Abstract: A lower fuel injector filter includes a generally planar disk having an annular shape and including a plurality of filter holes. The disk is retained by a valve guide within a valve seat. The disk prevents internally generated contamination particles contained in fuel flowing through the filter holes from reaching a valve and seat interface positioned downstream of the valve guide. The disk may also be retained by a ball valve stop proximate the valve seat.

Abstract: A lower filter for a fuel injector includes a disk having an annular shape and including a plurality of filter holes. The disk is positioned upstream of a valve guide of an internal valve assembly without contacting the valve guide. The disk prevents internally generated contaminants contained in fuel flowing through the filter holes from reaching a valve guide area and a sealing area of the internal valve assembly. By installing the lower filter upstream of the valve guide and without contact to the valve guide, interference with the guidance and reciprocal movement of the valve is avoided. Application of the lower filter in fuel injectors may reduce the occurrence of injector failures by reducing the number of stuck open conditions in injectors and by reducing the number of hydro lock engine incidents without interference with the valve guide.

Abstract: An internal lower filter for a fuel injector includes a self-supporting guide guiding a reciprocably activated valve of an internal valve assembly of a fuel injector and a plurality of filter holes formed in said guide filtering fuel flowing through the fuel injector and preventing contaminants contained in the fuel from entering a sealing area of the internal valve assembly. Incorporating the guide filter in accordance with the invention in a fuel injector enables capturing particles or contaminants, generated within the fuel injector during assembly or during operation, before entering the sealing area of an internal valve assembly. Accordingly, failure modes of the injector, such as a stuck open condition that may lead to a hydraulic lock of the engine, can be reduced. By forming the filter holes in a typically used ball guide, no changes are required to the currently used assembly line equipment or the current assembly process.

Abstract: A valve to shaft assembly includes a butterfly-type valve, a pair of bushings receiving the valve and holding the valve in axial position within a housing, and a shaft engaging the valve and the bushings and rotating the bushings in the housing. The bushings include features to hold the valve in position in the bore prior to assembly of the valve and, furthermore, act as rotating bearing surfaces for the valve. The valve to shaft assembly process may be simplified, especially where multiple valves are assembled to a single common drive shaft, such as in a port face charge motion control valve. Furthermore, the valve to shaft assembly provides an axial degree of freedom between valve, drive shaft, and bore, which allows the valve to float on the axis of the drive shaft, to facilitate self centering of the valve in the valve housing.

Abstract: An improved air intake manifold for a V-style internal combustion engine comprising three individual injection molded sections joined by friction welding of flanged mating elements. Each section is formed of a high-melting temperature composite polymer. The welds are all on the exterior of the manifold. The mating surfaces are formed to be directly accessible to welding apparatus and are so oriented that friction welding may be carried out by relative motion between the components in the axial direction. When joined, the lower and middle sections form the individual air distribution runners from the plenum to the intake ports in the engine heads. The lower and middle sections are so configured that each such runner crosses the valley of the engine, providing great strength and rigidity to the module. All runners are identical, so that air flows from the plenum to the individual cylinders are substantially identical.

Abstract: An improved air intake manifold for a V-style internal combustion engine comprising three individual injection molded sections joined by friction welding of flanged mating elements. Each section is formed of a high-melting temperature composite polymer. The welds are all on the exterior of the manifold. The mating surfaces are formed to be directly accessible to welding apparatus and are so oriented that friction welding may be carried out by relative motion between the components in the axial direction. When joined, the lower and middle sections form the individual air distribution runners from the plenum to the intake ports in the engine heads. The lower and middle sections are so configured that each such runner crosses the valley of the engine, providing great strength and rigidity to the module. All runners are identical, so that air flows from the plenum to the individual cylinders are substantially identical.

Abstract: An end fitting for a serpentine heat exchanger couples an inlet or outlet port to a pair of flat tubes comprising the heat exchanger core. The fitting comprises three laminated plates and a nipple coupled to an opening in the outermost of the plates. The inner plate is a header plate with the slots for receiving the flat tubing. A spacer plate interconnects the outer and inner plates and has an aperture shaped to couple the port to the slots for defining a fluid flow path. The plates are stamped from aluminum sheet stock clad with a brazing alloy. The plates are assembled and secured by a steel rivet and the nipple is attached. The parts are joined by brazing. The fitting can be brazed to the exchanger core at the same time.

Abstract: An end fitting for a serpentine heat exchanger couples an inlet or outlet port to a pair of flat tubes comprising the heat exchange core. The fitting comprises three laminated plates and a nipple coupled to an opening in the outermost of the plates. The inner plate is a header plate with slots for receiving the flat tubing. A spacer plate interconnects the outer and inner plates and has an aperture shaped to couple the port to the slots for defining a fluid flow path. The plates are stamped from aluminum sheet stock clad with a brazing alloy. The plates are assembled and secured by a steel rivet and the nipple is attached. The parts are joined by brazing. The fitting can be brazed to the exchanger core at the same time.

Abstract: A fitting for a two flat tube serpentine heat exchanger having high burst pressure comprises a header plate with two slots for receiving the flat tubing and a cover plate with a port, a nipple protruding from the port, and a recess surrounding the port and extending over the slots to provide communication between the port and the slots. The plates are formed by extrusion with the appropriate apertures, cut to the desired thickness and the recess is milled out, or the plates and apertures are stamped from sheet stock. The plates are welded together at their common periphery or brazed together at their margins outboard of the recess.

Abstract: A fitting for a two flat tube serpentine heat exchanger having high burst pressure comprises a header plate with two slots for receiving the flat tubing and a cover plate with a port, a nipple protruding from the port, and a recess surrounding the port and extending over the slots to provide communication between the port and the slots. The plates are formed by extrusion with the appropriate apertures, cut to the desired thickness and the recess is milled out, or the plates and apertures are stamped from sheet rock. The plates are welded together at their common periphery or brazed together at their margins outboard of the recess.