Abstract: A fuel pump includes a fuel pump housing with a pumping chamber and an inlet valve bore which extends along an inlet valve bore axis. The inlet valve bore is stepped such that the inlet valve bore includes a shoulder which is traverse to the inlet valve bore axis. A pumping plunger reciprocates within a plunger bore along a plunger bore axis such that an intake stroke of the pumping plunger increases volume of the pumping chamber and a compression stroke of the pumping plunger decreases volume of the pumping chamber. An inlet valve assembly includes a valve seat with a valve seat flow passage extending therethrough, the valve seat abuts the shoulder and is urged toward the shoulder by pressure within the pumping chamber during the compression stroke. The inlet valve assembly also includes a valve member which is moveable between an unseated position and a seated position.

Abstract: A combination outlet valve and pressure relief valve includes an outer housing having a passage. An inner housing is located within the passage and includes a first bore extending thereinto from one end and a second bore extending thereinto from the other end such that the first bore and the second bore terminate at an inner housing wall. An outlet valve assembly is located within the first bore and includes an outlet valve member, an outlet valve seat, and an outlet valve spring grounded to the inner housing wall and biasing the outlet valve member toward the outlet valve seat. A pressure relief valve assembly is located within the second bore and includes a pressure relief valve member, a pressure relief valve seat, and a pressure relief valve spring grounded to the inner housing wall and biasing the pressure relief valve member toward the pressure relief valve seat.

Abstract: A fuel injector with inlet and discharge ends includes a fuel tube through which fuel is admitted to a fuel passage extending to the discharge end. A valve element reciprocates against and away from a valve seat to prevent or allow fuel discharge. A calibration tube includes first and second ends and defines a portion of the fuel passage through which fuel must pass to the discharge end, the second end defining a spring seat engaging a spring and biasing the spring against the valve element. A fuel filter filters all fuel passing to the discharge end, and provides restriction of a first magnitude. The calibration tube includes a pressure pulsation damping orifice fluidly between the fuel filter and the discharge end through which fuel must pass to the discharge end, the pressure pulsation damping orifice provides restriction of a second magnitude which is greater than the first magnitude.

Abstract: An outlet valve includes an outlet valve housing with an outlet valve bore including an outlet valve seating surface. The outlet valve also includes an outlet valve member which moves within the outlet valve bore second portion between a closed position and an open position. A surface of the outlet valve bore guides the outlet valve member during movement between the closed position and the open position. The surface of the outlet valve bore and the outlet valve seating surface are provided on a continuous piece of material of the outlet valve housing. An outlet valve spring biases the outlet valve member toward the closed position and a retainer is fixed to the outlet valve housing which grounds the outlet valve spring to the outlet valve housing.

Abstract: A combination outlet valve and pressure relief valve includes an outer housing having a passage. An inner housing is located within the passage and includes a first bore extending thereinto from one end and a second bore extending thereinto from the other end such that the first bore and the second bore terminate at an inner housing wall. An outlet valve assembly is located within the first bore and includes an outlet valve member, an outlet valve seat, and an outlet valve spring grounded to the inner housing wall and biasing the outlet valve member toward the outlet valve seat. A pressure relief valve assembly is located within the second bore and includes a pressure relief valve member, a pressure relief valve seat, and a pressure relief valve spring grounded to the inner housing wall and biasing the pressure relief valve member toward the pressure relief valve seat.

Abstract: A fuel pump includes a fuel pump housing with a pumping chamber and an inlet valve bore which extends along an inlet valve bore axis. The inlet valve bore is stepped such that the inlet valve bore includes a shoulder which is traverse to the inlet valve bore axis. A pumping plunger reciprocates within a plunger bore along a plunger bore axis such that an intake stroke of the pumping plunger increases volume of the pumping chamber and a compression stroke of the pumping plunger decreases volume of the pumping chamber. An inlet valve assembly includes a valve seat with a valve seat flow passage extending therethrough, the valve seat abuts the shoulder and is urged toward the shoulder by pressure within the pumping chamber during the compression stroke. The inlet valve assembly also includes a valve member which is moveable between an unseated position and a seated position.

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: An outlet valve includes an outlet valve housing with an outlet valve bore including an outlet valve seating surface. The outlet valve also includes an outlet valve member which moves within the outlet valve bore second portion between a closed position and an open position. A surface of the outlet valve bore guides the outlet valve member during movement between the closed position and the open position. The surface of the outlet valve bore and the outlet valve seating surface are provided on a continuous piece of material of the outlet valve housing. An outlet valve spring biases the outlet valve member toward the closed position and a retainer is fixed to the outlet valve housing which grounds the outlet valve spring to the outlet valve housing.

Abstract: A fuel injector with inlet and discharge ends includes a fuel tube through which fuel is admitted to a fuel passage extending to the discharge end. A valve element reciprocates against and away from a valve seat to prevent or allow fuel discharge. A calibration tube includes first and second ends and defines a portion of the fuel passage through which fuel must pass to the discharge end, the second end defining a spring seat engaging a spring and biasing the spring against the valve element. A fuel filter filters all fuel passing to the discharge end, and provides restriction of a first magnitude. The calibration tube includes a pressure pulsation damping orifice fluidly between the fuel filter and the discharge end through which fuel must pass to the discharge end, the pressure pulsation damping orifice provides restriction of a second magnitude which is greater than the first magnitude.

