Patents by Inventor Michael J. Hornby

Michael J. Hornby has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 10539057
    Abstract: An RDU fluid injector includes a fluid inlet and a fluid outlet; a fluid path; an actuator unit including a pole piece, a movable armature and a coil; a valve assembly including a valve seat and a seal member connected to the armature and engageable with the valve seat; and a volume reduction member upstream of the actuator unit. The volume reduction member includes a throughbore partly defining the fluid path. The actuator unit, the valve assembly and the volume reduction member are disposed in one or more body portions of the injector, wherein each of the actuator unit, the valve assembly, the volume reduction member and the one or more body portions includes one or more components of the fluid injector. A ratio of a volume of the fluid path to a volume of the components of the fluid injector is between 0.08 and 0.30.
    Type: Grant
    Filed: September 14, 2017
    Date of Patent: January 21, 2020
    Assignee: Vitesco Technologies USA, LLC
    Inventors: Willem Nicolaas VanVuuren, Stephen C Bugos, Michael J Hornby, Douglas Edward Cosby
  • Publication number: 20190359178
    Abstract: A manifold assembly for a camera wash system of an autonomous vehicle is disclosed. The manifold assembly includes a fluid inlet; a plurality of fluid injectors, each fluid injector configured to switch between an open state in which fluid passes through the fluid injector and a closed state in which fluid does not pass through the fluid injector; a block member configured to hold the fluid injectors in a fixed position; and a rail member including a fluid passage in fluid communication between the fluid inlet and each fluid injector for providing a cleaning fluid to each of the fluid injectors.
    Type: Application
    Filed: May 21, 2019
    Publication date: November 28, 2019
    Applicant: Continental Automotive Systems, Inc.
    Inventors: Michael J. Hornby, Steven Paul Nowinski, Michael J. Zaitz
  • Patent number: 10364758
    Abstract: An injector, including: a moveable armature having a bore and upper and lower control surfaces; a lower housing including a bore and upper and lower stationary control surfaces; and a flow geometry defined along an exterior of the armature. The armature includes a transverse flow path fluidly coupled with the armature bore and the flow geometry. The lower housing includes a transverse flow path fluidly coupled with the lower housing bore. Upon moving the armature from a first position to a second position, a first flow path is formed between the flow geometry and the lower housing transverse flow geometry through a space between the lower stationary control surface and the lower armature control surface, and a second flow path is formed between the armature bore and the lower housing transverse flow geometry through a space between the upper stationary control surface and the armature upper control surface.
    Type: Grant
    Filed: December 18, 2017
    Date of Patent: July 30, 2019
    Assignee: Continental Powertrain, USA, LLC
    Inventors: Perry Robert Czimmek, Michael J Hornby, Douglas Edward Cosby
  • Publication number: 20190186419
    Abstract: Various embodiments include a fluid injector comprising: an injector housing defining a fluid path; a needle within the housing and movable to a closed position and an open position. The needle comprises two axial ends, an end face on the second, and an axial needle section surrounded by the housing. Between the axial section and the surrounding housing, there is a gap comprising at least part of the fluid path. The needle includes a hole extending from the end face and a connecting hole providing fluid connection between the hole and the gap. The valve also includes a plate defining a through-hole. A first valve seat is defined at a surface of the plate facing the end face and adjoining the through-hole and when the needle is in the closed position the through-hole is closed by the end face.
    Type: Application
    Filed: August 22, 2017
    Publication date: June 20, 2019
    Applicant: CPT Group GmbH
    Inventors: Mauro Grandi, Michael J. Hornby, Valerio Polidori
  • Publication number: 20190168243
    Abstract: A dosing unit includes a fluid injector having a valve seat; a valve needle movable within the fluid injector between a closed position in which an end engages with the valve seat to block a flow of fluid from exiting the fluid injector and an open position in which the end is spaced apart from the valve seat so as to allow fluid to exit the fluid injector. The valve body, the valve seat and the valve needle form an outwardly opening valve assembly. A pole piece fixedly is disposed within the valve body, and an armature is coupled to the valve needle upstream of the pole piece. A coil is disposed around the pole piece and the armature so as to generate a force when energized to move the armature toward the pole piece and to cause the valve needle to move from the closed to the open position.
    Type: Application
    Filed: December 5, 2018
    Publication date: June 6, 2019
    Applicant: Continental Automotive Systems, Inc.
