Abstract: A valve subassembly of a fuel injector that allows spray targeting and distribution of fuel to be configured using non-angled or straight orifice having an axis parallel to a longitudinal axis of the subassembly. Metering orifices are located about the longitudinal axis and defining a first virtual circle greater than a second virtual circle defined by a projection of the sealing surface onto the metering disc so that all of the metering orifices are disposed outside the second virtual circle. The projection of the sealing surface converges at a virtual apex disposed within the metering disc. At least one channel extends between a first end and second end. The first end is disposed at a first radius from the longitudinal axis and spaced at a first distance from the metering disc.

Abstract: A method of preheating fuel in a fuel injector with an internal heater energized to reduce emissions. The heater being a ceramic hollow cylinder disposed within a valve body just upstream of a valve seat where fuel is injected through an orifice into the engine. Conductors for energizing the heater extend into the valve body and are sealed against the escape of pressurized fuel. In one version, the conductors are extended through an O-ring to be sealed. In another version the conductors include pins extending through the valve body sidewall with glass seals fused to the valve body and the pins. The conductors may comprise flat foil strips clamped between the O-ring and an elastomeric washer. The conductors also may be molded into the magnetic coil bobbin and sealed where the conductors emerge into the fuel cavity.

Abstract: A fuel injector has an internal heater energized during cold starting to reduce emissions, the heater being a ceramic hollow cylinder disposed within a valve body just upstream of a valve seat where fuel is injected through an orifice into the engine. Conductors for energizing the heater extend into the valve body and are sealed against the escape of pressurized fuel. In one version, the conductors extend through an O-ring to be sealed. In another version the conductors include pins extending through the valve body sidewall with glass seals fused to the valve body and the pins. The conductors may comprise flat foil strips clamped between the O-ring and an elastomeric washer. The conductors also may be molded into the magnetic coil bobbin and sealed where the conductors emerge into the fuel cavity.

Abstract: A typical solenoid-operated fuel injector solenoid motion initiator provided to initiate motion of the armature during de-energization of the solenoid. The solenoid motion initiator is a piezoelectric device mounted adjacent to or within the pole of the stator of the solenoid.

Abstract: A device comprises an armature movable in a first direction and a second direction for causing a needle to contact and separate from a seat assembly. Stop means provide a motion stop in at least the first direction. Damping means are applied to the needle for reducing bounce of the needle when the needle contacts the stop means, by altering spring rates and vibration modes of the needle.

Abstract: Projection welding is used to join a needle guide member and a valve seat member together preparatory to their assembly into the nozzle of a fuel injector. Various embodiments are disclosed, including various ways for creating the projections. In the preferred embodiment the projections on the end face of the guide member are made my forming a small holes in the frustoconical surface of the guide plate. As the tool is used to form the small holes in the guide plate, the material of the guide plate is displaced creating small projections from the frustoconial guide surface.

Abstract: A length of wire is toroidally wound, and then the toroid is encapsulated and cut in two along a plane that is perpendicular to the toroidal axis. The resulting portions are used as stator and/or armature of a solenoid, and in the solenoid the cut face of each forms one side of the solenoid's working gap so that the faces move toward and away from each other as the solenoid operates.

Abstract: The solenoid portion of a solenoid-operated valve is resiliently biased by a pre-loader against an internal shoulder on the valve body to maintain precision of the stator-armature working gap during the useful life of the valve. Several embodiments of pre-loader are disclosed, including a Belleville spring, a wave spring, and an elastomeric ring.

Abstract: An absorber is position on the back or opposite side of a solenoid to receive the kinetic energy of the armature. The energization of the solenoid attracts the armature to the solenoid core and upon striking the core, the kinetic energy of the armature is transferred through the core and to the absorber. The absorber is launched into flight for the purposes of dissipating the kinetic energy and returns to rest on the core without effecting the movement of the armature. The absorber dissipates the kinetic energy by transferring it to a spring means and also may dissipate the energy by means of viscous damping or the flow of fluid from one side of the absorber to the opposite side.

Abstract: The valve has a diaphragm connected to the operating mechanism which couples the valve element with the solenoid. Opposite sides of the diaphragm are respectively piloted to one pair of the three ports. The valve may also have a second diaphragm which is also connected to the operating mechanism and has its opposite sides respectively piloted to another pair of the three ports.