Abstract: A module, direct fuel injector (10) includes a fuel side sub-assembly (78) having valve body structure (12, 14) defining a main flow passage (16) there-through, an outlet opening (26) and a seating surface (24). A needle (18) is in the main flow passage and has first and second ends. The second end (22) has a sealing surface (20). The needle is movable between a closed position with the sealing surface engaging the seating surface to prevent fuel from passing through the outlet opening, and an open position. A spring (30) biases the needle to the closed position. Manifold structure (36, 48) is coupled to the valve body structure. The injector also includes a dry side sub-assembly including a piezo stack (42) coupled to the manifold structure and changes length when voltage is applied thereto. The piezo stack is associated with the first end of the needle so that when the length of the piezo stack changes, the needle moves from the closed position to the open position thereof.

Abstract: A module, direct fuel injector (10) includes a fuel module (46) having a valve body (12) defining an outlet opening (20) and including a seating surface (18). A needle 14, disposed in valve body, has a sealing surface (16). An armature (28) is coupled with the needle such that movement of the armature moves the needle between a closed position with the sealing surface engaging the seating surface and an open position with the needle moving outwardly from the valve body with the sealing surface being disengaged from the seating. A spring (38) biases the armature and thus the needle to the closed position. An inlet tube (22) is coupled to the fuel module defining an inlet of the injector. A power assembly (42) is separate from, but coupled to, the fuel module. The power assembly includes an electromagnetic coil (44) for causing movement of the armature, and a connector (43).

Abstract: Methods of forming a hermetic seal between fuel system components are provided. One of the methods can be achieved by passing a light beam through a wall of a polymeric member to an inner surface of the wall that surrounds an outer surface of a polymeric body and defines an internal passage for a flow of fuel; and welding the inner surface of the polymeric member to the outer surface of the polymeric body to provide a hermetic seal at the respective inner and outer surfaces against the flow of fuel. Another method can be achieved by disposing an adhesive on an inner surface of polymeric member that surrounds an outer surface of a polymeric body and defines an internal passage for a flow of fuel; and activating the adhesive to bond the polymeric member to the polymeric body.

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.

Abstract: A solenoid device includes a solenoid assembly (30) including a stator (42, 32, 38) and a coil (36) for generating a magnetic field. An armature structure (14, 16) can move with respect to the solenoid assembly from a closed position, defining a working gap area (62) between the coil and a portion of the armature structure, to an open position in response to the magnetic field generated by the coil. Seal structure (22) is coupled with a proximal end of the armature structure and has a sealing edge (28) to seal with a component when the armature structure is in the closed position thereof. A spring (44) biases the armature structure to the closed position. Under certain operating conditions of the device, pressure is balanced between the working gap area and an area defined adjacent to 1) the sealing edge, and 2) a distal end of the armature structure.

Abstract: A solenoid device includes a solenoid assembly (30) including a stator (42, 32, 38), a coil (36) for generating a magnetic field, and first retention structure (64). Armature and seal assembly includes armature structure (14, 16) that moves with respect to the solenoid assembly from a closed position to an open position in response to the magnetic field generated by the coil, seal structure (22) that is coupled with a proximal end of the armature structure and has a sealing edge (28) to seal with a component when the armature structure is in the closed position thereof, and second retention structure (68). A spring (44) biases the armature structure to the closed position. The first and second retention structures engage and retain the armature and seal assembly with respect to the stafor assembly prior to installation of the device.

Abstract: An armature-stator structure (45) includes a stator (56) having a magnetic housing (57) of generally U-shaped cross-section. The housing includes an open end (58) in communication with an interior portion (60). A coil (94) is associated with the stator and to be energized to generate a magnetic field. An armature (46) has a generally ring-shaped base (48) and a generally rod-shaped stem portion (50) extending transversely from the base such that the base and stem portion define a generally T-shaped cross-section. The base is able to be received in the opened end of the housing with the stem portion extending into the interior portion. The armature moves with respect to the stator from a first position to a second position in response to the generated magnetic field. The stator and armature are configured such that a force on the armature decreases as a portion of the armature moves further into the interior portion of the body of the stator, towards the second position.

