting tube that is disposed in the tube assembly and that engages the member for adjusting a biasing force of the member; a filter that is located at the first end of the tube assembly and that has an integral retaining portion; an O-ring that circumscribes the first end of the tube assembly and that is maintained by the retaining portion of the filter; and a first attachment portion.

Abstract: A method of setting a distance between a first body and a second body in a fuel injector is disclosed. The method includes providing an intermediate body having a first end, a second end and a longitudinal axis, the first end being fixedly connected to the first body and the second end being fixedly connected to the second body. The intermediate body is compressed toward the longitudinal axis. The compression axially elongates the intermediate body, such that the first body is separated from the second body. An apparatus used to set the distance is also disclosed.

Abstract: A method of selecting at least one optimal combination of engine or fuel injector characteristics that minimize injector tip deposit formation of one or more selected internal combustion engine and fuel injector. The combination can be different engines with different injectors or the same engine or the same injector but with different characteristics for the engine and injector. For each combination selected, the method involves generating at least two maps different maps that are analyzed to determine whether a particular engine with the particular fuel injector has a tendency to promote injector tip deposits formation. The first map is a map of the range of injector tip temperatures of a particular engine and injector combination. The first map is a rough indicator of a tendency towards combustion deposits. The second map is an engine characterization map that correlates testing conditions to actual combustion deposits formation.

Abstract: A flow master for testing a leak test head includes a housing having an upper body portion and a lower body portion, the housing defining a passageway therethrough, the housing further defining an internal volume substantially equal to a fuel volume of a fuel injector to be tested; and a porous metal flow restrictor disposed in the passageway. A method of testing a leak test head includes providing a flow master; measuring a flow rate of the flow master from a known standard; connecting the flow master to the leak test head; pressurizing the leak test head; measuring a flow rate through the flow master using the leak test head; and comparing the flow rate measured by the leak test head to the flow rate measured by the known standard to determine if the leak test head is accurate.

Abstract: A fuel communicating assembly including a base having a wall disposed about a longitudinal axis. The wall having a surface exposed to the longitudinal axis. The surface defining a chamber. The wall having an end that defines an aperture to the chamber. The assembly further including a component having a housing. The housing having an exterior surface. A portion of the exterior surface disposed within the chamber. A metallic member having an inner surface and an outer surface contiguous with the exterior surface of the component. The outer surface is contiguous with the surface of the wall so that the portion of the exterior surface of the component is retained within the chamber and the aperture of the chamber is hermetically sealed. A method of retaining a component within a base is also described.

Abstract: A fuel injector having a housing including an inlet, an outlet, and a passageway for fuel flow from the inlet to the outlet. A coil assembly is disposed proximate the inlet of the fuel injector. A seat is disposed proximate the outlet of the fuel injector. A closure member is disposed in the housing and operable by the coil assembly to permit and prohibit fuel flow through the seat. The closure member includes a sleeve and an armature. The sleeve extends along a longitudinal axis and has first and second ends, the sleeve including an outer surface a first distance from the longitudinal axis. The armature is coupled to the first end of the sleeve, the armature having an outer perimeter a second distance from the longitudinal axis, the second distance not greater than the first distance.

Abstract: A fuel injector for use with an internal combustion engine. The fuel injector comprises a valve group subassembly and a coil group subassembly. The valve group subassembly includes a tube assembly having a longitudinal axis that extends between a first end and a second end; a seat that is secured at the second end of the tube assembly and that defines an opening; an armature assembly that is disposed within the tube assembly; a member that biases the armature assembly toward the seat; an adjusting tube that is disposed in the tube assembly and that engages the member for adjusting a biasing force of the member; a filter that is located at least within the tube assembly and may include an integral retaining portion; an O-ring that circumscribes the first end of the tube assembly and that is maintained by the retaining portion of the filter; and a first attachment portion.

Abstract: A tool for forming an armature guide eyelet. The tool having a body with a working end, a support end and at least one sizing rib disposed along a longitudinal axis. The at least one sizing rib has a perimeter having a first portion and a second portion. The first portion has a substantially constant distance Dc, from the longitudinal axis. The second portion has a varying distance Dv from the longitudinal axis. Also, a method for forming the armature guide eyelet with the tool. The method including aligning at least one non-uniform sizing rib and an armature guide eyelet having a constant inner diameter along a longitudinal axis and forming the constant inner diameter of the armature guide eyelet into a non-uniform inner diameter with the at least one non-uniform sizing rib.

Abstract: A fuel injector for use with an internal combustion engine. The fuel injector comprises a valve group subassembly and a coil group subassembly. The valve group subassembly includes a tube assembly having a longitudinal axis that extends between a first end and a second end; a seat that is secured at the second end of the tube assembly and that defines an opening; an armature assembly that is disposed within the tube assembly; a member that biases the armature assembly toward the seat; an adjusting tube that is disposed in the tube assembly and that engages the member for adjusting a biasing force of the member; a filter that is located within the tube assembly and integral with the adjusting tube; and a first attachment portion. The coil group subassembly includes a solenoid coil that is operable to displace the armature assembly with respect to the seat; and a second attachment portion that is fixedly connected to the first attachment portion.

Abstract: A method for making a valve assembly is disclosed. The method includes providing a first work piece having a longitudinal axis and a first end and providing a second work piece having a surface. The method also includes disposing the first work piece and the second work piece axially between a pair of aligned elements that are relatively movable toward and away from each other along the longitudinal axis of the first work piece. Additionally, the method includes relatively moving the pair of aligned elements toward each other to axially clamp the first work piece and the second work piece and actuating the pair of aligned elements and delivering to the first work piece and the second work piece a controlled clamping force that acts to coin a zone of surface contact between the first end and the surface. Further, the method includes repeating the actuating of the pair of elements a plurality of times. An apparatus used to perform the method is also disclosed.

Abstract: A fuel injector for use with an internal combustion engine. The fuel injector comprises a valve group subassembly and a coil group subassembly. The valve group subassembly includes a tube assembly having a longitudinal axis that extends between a first end and a second end; a seat that is secured at the second end of the tube assembly and that defines an opening; an armature assembly that is disposed within the tube assembly; a member that biases the armature assembly toward the seat; an adjusting tube that is disposed in the tube assembly and that engages the member for adjusting a biasing force of the member; a filter that is located within the tube assembly and integral with the adjusting tube; an O-ring that circumscribes the first end of the tube assembly and that is maintained by a retaining portion; and a first attachment portion.