Abstract: A fuel pump includes a fuel pump housing with a pumping chamber; a pumping plunger which reciprocates within a plunger bore; and an inlet valve assembly. The inlet valve assembly includes a check valve member which is moveable between an unseated position which provides fluid communication between the pumping chamber and a fuel supply passage and a seated position which prevents fluid communication between the pumping chamber and the fuel supply passage; and a solenoid assembly which includes a wire winding; a pole piece; an armature which is moveable between a first position when the wire winding is not energized and a second position when the wire winding is energized; a return spring which biases the armature away from the pole piece; and a control rod which is moveable along the inlet valve axis independently of the armature.

Abstract: A fuel pump includes a fuel pump housing with a pumping chamber; a pumping plunger which reciprocates within a plunger bore; and an inlet valve assembly. The inlet valve assembly includes a check valve member which is moveable between an unseated position which provides fluid communication between the pumping chamber and a fuel supply passage and a seated position which prevents fluid communication between the pumping chamber and the fuel supply passage; and a solenoid assembly which includes a wire winding; a pole piece; an armature which is moveable between a first position when the wire winding is not energized and a second position when the wire winding is energized; a return spring which biases the armature away from the pole piece; and a control rod which is moveable along the inlet valve axis independently of the armature.

Abstract: A method for controlling electrical power applied to a fuel heater includes applying power to the heater, determining a value for an electrical parameter that varies as a function of the temperature of the heater, and determining a value representative of the time rate of change of the electrical parameter. The method further includes determining the value of the electrical parameter corresponding to a change in the time rate of change of the electrical parameter, wherein the change in the time rate of change of the electrical parameter exceeds a predetermined threshold, and controlling electrical power applied to the heater so as to maintain the temperature of the heater about a target temperature that is a predetermined level below the heater temperature at the time at which said change in the time rate of change of the electrical parameter exceeds the predetermined threshold.

Abstract: A heated fuel injector for supplying fuel to a fuel consuming device includes a fuel inlet for receiving fuel, a fuel outlet for dispensing fuel from the fuel injector, and a fuel injector body extending along an axis and fluidly connecting the fuel inlet to the fuel outlet such that fuel flows within the injector body. A cylindrical heating element radially surrounds the fuel injector body and operates to heat fuel flowing through the fuel injector body. An annular space is defined between the heating element and the fuel injector body sufficiently large to accommodate thermally caused radial differential expansion between the fuel injector body and the heating element. A conductive material fills the annular space and has a melting point sufficiently low to be a liquid as the heating element operates to thereby substantially prevent transfer of mechanical stress to the heating element due to the radial differential expansion.

Abstract: A fuel injector wherein a cylindrical surface supports an electrical heating structure covering 360° or almost 360° of the surface for heating fuel. The structure comprises a first dielectric layer adhered to the surface; a thick film resistance heating element; a second dielectric layer; spaced-apart first and second conductor pads, wherein the first conductor pad is disposed in contact with a dielectric layer and a first end of the heating element, and wherein the second conductor pad is disposed in contact with a dielectric layer and a second end of the heating element. Another dielectric layer may be disposed over the preceding layers and the first and second conductor pads and having first and second windows formed therein for access to the first and second conductor pads. The resistance heating element may selectively be trimmed by overprinting in a pattern one or more times to improve the uniformity of heating.

Abstract: A method for controlling electrical power applied to a fuel heater includes applying power to the heater, determining a value for an electrical parameter that varies as a function of the temperature of the heater, and determining a value representative of the time rate of change of the electrical parameter. The method further includes determining the value of the electrical parameter corresponding to a change in the time rate of change of the electrical parameter, wherein the change in the time rate of change of the electrical parameter exceeds a predetermined threshold, and controlling electrical power applied to the heater so as to maintain the temperature of the heater about a target temperature that is a predetermined level below the heater temperature at the time at which said change in the time rate of change of the electrical parameter exceeds the predetermined threshold.

Abstract: A heated fuel injector for supplying fuel to a fuel consuming device includes a fuel inlet for receiving fuel, a fuel outlet for dispensing fuel from the fuel injector, and a fuel injector body extending along an axis and fluidly connecting the fuel inlet to the fuel outlet such that fuel flows within the injector body. A cylindrical heating element radially surrounds the fuel injector body and operates to heat fuel flowing through the fuel injector body. An annular space is defined between the heating element and the fuel injector body sufficiently large to accommodate thermally caused radial differential expansion between the fuel injector body and the heating element. A conductive material fills the annular space and has a melting point sufficiently low to be a liquid as the heating element operates to thereby substantially prevent transfer of mechanical stress to the heating element due to the radial differential expansion.

Abstract: A fuel injector wherein a cylindrical surface supports an electrical heating structure covering 360° or almost 360° of the surface for heating fuel. The structure comprises a first dielectric layer adhered to the surface; a thick film resistance heating element; a second dielectric layer; spaced-apart first and second conductor pads, wherein the first conductor pad is disposed in contact with a dielectric layer and a first end of the heating element, and wherein the second conductor pad is disposed in contact with a dielectric layer and a second end of the heating element. Another dielectric layer may be disposed over the preceding layers and the first and second conductor pads and having first and second windows formed therein for access to the first and second conductor pads. The resistance heating element may selectively be trimmed by overprinting in a pattern one or more times to improve the uniformity of heating.