Abstract: A fuel injection system (60) is provided for an internal combustion engine (62). The engine has a plurality of cylinders (70). The system includes a plurality of fuel injectors (10?) constructed and arranged to receive fuel. One fuel injector is associated with a cylinder for injecting fuel into the associated cylinder. Each fuel injector has a valve body (14), a fuel volume V, and a coil (50) to inductively heat the valve body and thus heat fuel in the fuel volume to vaporize the fuel prior to injection into the associated cylinder. A cold start fuel injector (10, 10?) is disposed in an air supply passage (72) that supplies air to the cylinders. The cold start fuel injector has a valve body (14), a fuel volume (V) and a coil (50) to inductively heat the valve body to vaporize the fuel in the fuel volume prior to injection into the supply passage.

Abstract: A fuel injector is described that includes a polymeric housing, pole piece, filter assembly, coil assembly, spring member, armature assembly and metering assembly. The polymeric housing has a passageway extending between an inlet and an outlet along a longitudinal axis. The pole piece is disposed in the passageway, the pole piece having a through opening. The filter assembly has a portion disposed in the through opening of the pole piece. The coil assembly is disposed in the polymeric housing to surround the pole piece. The spring member is disposed partly in the pole piece and including a spring portion contiguous with the portion of the filter assembly. The armature assembly is disposed in the passageway in a first position having a first portion confronting the pole piece and in a second position having a closure member contiguous to an end face of the pole piece. The metering assembly is secured to the polymeric housing proximate the outlet.

Abstract: A module solenoid valve (14) includes a valve body (16) defining an inlet opening (22) and an outlet opening (20). The valve body includes a seating surface (18) at a distal end thereof. A valve member (24) controls flow of fuel through the outlet opening. A movable armature (26) is coupled with the valve member such that movement of the armature moves the valve member between a closed position and an open position. A stator (38) is associated with the armature. A first spring (32) biases the armature and thus the valve member to the closed position. A cover (28) is coupled to the stator. A second spring 34 is between the cover and the armature to provide a biasing force on the armature. An electromagnetic coil (36) is associated with the stator and armature for causing movement of the armature towards the stator.

Abstract: A module, direct fuel injector (10) includes a fuel module (46) having a valve body (12) defining an outlet opening (20) and including a seating surface (18). A needle 14, disposed in valve body, has a sealing surface (16). An armature (28) is coupled with the needle such that movement of the armature moves the needle between a closed position with the sealing surface engaging the seating surface and an open position with the needle moving outwardly from the valve body with the sealing surface being disengaged from the seating. A spring (38) biases the armature and thus the needle to the closed position. An inlet tube (22) is coupled to the fuel module defining an inlet of the injector. A power assembly (42) is separate from, but coupled to, the fuel module. The power assembly includes an electromagnetic coil (44) for causing movement of the armature, and a connector (43).

Abstract: A module, direct fuel injector (10) includes a fuel side sub-assembly (78) having valve body structure (12, 14) defining a main flow passage (16) there-through, an outlet opening (26) and a seating surface (24). A needle (18) is in the main flow passage and has first and second ends. The second end (22) has a sealing surface (20). The needle is movable between a closed position with the sealing surface engaging the seating surface to prevent fuel from passing through the outlet opening, and an open position. A spring (30) biases the needle to the closed position. Manifold structure (36, 48) is coupled to the valve body structure. The injector also includes a dry side sub-assembly including a piezo stack (42) coupled to the manifold structure and changes length when voltage is applied thereto. The piezo stack is associated with the first end of the needle so that when the length of the piezo stack changes, the needle moves from the closed position to the open position thereof.

Abstract: A fuel injector assembly includes a first coil that induces a time varying magnetic field into a second coil that is utilized to heat fuel flowing through the fuel injector. The second coil generates a second magnetic field generated by a current induced by the first coil into the second coil. The induced current is generated by an alternating current signal that is interposed onto a direct current signal sent to the first coil. The second coil also is electrically connected to pass current induced from the first coil into a component in thermal contact with the flowing fuel. The current from the secondary coil resistibly heats the component to provide an alternate mode of heating fuel flow.

