Abstract: A method for reducing “blow-out” of annular welds for attaching press-fit components in a fuel injector assembly is disclosed. The method employs a multi-step welding procedure whereby a first annular weld bead that corresponds to less than 360° of rotation of the assembly about a longitudinal axis leaves a radial void that is thereafter sealed with a second annular weld bead. In an alternative embodiment, a relief region is formed on radially-facing surfaces of the components, the relief region being disposed adjacent to a press-fit region. A sealed gap is thereby formed in the relief region between the welds and the press-fit region. The sealed gap provides a further means for expansion of trapped gases that could otherwise “blow out” the liquid weld bead.

Abstract: In a method for reducing “blow-out” of annular welds for attaching components in a fuel injector, a relief region is formed on radially-facing surfaces of the components. The relief region is adjacent to a press-fit region. The components are then pressed together, and a weld is made in the relief region. A sealed gap is thereby formed in the relief region between the weld and the press-fit region. The sealed gap provides for the expansion of trapped gases that could otherwise “blow out” the liquid weld bead.

Abstract: In a method for reducing “blow-out” of annular welds for attaching components in a fuel injector, a relief region is formed on radially-facing surfaces of the components. The relief region is adjacent to a press-fit region. The components are then pressed together, and a weld is made in the relief region. A sealed gap is thereby formed in the relief region between the weld and the press-fit region. The sealed gap provides for the expansion of trapped gases that could otherwise “blow out” the liquid weld bead.

Abstract: The present invention provides a solenoid actuated fuel injector. The fuel injector includes a housing having a fuel inlet, a fuel outlet, and a fuel passageway extending along a longitudinal axis. The fuel injector additionally includes a valve body having an inlet portion and an armature guide eyelet that is disposed in the inlet portion of the valve body within the fuel passageway. A closure assembly includes an upper bearing guide fixedly connected to a stem portion. The upper bearing guide includes a bearing portion and a contacting portion. The armature guide eyelet includes a first portion circumscribing the upper bearing guide portion, and a second portion engaging the upper bearing guide contacting portion. Methods of mechanically insuring a repeatable stroke of a closure assembly and operating a closure assembly within a solenoid actuated fuel injector are also provided.

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 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: The present invention provides a solenoid actuated fuel injector with a repeatable stroke. The fuel injector includes a housing having a fuel inlet, a fuel outlet, and a fuel passageway extending from the fuel inlet to the fuel outlet along a longitudinal axis. The fuel injector additionally includes a valve body having an inlet portion and an armature guide eyelet that is disposed in the inlet portion of the valve body within the fuel passageway. The armature guide eyelet is sized to direct and support reciprocal motion of the needle/armature assembly within the fuel passageway along the longitudinal axis. The needle/armature assembly is reciprocally disposed in and axially aligned with the fuel passageway. The needle/armature assembly includes an upper bearing guide fixedly connected to a needle stem portion. The upper bearing guide includes a bearing portion and a contacting portion.

Abstract: A fuel injector having a housing, an armature, and an inlet member, and a needle. The housing has a fuel inlet, a fuel outlet, and a fuel passageway extending from the fuel inlet to the fuel outlet along a longitudinal axis. The inlet member is disposed within the fuel passageway. The armature is also disposed within the fuel passageway. The needle is operatively connected to the armature, and is positionable to permit or inhibit fuel flow through the fuel outlet. A first surface is located on one of the inlet member or the armature. The first surface has a first perimeter located on a first plane that is substantially perpendicular to the longitudinal axis. A second surface, which is exposed to the first surface, is located on the other of the inlet member and the armature. The second surface has a second perimeter at least partially located on a second plane that is oblique to the longitudinal axis.