Abstract: A dual stroke fuel injector including a shape memory alloy component for controlling the short and long strokes of the injector.

Abstract: Apparatus and method for substantially reducing or eliminating pressure pulsations caused by the opening and closing of fuel injectors. A preferred embodiment provides a restriction orifice adjacent the inlet end of a fuel injector filter of a respective fuel injector.

Abstract: A precision fuel rail assembly for direct fuel injection comprising a plurality of formed parts first assembled and positioned loosely on a precision fixture, then joined (e.g. tack welded), by applying a BFM on all joints forming a “green” assembly and firing in a brazing oven, to produce a precision assembly formed from stainless steel parts. A bracket defining a sole plate for the assembly may be formed as a continuous element or a plurality of individual fuel rail brackets. Flanged sockets are attached to the bracket at locations corresponding to the fuel injector locations on an engine bank. Bolt holes are provided along the centerline of the sockets and fuel injectors. The bracket supports a fuel distribution tube via saddle elements disposed between the bracket and the tube. A jump tube supplies fuel from the distribution tube to each socket.

Abstract: A thermoplastic carrier sheet is die-cut to have a size and shape matching that of a PEM bipolar plate. A plurality of holes are punched in the carrier sheet in the pattern of gasket beading to be formed subsequently. In a mold, liquid gasket resin fills the mold on both sides of the carrier sheet to form the gasket, flowing through the holes in the sheet and thereby causing the gasket to become mechanically attached to the sheet. A carrier element having a flange portion substantially identical with the outer profile of the bipolar plates is laminated to the sheet edge. During assembly of a fuel cell, the carrier element automatically positions the gasket correctly on the plate and prevents the gasket from twisting or shifting. In a currently preferred embodiment, a membrane electrode assembly is attached within an appropriate opening in the carrier sheet.

Abstract: A method for forming a fuel cell assembly including the pre-final-assembly step of forming a plurality of fuel cell sub-assembly modules, each module including a predetermined number of individual fuel cell repeating units, for example, ten. Each module may be leak and performance tested and certified prior to inclusion in the final fuel cell stack, thus limiting potential rework to only an individual module and only before assembly of the final stack. Preferably, each module is assembled on an assembly fixture having alignment rods, using a combination of resilient gasketing and RTV to seal between the elements. The assembled module is then placed under compression while the silicone is cured.

Abstract: The invention includes an end cap that can be securely mounted to the end of a ceramic spool. The end cap comprises a locking plate adapted to fit into a groove in the ceramic spool. A plurality of angularly offset holes in the locking plate align with similar holes in the end cap. Screws or pins are placed in the holes and welded in place to prevent backing out or loosening. In use, the locking plate is secured by the pins, the groove and the inside surface of the end cap, the combination of which inhibits misalignment. Thermal cycling does not loosen the end cap, cause eccentric rotation or crack the ceramic spool.