Abstract: A fuel pump, is disclosed, including a power group having a housing, a coil, a pole piece and a movable armature; a valve group including a valve body, a plunger connected to the armature, a bushing in which the plunger is disposed, an inlet chamber, an outlet chamber, a pump chamber, an inlet valve disposed between the inlet chamber and the pump chamber and an outlet valve disposed between the pump chamber and the outlet valve; and an inlet filter coupled to a fluid inlet of the valve group. The inlet filter is disposed relative to the coil such that when the fuel pump is disposed within a fuel tank, a bottom of the inlet filter as oriented in the fuel tank is disposed above a fuel level in the fuel tank and the coil is at least partly submerged in the fuel.

Abstract: A valve assembly for a fluid pump includes a valve body; an inlet disk movably disposed in the valve body; an outlet disk movably disposed in the valve body; and a valve seat fixed within the valve body. The valve seat includes a first aperture defined axially through the valve seat in a radial central portion thereof, and one or more second apertures disposed at least partly around the first aperture. The inlet disk is biased in a closed position against the valve seat along a first surface thereof, the closed position of the inlet disk covering the one or more second apertures of the valve seat. The outlet disk is biased in a closed position against the valve seat along a second surface thereof.

Abstract: A solenoid assembly of a fuel pump includes a housing; a pole piece disposed within the housing; an armature assembly movably disposed within the housing and including an armature and a plunger; and a coil disposed within the housing. A plurality of metal disks are disposed in a stacked arrangement, coupled to the pole piece and situated so as to be impacted by the armature during a full stroke of the armature assembly. The solenoid assembly further includes at least one fluid path in fluid communication with the region surrounding the metal disks, the at least one fluid path configured such that only a portion of a secondary swept volume of fuel associated with the armature assembly during operation of the fuel pump passes through the region and decelerates the armature assembly when the armature assembly moves towards the pole piece responsive to a current passing through the coil.

Abstract: A fluid pump valve assembly includes: a valve body; a fluid inlet and a fluid outlet defined in the valve body; an inlet disk and an outlet disk movably disposed in the valve body; and a valve seat fixed within the valve body and including a disk member including at least one first aperture defined axially through the disk member, and at least one second aperture defined axially through the disk member, the inlet disk and the valve seat forming at least part of an inlet valve and the outlet disk and the valve seat forming at least part of an outlet valve. An inlet chamber is disposed upstream of the inlet valve, a pump chamber is disposed between and in fluid communication with the inlet valve and the outlet valve, and an outlet chamber is disposed downstream of the outlet valve. The inlet chamber surrounds the outlet chamber.

Abstract: A solenoid assembly of a fuel pump is disclosed, including a housing having an open end and a partly closed end; a pole piece fixedly disposed within the housing; a bobbin assembly disposed within the housing and including a coil disposed proximal to the pole piece; and a bobbin retainer disposed between the open end of the housing and the bobbin assembly, a radially outer surface of the bobbin retainer contacting the housing. A portion of the housing which is adjacent the bobbin retainer has an outer surface that is recessed and an inner surface that protrudes against the bobbin retainer. The portion is created by deforming the housing to create the protrusion on the inner surface of the housing. The housing inner surface protrusion provides a press fit engagement with the bobbin retainer.

Abstract: A valve assembly for a fluid pump includes a valve body; a fluid inlet and a fluid outlet defined in the valve body; a valve seat; and an inlet disk disposed in the valve body having an inner portion, an outer portion fixed within the valve body, and a plurality of legs connected between the inner portion and the outer portion so that the inner portion is movable between a first position against the valve seat and a second position spaced apart from the valve seat. The connection between the legs, the inner portion and the outer portion provides a spring bias force to the inner portion against movement of the inner portion from the first position. The plurality of legs, the inner portion and the outer portion are configured such that the spring bias force is asymmetric as applied to the inner portion of the inlet disk.

