Abstract: A dual-mode fuel injector has an internal part containing a variable volume chamber space which fills with fuel at common rail pressure and a plunger which is operable to force fuel out of the variable volume chamber space and to be injected out of the nozzle through the injection orifices at amplified pressure greater than common rail pressure. The plunger and the internal part have respective surfaces which come into mutual abutment during filling of the variable volume chamber space with fuel at common rail pressure and which, when in mutual abutment, create a seal which seals fuel in the variable volume chamber space against escape from the variable volume chamber space past the seal.

Abstract: An assembly for a fuel injector that includes a piston that is decoupled from the needle of a needle valve. The piston is slidingly positioned in a disk bore. The portion of needle in the disk bore is smaller than the disk bore so as to prevent the disk bore from interfering with movement of the needle between seated and unseated positions. During periods of operation, the upper surface of the piston is engaged by a control volume of fuel that pushes the needle toward a seated position, while the needle pushes in an opposing direction against a lower surface of the piston. The surface area of the piston acted on by the control volume is larger than the upper portion of the needle that is typically acted upon by the control volume, thereby providing a larger force on the piston that keeps the needle in a seated.

Abstract: A needle body for a fuel injector that controls or prevents high pressure fuel leaks by dynamically controlling the size of the clearance between a longitudinal bore in a nozzle body and the needle that travels along the bore. The longitudinal bore passes through a body portion and a clearance control protrusion of the needle body. The clearance control protrusion extends from the body portion into a nozzle chamber of a nozzle section of the fuel injector. The clearance control protrusion is configured to prevent expansion of the clearance that is typically associated with hydraulic forces caused by pressurized fuel in the clearance. The clearance control protrusion is configured so that as fuel pressure in the nozzle chamber increases, hydraulic forces act against an outer surface of the clearance control protrusion to prevent expansion of the portion of the clearance positioned within the clearance control protrusion.

Abstract: In one embodiment, a fuel injector assembly is described. The fuel injector assembly includes a terminal assembly that electrically connects a plurality of wire cables to a plurality of control valve solenoids. The control valve solenoids can include, for example, a needle control valve solenoid and/or an intensifier control valve solenoid. The terminal assembly can be physically configured with a radius profile that prevents excessive bending of the wire cables. A connector bridge may allow for the offsetting of a first pair and a second pair of electrical rods that are used to provide electrical current from the terminal assembly to the needle control valve solenoid. Alternatively, the intensifier control valve solenoid may have an aperture, and an armature of an associated poppet valve may have a slot, that are configured to receive the placement of at least a portion of the pair of electrical rods.

Abstract: A unit fuel injector (30) has a reverse flow check (122) disposed in a circular reverse flow check cavity (124) to substantially close an exit through-passage (112) to the cavity which has a central axis (125) parallel to and spaced radially from a longitudinal axis (AX) of the unit fuel injector. The exit through-passage opens to the circular reverse flow check cavity at the central axis of the circular reverse flow check cavity. An adjoining cavity (131) distally adjoins the circular reverse flow check cavity. A passage (132) that at the adjoining cavity is radially off-set from the central axis of the circular cavity extends distally to a distal end of the spring cage.

Abstract: A proximal end face of a proximal end wall (82) of a spring cage (42) in a unit fuel injector (30) and a distal end face of a check valve body (44) cooperatively define a reverse flow check cavity (124) within which a reverse flow check (122) is disposed for selectively opening and substantially closing an exit through-passage (112) in the check valve body (44). The reverse flow check opens the exit through-passage during high-pressure injection and substantially closes the exit through-passage when injection ceases.

Abstract: A unit fuel injector (30) has a boundary edge filter. A first endless annular internal space (100) is open to a holes (92) forming a fuel inlet port, a second endless annular internal space (102) that is spaced axially of the first endless annular internal space and through which fuel is supplied to an injection mechanism, and a series of circumferentially spaced apart, axially extending channels (104) through which fuel can pass from the first endless annular internal space to the second endless annular internal space.

Abstract: A quick connect fluid valve assembly comprises a housing, a flow passage insert, and a movable connector. The flow passage insert is disposed at least partially within the housing and is movable relative to the housing. The flow passage insert forms a flow path from a first end of the flow passage insert to a second end of the flow passage insert. The movable connector is disposed in fluid communication with the flow path of the flow passage insert and the movable connector has at least one orifice. The movable connector is movable between a forward fluid flow position that allows forward fluid flow within the flow path of the flow passage insert and a backward fluid flow position that prevents backward fluid flow within the flow path of the flow passage insert.

Abstract: A check valve body (44) is disposed within the interior of a main body (32) of a fuel injector (30) and contains a continuous sealing ridge for sealing a perimeter of a cavity (124) between the proximal end face of the check valve body and the distal end face of an intensifier cartridge body (46). A spring cage (42) has a proximal end face disposed within the interior of the main body. An entry check (154) is disposed in an entry through-passage (132), and an exit check (156) is disposed in an exit through-passage (130). A continuous sealing ridge seals a perimeter of an exit cavity (140), and a discontinuous sealing ridge seals a portion of a perimeter of an entry cavity (144). The sealing ridges are asymmetric about a longitudinal axis AX.

Abstract: A unit fuel injector (30) has a boundary edge filter. A first endless annular internal space (100) is open to a holes (92) forming a fuel inlet port, a second endless annular internal space (102) that is spaced axially of the first endless annular internal space and through which fuel is supplied to an injection mechanism, and a series of circumferentially spaced apart, axially extending channels (104) through which fuel can pass from the first endless annular internal space to the second endless annular internal space.

Abstract: A quick connect fluid valve assembly comprises a housing, a flow passage insert, and a movable connector. The flow passage insert is disposed at least partially within the housing and is movable relative to the housing. The flow passage insert forms a flow path from a first end of the flow passage insert to a second end of the flow passage insert. The movable connector is disposed in fluid communication with the flow path of the flow passage insert and the movable connector has at least one orifice. The movable connector is movable between a forward fluid flow position that allows forward fluid flow within the flow path of the flow passage insert and a backward fluid flow position that prevents backward fluid flow within the flow path of the flow passage insert.