Abstract: A thermal fuse integrated into an electrical circuit powering a heater element having a positive temperature coefficient includes at least one terminal in electrical connection with the heater element thereby connecting the heater element to a power source, and a solder jacket that mechanically retains the electrical connection between the terminal and heater element, wherein a biasing load is applied to the terminal when retained by the solder jacket, and wherein the terminal breaks connection with the heater element under the force of the bias when the solder jacket melts should the heater element overheat. By selecting the solder material forming the solder jacket according to its melt temperature, a temperature specific overheat protection for a heated fuel injector can be provided. Since the injector's metering circuit is separate from the thermal fuse circuit, the fuel injector remains operational even after the heater circuit is opened.

Abstract: A fuel injector wherein a cylindrical surface supports an electrical heating structure covering 360° or almost 360° of the surface for heating fuel. The structure comprises a first dielectric layer adhered to the surface; a thick film resistance heating element; a second dielectric layer; spaced-apart first and second conductor pads, wherein the first conductor pad is disposed in contact with a dielectric layer and a first end of the heating element, and wherein the second conductor pad is disposed in contact with a dielectric layer and a second end of the heating element. Another dielectric layer may be disposed over the preceding layers and the first and second conductor pads and having first and second windows formed therein for access to the first and second conductor pads. The resistance heating element may selectively be trimmed by overprinting in a pattern one or more times to improve the uniformity of heating.

Abstract: A heated fuel injector includes a fuel inlet for receiving fuel, a fuel outlet for dispensing fuel from the heated fuel injector, and a heated body having an inside surface fore fluidly connecting the fuel inlet to the fuel outlet. The heated fuel injector also includes a hollow pintle shaft that is reciprocably movable within the heated body for selectively permitting and preventing the dispensing of fuel from the fuel outlet. A fuel passage is formed between the inside surface and the hollow pintle shaft such that fuel flows through the passage from the fuel inlet to the fuel outlet. The hollow pintle shaft defines a sealed chamber within the hollow pintle shaft which thereby increases the efficiency by which the heated body can heat the fuel flowing through the fuel passage.

Abstract: A heated fuel injector includes a heated body, liquid fuel flowing through a fuel passage within the body, and a member that increases heat transfer from the heated body to the fuel within the fuel passage. The thermal efficiency of the fuel injector is increased separately or in combination by diverting the fuel flow along an inner circumferential contour of the heated body, by limiting the volume of fuel bypassing the heated inner surface of the body, by redirecting heat from the body to unheated portions of the fuel flow field within the fuel passage, and by increasing the available contact surface area for heat transfer. Improved heat transfer from the heated body to the fuel is achieved by integrating features that increase the contact surface area into the inside surface of the body or by positioning an insulating or a thermally conductive spacer within the fuel passage.

Abstract: A thermal fuse integrated into an electrical circuit powering a heater element having a positive temperature coefficient includes at least one terminal in electrical connection with the heater element thereby connecting the heater element to a power source, and a solder jacket that mechanically retains the electrical connection between the terminal and heater element, wherein a biasing load is applied to the terminal when retained by the solder jacket, and wherein the terminal breaks connection with the heater element under the force of the bias when the solder jacket melts should the heater element overheat. By selecting the solder material forming the solder jacket according to its melt temperature, a temperature specific overheat protection for a heated fuel injector can be provided. Since the injector's metering circuit is separate from the thermal fuse circuit, the fuel injector remains operational even after the heater circuit is opened.

Abstract: A fuel injector having a fuel heater and an insulating air jacket. The fuel injector includes a fuel heater disposed on the outside of the injector body. The injector body conducts heat energy from the heater element to the fuel chamber preferably via cooling fins that protrude into the fuel path. The heater and injector body are disposed within a closed air jacket formed with the shell of the injector. As air has low thermal conductivity, this feature directs most of the heat energy radially inward through the wall of the injector body into the fuel. The injector is especially useful in injecting low-volatility fuels into internal combustion engines under low-temperature conditions.

Abstract: A heated fuel injector includes a heated body, liquid fuel flowing through a fuel passage within the body, and a member that increases heat transfer from the heated body to the fuel within the fuel passage. The thermal efficiency of the fuel injector is increased separately or in combination by diverting the fuel flow along an inner circumferential contour of the heated body, by limiting the volume of fuel bypassing the heated inner surface of the body, by redirecting heat from the body to unheated portions of the fuel flow field within the fuel passage, and by increasing the available contact surface area for heat transfer. Improved heat transfer from the heated body to the fuel is achieved by integrating features that increase the contact surface area into the inside surface of the body or by positioning an insulating or a thermally conductive spacer within the fuel passage.

Abstract: A compression resistant isolator disposed between a direct fuel injector and a cylinder head of an internal combustion engine provides thermal, or thermal and vibrational isolation therebetween. A plurality of radially spaced rigid axial support members provide axial load support to maintain proper direct fuel injector positioning within the cylinder head bore. Spaces formed between the rigid axial support members may have isolation materials positioned therein. The implementation of the isolator may reduce the operating temperature of a fuel injector for direct injection, which is critical to avoid injector tip plugging.

Abstract: A heated fuel vaporizer is disposed in an intake component, such as a throttle valve or an intake manifold, of a fuel injected and spark-ignited internal combustion engine. The engine may be fueled by any liquid fuel, such as gasoline, diesel or by fuels much less volatile than gasoline, for example, alcohols such as ethanol, or mixtures of ethanol and gasoline. A configurable heating element is made from a single piece of sheet metal and includes one or two grids each formed by slots and segments. By controlling the geometry of the element, the power and surface area can be configured to any desired value. A single piece heater assembly is designed for installation in an intake component, such as throttle valve or intake manifold, of an internal combustion engine. The heater assembly includes a single-grid or dual-grid heating element that is over-molded with a high melting temperature polymer.