    Inventors: Willem Nicolaas Van Vuuren, Michael J. Hornby, Stephen C. Bugos
  • Publication number: 20190078485
    Abstract: An RDU fluid injector includes a fluid inlet and a fluid outlet; a fluid path; an actuator unit including a pole piece, a movable armature and a coil; a valve assembly including a valve seat and a seal member connected to the armature and engageable with the valve seat; and a volume reduction member upstream of the actuator unit. The volume reduction member includes a throughbore partly defining the fluid path. The actuator unit, the valve assembly and the volume reduction member are disposed in one or more body portions of the injector, wherein each of the actuator unit, the valve assembly, the volume reduction member and the one or more body portions includes one or more components of the fluid injector. A ratio of a volume of the fluid path to a volume of the components of the fluid injector is between 0.08 and 0.30.
    Type: Application
    Filed: September 14, 2017
    Publication date: March 14, 2019
    Applicant: Continental Automotive Systems, Inc.
    Inventors: Willem Nicolaas VanVuuren, Stephen C. Bugos, Michael J. Hornby, Douglas Edward Cosby
  • Publication number: 20180171888
    Abstract: An injector, including: a moveable armature having a bore and upper and lower control surfaces; a lower housing including a bore and upper and lower stationary control surfaces; and a flow geometry defined along an exterior of the armature. The armature includes a transverse flow path fluidly coupled with the armature bore and the flow geometry. The lower housing includes a transverse flow path fluidly coupled with the lower housing bore. Upon moving the armature from a first position to a second position, a first flow path is formed between the flow geometry and the lower housing transverse flow geometry through a space between the lower stationary control surface and the lower armature control surface, and a second flow path is formed between the armature bore and the lower housing transverse flow geometry through a space between the upper stationary control surface and the armature upper control surface.
    Type: Application
    Filed: December 18, 2017
    Publication date: June 21, 2018
    Applicant: Continental Automotive Systems, Inc.
    Inventors: Perry Robert Czimmek, Michael J Hornby, Douglas Edward Cosby
  • Patent number: 9689293
    Abstract: A reductant delivery unit reduces nitrogen oxide (NOx) emissions from a vehicle. The delivery unit includes a solenoid operated fluid injector having a fluid inlet and a fluid outlet. The inlet receives a source of reducing agent and the outlet communicates with an exhaust gas flow path of the vehicle so that the fluid injector controls injection of the reducing agent into the exhaust gas flow path. The fluid injector has an inlet tube for directing the reducing agent between the inlet and the outlet. A coil heater is integral with the fluid injector and is constructed and arranged, when energized, to inductively heat the inlet tube and thus at least a portion of the reducing agent so that an unheated volume, of the reducing agent in the inlet tube, which is adjacent to the fluid outlet, is less than about 100 mm3.
    Type: Grant
    Filed: August 4, 2015
    Date of Patent: June 27, 2017
    Assignee: Continental Automotive Systems, Inc.
    Inventors: Willem Nicolaas van Vuuren, Stephen C Bugos, Michael J Hornby
  • Patent number: 9617884
    Abstract: A liquid cooled reduction unit includes a diesel exhaust fluid (DEF) injection valve. The valve includes an end portion extending to a distal end. The valve is configured to receive a DEF and force the DEF to exit at the distal end such that the DEF is then directed and applied to an exhaust stream of a vehicle engine. A coolant jacket is selectively filled with a coolant and has an outer side and an inner side. The inner side of the jacket faces a length of the end portion and is separated from the length of the end portion by an air gap.
    Type: Grant
    Filed: September 18, 2014
    Date of Patent: April 11, 2017
    Assignee: Continental Automotive Systems, Inc.
    Inventors: Robert Wayne McFarland, Keith Aaron Shaw, Michael J. Hornby, James A. Wynn, Joshua Lee Hatfield, Christopher Caulkins, Stephen C. Bugos
  • Patent number: 9453486
    Abstract: An injector has an inlet and an outlet and an armature tube having passage structure and having a distal end spaced from the outlet. The passage structure communicates with the inlet. A movable, magnetic armature is coupled to the armature tube. An electromagnetic coil is associated with a stator and with the armature. A first spring is constructed and arranged, when the coil is not activated, to bias the armature tube so that the distal end engages in a sealing manner with a first seat to limit leakage of the gaseous fuel from the outlet. A second valve is movable in a valve body. A second spring is constructed and arranged, when the coil is not activated, to bias the second valve so that a seating surface thereof engages a second seat to close the outlet.
    Type: Grant
    Filed: March 20, 2015
    Date of Patent: September 27, 2016
    Assignee: Continental Automotive Systems, Inc.