Abstract: In some embodiments, a solenoid-actuated pump includes a first pumping chamber and a second pumping chamber, where the first pumping chamber delivers fluid from the pump to portions of a vehicle to facilitate the operation of the vehicle. The second (or “parasitic”) pumping chamber implements a forced convection cooling method, which utilizes parasitic pumping loss to produce a flow within and/or around the solenoid coil to cool the coil and/or maintain the temperature of the coil during operation. In this manner, the second pumping chamber produces a flow that reduces thermally-related increases in electrical resistance of the solenoid coil of the solenoid-actuated pump.

Abstract: A solenoid assembly of a fuel pump is disclosed, including a housing having an open end and a partly closed end; a pole piece fixedly disposed within the housing; a bobbin assembly disposed within the housing and including a coil disposed proximal to the pole piece; and a bobbin retainer disposed between the open end of the housing and the bobbin assembly, a radially outer surface of the bobbin retainer contacting the housing. A portion of the housing which is adjacent the bobbin retainer has an outer surface that is recessed and an inner surface that protrudes against the bobbin retainer. The portion is created by deforming the housing to create the protrusion on the inner surface of the housing. The housing inner surface protrusion provides a press fit engagement with the bobbin retainer.

Abstract: A solenoid assembly of a fuel pump includes a housing; a pole piece disposed within the housing; an armature assembly movably disposed within the housing and including an armature and a plunger; and a coil disposed within the housing. A plurality of metal disks are disposed in a stacked arrangement, coupled to the pole piece and situated so as to be impacted by the armature during a full stroke of the armature assembly. The solenoid assembly further includes at least one fluid path in fluid communication with the region surrounding the metal disks, the at least one fluid path configured such that only a portion of a secondary swept volume of fuel associated with the armature assembly during operation of the fuel pump passes through the region and decelerates the armature assembly when the armature assembly moves towards the pole piece responsive to a current passing through the coil.

Abstract: A fluid pump valve assembly includes: a valve body; a fluid inlet and a fluid outlet defined in the valve body; an inlet disk and an outlet disk movably disposed in the valve body; and a valve seat fixed within the valve body and including a disk member including at least one first aperture defined axially through the disk member, and at least one second aperture defined axially through the disk member, the inlet disk and the valve seat forming at least part of an inlet valve and the outlet disk and the valve seat forming at least part of an outlet valve. An inlet chamber is disposed upstream of the inlet valve, a pump chamber is disposed between and in fluid communication with the inlet valve and the outlet valve, and an outlet chamber is disposed downstream of the outlet valve. The inlet chamber surrounds the outlet chamber.

Abstract: A fuel pump, is disclosed, including a power group having a housing, a coil, a pole piece and a movable armature; a valve group including a valve body, a plunger connected to the armature, a bushing in which the plunger is disposed, an inlet chamber, an outlet chamber, a pump chamber, an inlet valve disposed between the inlet chamber and the pump chamber and an outlet valve disposed between the pump chamber and the outlet valve; and an inlet filter coupled to a fluid inlet of the valve group. The inlet filter is disposed relative to the coil such that when the fuel pump is disposed within a fuel tank, a bottom of the inlet filter as oriented in the fuel tank is disposed above a fuel level in the fuel tank and the coil is at least partly submerged in the fuel.

Abstract: A valve assembly for a fluid pump includes a valve body; a fluid inlet and a fluid outlet defined in the valve body; a valve seat; and an inlet disk disposed in the valve body having an inner portion, an outer portion fixed within the valve body, and a plurality of legs connected between the inner portion and the outer portion so that the inner portion is movable between a first position against the valve seat and a second position spaced apart from the valve seat. The connection between the legs, the inner portion and the outer portion provides a spring bias force to the inner portion against movement of the inner portion from the first position. The plurality of legs, the inner portion and the outer portion are configured such that the spring bias force is asymmetric as applied to the inner portion of the inlet disk.

Abstract: A valve assembly for a fluid pump includes a valve body; an inlet disk movably disposed in the valve body; an outlet disk movably disposed in the valve body; and a valve seat fixed within the valve body. The valve seat includes a first aperture defined axially through the valve seat in a radial central portion thereof, and one or more second apertures disposed at least partly around the first aperture. The inlet disk is biased in a closed position against the valve seat along a first surface thereof, the closed position of the inlet disk covering the one or more second apertures of the valve seat. The outlet disk is biased in a closed position against the valve seat along a second surface thereof.