Abstract: A fuel injector that includes a flying armature movable relative to a pintle stop, and an electromagnetic circuit configured to move the flying armature away from the pintle stop prior to accelerating the armature toward the pintle stop as part of moving the pintle to open the fuel injector. The flying armature increases the total force applied to the pintle to open the fuel injector by supplementing the static force imparted to the armature by a magnetic field with an impact force imparted by the armature being in motion toward and impacting with the pintle stop. The arrangement of magnetic circuit devices and materials used to make the magnetic circuit devices cooperate to provide a reversing force that urges the armature away from before urging the armature toward the pintle stop, and increases the rate at which the force that urges the armature toward the pintle stop increases.

Abstract: A fuel injector that includes a sliding armature, decoupled armature, or flying armature movable between a pintle stop and a housing stop. Flying armatures are generally used to increase the total force applied to the pintle stop for lifting the pintle off a nozzle seat to open the fuel injector. When the fuel injector is turned off, a housing stop is arranged to absorb kinetic energy present in the flying armature so that the kinetic energy is not imparted to the nozzle seat.

Abstract: A fuel injector that includes a sliding armature, decoupled armature, or flying armature movable between a pintle stop and a housing stop. Flying armatures are generally used to increase the total force applied to the pintle stop for lifting the pintle off a nozzle seat to open the fuel injector. When the fuel injector is turned off, a housing stop is arranged to absorb kinetic energy present in the flying armature so that the kinetic energy is not imparted to the nozzle seat.

Abstract: A fuel injector that includes a flying armature movable relative to a pintle stop, and an electromagnetic circuit configured to move the flying armature away from the pintle stop prior to accelerating the armature toward the pintle stop as part of moving the pintle to open the fuel injector. The flying armature increases the total force applied to the pintle to open the fuel injector by supplementing the static force imparted to the armature by a magnetic field with an impact force imparted by the armature being in motion toward and impacting with the pintle stop. The arrangement of magnetic circuit devices and materials used to make the magnetic circuit devices cooperate to provide a reversing force that urges the armature away from before urging the armature toward the pintle stop, and increases the rate at which the force that urges the armature toward the pintle stop increases.

Abstract: A fuel injector-engine component assembly includes an engine component with a stepped bore defined along an axis and having a stepped bore stop surface facing axially upward. A fuel injector extending along the axis is disposed in the stepped bore and includes a fuel injector stop surface facing axially downward and axially opposing the stepped bore stop surface. An isolation ring is disposed between the engine component and fuel injector stop surfaces for axially isolating the fuel injector from the engine component. The isolation ring includes a rigid support member for limiting the axial motion of the engine component and fuel injector stop surfaces together. The isolation ring also includes a resilient and compliant isolation member located axially between the engine component and fuel injector stop surfaces to provide acoustic and thermal isolation between the fuel injector and the engine component below a predetermined pressure of the fuel injector.

Abstract: A method for externally adjusting the axial length of a solenoid actuated fuel injector includes the step of externally forming a helical scribe mark in a housing component, thereby changing the axial length of the injector. By adjusting the length of the helical scribe mark and the depth of the scribe mark, and by measuring the stroke or the flow rate of the injector, the stroke or the flow rate of injector may be set precisely. The external adjustment of the length of the housing component may be made in cartridge form as well as in final assembly form of the fuel injector complementing the manufacturing process versatility.

Abstract: An upper guide system for a solenoid actuated fuel injector of an internal combustion engine includes an armature and a guide ring having a cylindrical shape and surrounding the armature and positioning the armature in a radial direction. The location of the upper guide system is substantially in the same axial location as the radial magnetic forces imposed on the armature. Features such as flutes or grooves are disposed on an outer diameter surface of the armature and/or holes through a body portion of the armature. Accordingly, the response performance of the solenoid actuated fuel injector is improved.

Abstract: An upper guide system for a solenoid actuated fuel injector of an internal combustion engine includes an armature having a first diameter section, a reduced diameter second section, and a concave portion at the transition between the first and second sections. The guide system also includes a guide shaped to extend into the concave portion of the armature and includes a central opening that slidably receives the second diameter section. The guide positions and guides the armature in a radial and an axial direction. The guide is assembled in an axial location that is close to the axial location of the center of the magnetic force acting on the armature. The guide system allows for a desired relative large guide length to diameter ratio.

Abstract: A coupling for suspending a fuel injector from a fuel rail assembly of an internal combustion engine includes a collar that mates with the fuel injector and a retainer clip that engages with the collar and with an annular flange of an injector socket thereby mechanically connecting the fuel injector to the fuel rail assembly. The retainer clip includes windows having a convex profile to enable even load distribution upon the socket flange when assembled. Coincident keyed features are integrated in the flange of the injector socket and in the collar to facilitate correct alignment of the injector relative to the fuel rail. Paired together, the retainer clip and the collar enable a secure, and coincident keyed fuel injector-to-fuel rail connection that is able to withstand high pressure separating loads.

Abstract: A method for externally adjusting the axial length of a solenoid actuated fuel injector includes the step of externally forming a helical scribe mark in a housing component, thereby changing the axial length of the injector. By adjusting the length of the helical scribe mark and the depth of the scribe mark, and by measuring the stroke or the flow rate of the injector, the stroke or the flow rate of injector may be set precisely. The external adjustment of the length of the housing component may be made in cartridge form as well as in final assembly form of the fuel injector complementing the manufacturing process versatility.