    Inventors: Michael J Hornby, Klaus Husslein, Harry Schüle, Christopher Heukenroth, Wolfram Klemp, Thomas Komischke, Thomas Gerlach
  • Publication number: 20160273504
    Abstract: An injector has an inlet and an outlet and an armature tube having passage structure and having a distal end spaced from the outlet. The passage structure communicates with the inlet. A movable, magnetic armature is coupled to the armature tube. An electromagnetic coil is associated with a stator and with the armature. A first spring is constructed and arranged, when the coil is not activated, to bias the armature tube so that the distal end engages in a sealing manner with a first seat to limit leakage of the gaseous fuel from the outlet. A second valve is movable in a valve body. A second spring is constructed and arranged, when the coil is not activated, to bias the second valve so that a seating surface thereof engages a second seat to close the outlet.
    Type: Application
    Filed: March 20, 2015
    Publication date: September 22, 2016
    Inventors: Michael J. Hornby, Klaus Husslein, Harry Schüle, Christopher Heukenroth, Wolfram Klemp, Thomas Komischke, Thomas Gerlach
  • Patent number: 9416709
    Abstract: A dosing valve for administering a reducing agent into an exhaust stream within an exhaust manifold of an internal combustion engine. The dosing valve includes a valve needle internally coaxial to a valve body and held in a closed position by a force of compressed spring acting axially and held in relation to the valve needle and valve body. The negative impact of varnish and dehydrogenated compounds, or coking products, of hydrocarbon based reducing agents, is substantially reduced or eliminated. Additionally, this includes decreased sensitivity to the negative impact of the precipitates and crystals that come out of the solution due to temperature change with urea-based reducing agents.
    Type: Grant
    Filed: June 15, 2012
    Date of Patent: August 16, 2016
    Assignee: Continental Automotive Systems, Inc.
    Inventors: Hamid Sayer, Michael J. Hornby, Perry Robert Czimmek, Christopher Lee Szymanski
  • Patent number: 9399975
    Abstract: A fluid injector includes a valve structure movable in the passageway between a first position and a second position. The valve structure includes a hollow tube having a longitudinal axis and a valve member connected to an end of the tube by a weld, with a weld zone being defined inside of the tube generally adjacent to the weld. The tube has surfaces defining a through-hole that is disposed transversely with respect to the longitudinal axis of the tube. The through-hole permits the fluid to enter an interior of the tube. Corrosion prevention structure is disposed in the tube between the through-hole and the valve member to prevent the fluid in the tube from accessing the weld zone.
    Type: Grant
    Filed: September 25, 2014
    Date of Patent: July 26, 2016
    Assignee: Continental Automotive Systems, Inc.
    Inventors: Michael J. Hornby, Carl F. Hayden
  • Publication number: 20160090952
    Abstract: A fluid injector includes a valve structure movable in the passageway between a first position and a second position. The valve structure includes a hollow tube having a longitudinal axis and a valve member connected to an end of the tube by a weld, with a weld zone being defined inside of the tube generally adjacent to the weld. The tube has surfaces defining a through-hole that is disposed transversely with respect to the longitudinal axis of the tube. The through-hole permits the fluid to enter an interior of the tube. Corrosion prevention structure is disposed in the tube between the through-hole and the valve member to prevent the fluid in the tube from accessing the weld zone.
    Type: Application
    Filed: September 25, 2014
    Publication date: March 31, 2016
    Inventors: Michael J. Hornby, Carl F. Hayden
  • Publication number: 20160084129
    Abstract: A liquid cooled reduction unit includes a diesel exhaust fluid (DEF) injection valve. The valve includes a housing that forms an elongated chamber therein. The valve configured to receive a DEF and force the DEF through the chamber to exit the chamber and the DEF is then being directed and applied to an exhaust stream of a vehicle engine. A coolant jacket is selectively filled with a coolant and has an outer side and an inner side. The inner side of the jacket faces a length of the valve body and is separated from the length of the valve body by an air gap.
    Type: Application
    Filed: September 18, 2014
    Publication date: March 24, 2016
    Inventors: Robert Wayne McFarland, Keith Aaron Shaw, Michael J. Hornby, James A. Wynn, Joshua Lee Hatfield, Christopher Caulkins, Stephen C. Bugos
  • Publication number: 20160053652
    Abstract: A reductant delivery unit reduces nitrogen oxide (NOx) emissions from a vehicle. The delivery unit includes a solenoid operated fluid injector having a fluid inlet and a fluid outlet. The inlet receives a source of reducing agent and the outlet communicates with an exhaust gas flow path of the vehicle so that the fluid injector controls injection of the reducing agent into the exhaust gas flow path. The fluid injector has an inlet tube for directing the reducing agent between the inlet and the outlet. A coil heater is integral with the fluid injector and is constructed and arranged, when energized, to inductively heat the inlet tube and thus at least a portion of the reducing agent so that an unheated volume, of the reducing agent in the inlet tube, which is adjacent to the fluid outlet, is less than about 100 mm3.
