Abstract: A fuel injector includes an injector body defining a terminal passage extending between a solenoid cavity and an outer surface. A solenoid assembly is press fit attached to the injector body and received in the solenoid cavity. The solenoid assembly includes a bobbin sandwiched between an upper magnetic flux carrier and a lower magnetic flux carrier. At least one of the flux carriers is plastically deformed when the solenoid assembly is attached to the injector body. A terminal assembly has an external terminal, an electrical conductor and a sealing member surrounding a portion of the electrical conductor. A portion of the electrical conductor and the sealing member are received in the terminal passage. A clamp is in contact with the outer surface of the injector body and the terminal assembly.

Abstract: A control valve, preferably for use with a fuel injector, includes a valve body defining an inlet passage separated from an outlet passage by a valve seat. A solenoid is attached to the valve body, and includes a coil and an armature. A portion of the armature is a permanent magnet. The polarity of the permanent magnet is oriented such that the armature is pushed away from the coil when the solenoid is energized. A valve member is positioned in the valve body and attached to the armature. The valve member is moveable between an open position in which the inlet passage is open to the outlet passage, and a closed position in which the inlet passage is closed to the outlet passage.

Abstract: A control valve includes a terminal assembly that has a terminal electrically connected to one of a male electrical connector and female electrical connector. A solenoid assembly includes a metallic solenoid housing defining a solenoid cavity. A solenoid coil and the other of the male electrical connector and the female electrical connector are molded into a plastic solenoid carrier. The plastic solenoid carrier is attached to the metallic solenoid housing and preferably molded into the solenoid cavity. The solenoid assembly is attached to the terminal assembly, and said male electrical connector is mated to the female electrical connector. An armature is positioned between a portion of the terminal assembly and the solenoid coil. A valve member is attached to the armature.

Abstract: A control valve assembly for a fuel injector includes a valve seat with fluid inlet and fluid outlet and a flat seating surface. A poppet valve has a concave end portion with knife edge for sealingly engaging the flat seating surface on the valve seat. The poppet valve is operated to close by a solenoid coil and is opened and maintained open by a return spring or a permanent magnet. Faster valve closing and faster valve opening is obtained.