Abstract: A fuel injector for use with LPG or other volatile fuels has fuel inlets through a cylindrical wall of a valve group tube assembly. Fuel venting is along a longitudinal axis of the fuel injector to an end opposite the injection end. An O-ring retaining cup is welded to the tube assembly above and below the fuel inlets to seal these members and to maintain alignment of holes in the cup with the fuel inlets.

Abstract: A fuel injector is described that includes a polymeric housing, pole piece, filter assembly, coil assembly, spring member, armature assembly and metering assembly. The housing has a passageway extending between an inlet opening and an outlet opening along a longitudinal axis. The pole piece is disposed in the passageway and has a through opening. The filter assembly has a portion disposed in the through opening of the pole piece. The coil assembly is disposed in the housing to surround the pole piece. The spring member is disposed partly in the pole piece and includes a spring portion contiguous with the portion of the filter assembly. The armature assembly is disposed in the passageway in a first position confronting the end face of the pole piece and in a second position contiguous to an end face of the pole piece. The metering assembly is disposed proximate the outlet opening and includes a seat and a polymeric support member secured to the polymeric housing.

Abstract: Cold start structure (10) for a fuel injection system includes a fuel rail (12) constructed and arranged to receive a source of fuel. A plurality of fuel injectors (14) is provided with each fuel injector being mounted to the fuel rail to receive fuel. Each fuel injector includes an injector body (24) having an inlet (22) and an outlet (25) and valve structure (26) in the injector body movable between open and closed positions to control flow of fuel from the outlet. Heating structure (16) is associated with each fuel injector and includes a main body (18) mounted to a portion of the fuel rail and a heating element (20) mounted with respect to the main body and extending through the fuel rail, into the inlet of the associated fuel injector, and extending into the injector body of the associated fuel injector.

Abstract: A fuel injector for an internal combustion engine includes a valve body 14. A valve seat 18 is associated with the valve body. The valve seat defines an outlet opening 24 through which fuel may flow. An armature 38 is associated with the valve body and is movable with respect to the valve body between a first position and a second position. The armature is associated with a closure member 24 proximate the outlet opening and contiguous to the valve seat when in the first position, and spaced from the valve seat when in the second position. An electromagnetic coil 44 is energizable to provide magnetic flux that moves the armature between the first and second positions to control liquid fuel flow through the outlet opening. A heating coil 50 is energizable to provide heat and thereby vaporize liquid fuel as it exits the outlet opening.

Abstract: A fuel injector is described that includes a polymeric housing, a metering assembly, and a closure assembly. The polymeric housing includes a continuous polymeric bore that extends from a first external seal proximate an inlet to a second external seal proximate an outlet of the bore along a longitudinal axis. The metering assembly is disposed proximate the second external seal. The closure assembly is disposed proximate the metering assembly, and a portion of the closure assembly is contiguous to the polymeric bore and disposed between the first and second external seals. A method of maintaining leak integrity is described.

Abstract: A fuel injection system (60) is provided for an internal combustion engine (62). The engine has a plurality of cylinders (70). The system includes a plurality of fuel injectors (10?) constructed and arranged to receive fuel. One fuel injector is associated with a cylinder for injecting fuel into the associated cylinder. Each fuel injector has a valve body (14), a fuel volume V, and a coil (50) to inductively heat the valve body and thus heat fuel in the fuel volume to vaporize the fuel prior to injection into the associated cylinder. A cold start fuel injector (10, 10?) is disposed in an air supply passage (72) that supplies air to the cylinders. The cold start fuel injector has a valve body (14), a fuel volume (V) and a coil (50) to inductively heat the valve body to vaporize the fuel in the fuel volume prior to injection into the supply passage.

Abstract: A fuel injector for use with LPG or other volatile fuels has fuel inlets through a cylindrical wall of a valve group tube assembly. Fuel venting is along a longitudinal axis of the fuel injector to an end opposite the injection end. An O-ring retaining cup is welded to the tube assembly above and below the fuel inlets to seal these members and to maintain alignment of holes in the cup with the fuel inlets.