    Type: Application
    Filed: August 4, 2015
    Publication date: February 25, 2016
    Inventors: Willem Nicolaas van Vuuren, Stephen C. Bugos, Michael J. Hornby
  • Patent number: 9157545
    Abstract: An air bypass valve (10) includes a solenoid assembly (30) including a magnetic housing (32), a coil bobbin (34) in the magnetic housing, a coil (36) disposed about the coil bobbin, and a magnetic flux ring (38) coupled with the magnetic housing. An armature and seal assembly (12) includes an armature structure (14, 16) that can move with respect to the solenoid assembly from a closed position to an open position in response to a magnetic field generated by the coil. Seal structure (22) is coupled with armature structure so that the seal structure can pivot with respect to the armature structure. The seal structure has a sealing edge (28) to seal with a manifold component when the armature structure is in the closed position thereof. A spring (44) biases the armature structure to the closed position and a main housing covers (46) the magnetic housing.
    Type: Grant
    Filed: February 17, 2009
    Date of Patent: October 13, 2015
    Assignee: Continental Automotive Systems, Inc.
    Inventors: Perry Robert Czimmek, Michael J. Hornby
  • Patent number: 9151201
    Abstract: Dosing structure (30) supplies diesel fuel to an exhaust passage of a diesel system. The dosing structure includes an electrically operated control valve (31). An inlet tube (45) is coupled with an inlet of the control valve. A first welded joint (6) is between the inlet tube and the control valve. The inlet tube is constructed and arranged to be coupled to a supply of diesel fuel for feeding fuel to the control valve. A dosing valve (32) is constructed and arranged to receive fuel from the control valve and deliver the fuel to the exhaust passage. An extension tube (33) is fluidly coupled between the control valve and the dosing valve to space the control valve from the dosing valve. A second welded joint (62) is between the extension tube and the control valve and a third welded joint (64) is between the extension tube and the dosing valve.
    Type: Grant
    Filed: June 11, 2007
    Date of Patent: October 6, 2015
    Assignee: Continental Automotive Systems, Inc.
    Inventors: Michael J. Hornby, Stephen C. Bugos, Hamid Sayar, David Stockmaster
  • Patent number: 9010089
    Abstract: A reductant delivery unit (10) includes a fluid injector (12) and a flange (20) coupled with the fluid injector. An exhaust boss (28) has a surface (39) defining a through-hole (40) that communicates with a vehicle's exhaust flow path. The flange is coupled to a mounting surface such that the outlet of the fluid injector communicates with the exhaust flow path so as to control injection of urea solution into the exhaust gas flow path. A gasket (32) is sandwiched between the flange and the mounting surface. The gasket has a surface (37) defining a through-hole (38) therein that communicates with the through-hole in the exhaust boss to permit the urea solution to pass from the fluid outlet to the exhaust flow path. Gasket shielding structure (44) covers the surface defining the through-hole in the gasket to prevent the urea solution from contacting the gasket.
    Type: Grant
    Filed: August 18, 2011
    Date of Patent: April 21, 2015
    Assignee: Continental Automotive Systems, Inc.
    Inventors: Stephen C. Bugos, Michael J. Hornby
  • Patent number: 8997463
    Abstract: A reductant delivery unit for selective catalytic reduction (SCR) after-treatment for vehicles includes a solenoid operated fluid injector associated with an exhaust gas flow path upstream of a SCR catalytic converter. The fluid injector has a fluid inlet and a fluid outlet. The fluid inlet receiving a source of reducing agent and the fluid outlet communicating with the exhaust gas flow path so that the fluid injector controls injection of urea solution into the exhaust gas flow path. The fluid injector has an inlet tube for directing the reducing agent between the fluid inlet and the fluid outlet. A shield is fixed with respect to the fluid injector and surrounds at least portions of the fluid injector. A coil heater is integral with the fluid injector and is constructed and arranged, when energized, to inductively heat the inlet tube to thereby heat the reducing agent within the inlet tube.
    Type: Grant
    Filed: April 17, 2013
    Date of Patent: April 7, 2015
    Assignee: Continental Automotive Systems, Inc.
    Inventors: Stephen C. Bugos, Michael J. Hornby, Perry Czimmek, Keith Shaw, Willem Nicolaas van Vuuren