Abstract: In some embodiments, an apparatus includes a solenoid and a solenoid controller. The solenoid is configured to move an actuator a distance between a first position and a second position when a voltage is supplied to the solenoid. The solenoid controller is implemented in at least one of a memory or a processor, and includes a feedback module and an output module. The feedback module is configured to receive a feedback signal associated with a solenoid current after the voltage is removed from the solenoid. The feedback module is further configured to determine whether the distance is less than a maximum distance between the first position and the second position (i.e., a “stroke”). The output module configured to produce an output signal when the feedback module determines that the distance is less than the maximum distance.

Abstract: In some embodiments, a solenoid-actuated pump includes a first pumping chamber and a second pumping chamber, where the first pumping chamber delivers fluid from the pump to portions of a vehicle to facilitate the operation of the vehicle. The second (or “parasitic”) pumping chamber implements a forced convection cooling method, which utilizes parasitic pumping loss to produce a flow within and/or around the solenoid coil to cool the coil and/or maintain the temperature of the coil during operation. In this manner, the second pumping chamber produces a flow that reduces thermally-related increases in electrical resistance of the solenoid coil of the solenoid-actuated pump.

Abstract: In some embodiments, an apparatus includes a solenoid and a solenoid controller. The solenoid is configured to move an actuator a distance between a first position and a second position when a voltage is supplied to the solenoid. The solenoid controller is implemented in at least one of a memory or a processor, and includes a feedback module and an output module. The feedback module is configured to receive a feedback signal associated with a solenoid current after the voltage is removed from the solenoid. The feedback module is further configured to determine whether the distance is less than a maximum distance between the first position and the second position (i.e., a “stroke”). The output module configured to produce an output signal when the feedback module determines that the distance is less than the maximum distance.

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: A modular fuel injector that includes a coil group subassembly and a valve group subassembly. The coil group subassembly is independently testable. The valve group subassembly is independently testable and includes a tube assembly having a longitudinal axis extending between a first tube end and a second tube end, and a seat assembly disposed in the tube assembly proximate the second tube end. The seat assembly includes a flow portion and a securement portion. The flow portion extends along the longitudinal axis between a first surface and an orifice disk retention surface at a first length. The flow portion has a seat orifice extending therethrough and an orifice disk coupled to the orifice disk retention surface so that the orifice plate is aligned in a fixed spatial orientation with respect to the flow portion. The securement portion extends along the longitudinal axis away from the orifice disk retention surface at a second length greater than the first length.

Abstract: A fuel injector has a housing extending along a longitudinal axis between an inlet and an outlet. A seat assembly is disposed in a body proximate the outlet. The seat assembly includes a flow portion and a securement portion. The flow portion extends along the longitudinal axis between a first surface and an orifice disk retention surface at a first length. The flow portion has a seat orifice extending therethrough and an orifice disk coupled to the orifice disk retention surface so that the orifice plate is aligned in a fixed spatial axial orientation with respect to the flow portion. The securement portion extends along the longitudinal axis away from the orifice disk retention surface at a second length greater than the first length. A method of maintaining a fixed spatial axial orientation and dimensional symmetry of at least one of the seat and orifice disk in the body is disclosed.

Abstract: A valve seat and a needle for a fuel injector are disclosed. The fuel injector includes a longitudinal axis extending therethrough, the valve seat, and the needle. The valve seat includes a channel having a channel wall extending along the longitudinal axis and a needle contact area upstream from the channel. The needle contact area is proximate to the channel such that fuel deposits form exclusively on the channel wall and on the valve seat upstream of the needle contact area. The needle includes a generally tubular perimeter, a downstream end, and a generally circular recess in the downstream end. The generally circular recess has a center generally along the longitudinal axis and an outer recess perimeter. The outer recess perimeter is proximate to the generally tubular perimeter such that fuel deposits form exclusively in the generally circular recess. A method of forming fuel deposits on the injector is also disclosed.