Patents by Inventor Stephen C. Bugos

Stephen C. Bugos 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
  • Patent number: 10502112
    Abstract: A fluid injector, including a fluid inlet, a fluid outlet and a fluid path from the fluid inlet to the fluid outlet; a tube having an end at the fluid inlet; a filter disposed in the tube proximal to the fluid inlet; and a volume reduction member disposed in the tube downstream of the filter, contacting an inner surface of the tube and including a through-bore defining at least a portion of the fluid path, the bore having a smaller diameter than an inner diameter of the tube and the volume reduction member occupying a volume in the tube such that the volume reduction member reduces an amount of space for fluid in the fluid injector. A cap member, in which the filter is disposed, engages with the volume reduction member such that the filter, the volume reduction member and the cap form a single assembly member.
    Type: Grant
    Filed: September 14, 2017
    Date of Patent: December 10, 2019
    Assignee: Vitesco Technologies USA, LLC
    Inventors: Josh Lee Hatfield, Stephen C Bugos
  • Publication number: 20190234273
    Abstract: A fluid injector includes a fluid inlet, a fluid outlet, and a fluid path from the fluid inlet to the fluid outlet. An actuator unit is disposed within the fluid injector. A valve assembly operatively couples to the actuator unit. A spacer member is disposed between a downstream end portion of the actuator unit and a portion of the valve assembly, the spacer member constructed from a compressible, resilient material so as to compress due to expansion forces from fluid in the fluid injector freezing, and to expand when frozen fluid in the fluid injector melts. The spacer member occupies a space in the fluid path of the fluid injector.
    Type: Application
    Filed: January 29, 2019
    Publication date: August 1, 2019
    Applicant: Continental Powertrain USA, LLC
    Inventors: Joshua Lee Hatfield, Keith Aaron Shaw, Stephen C Bugos
  • Publication number: 20190234274
    Abstract: A fluid injector includes a calibration filter tube including a bore defined in an axial direction through the calibration filter tube, the bore defining at least a portion of a fluid path through the fluid injector, the calibration filter tube including a plurality of holes which extend from the bore to an outer surface of the calibration filter tube. A volume reduction member has a bore though which the calibration filter tube extends, the volume reduction member occupying a space between the outer surface of the calibration filter tube and an inner surface of the tube member, the volume reduction member being constructed from resilient, compressible material. Freezing or frozen fluid disposed in the calibration filter tube expands through the holes and at least partially compresses the volume reduction member, so as to reduce fluid expansion forces damaging other components of the fluid injector.
    Type: Application
    Filed: January 29, 2019
    Publication date: August 1, 2019
    Applicant: Continental Powertrain USA, LLC
    Inventors: Joshua Lee Hatfield, Keith Aaron Shaw, Stephen C Bugos
  • 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: 20190078486
    Abstract: A fluid injector, including a fluid inlet, a fluid outlet and a fluid path from the fluid inlet to the fluid outlet; a tube having an end at the fluid inlet; a filter disposed in the tube proximal to the fluid inlet; and a volume reduction member disposed in the tube downstream of the filter, contacting an inner surface of the tube and including a through-bore defining at least a portion of the fluid path, the bore having a smaller diameter than an inner diameter of the tube and the volume reduction member occupying a volume in the tube such that the volume reduction member reduces an amount of space for fluid in the fluid injector. A cap member, in which the filter is disposed, engages with the volume reduction member such that the filter, the volume reduction member and the cap form a single assembly member.
    Type: Application
    Filed: September 14, 2017
    Publication date: March 14, 2019
    Applicant: Continental Automotive Systems, Inc.
    Inventors: Josh Lee Hatfield, 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: 20190078488
    Abstract: A fluid injector includes a fluid inlet, a fluid outlet, a fluid path from the fluid inlet to the fluid outlet; a tube; a filter disposed in the tube proximal to the fluid inlet; and a calibration filter tube disposed downstream of the filter. The calibration filter tube includes a first end portion adjacent the filter and an axial throughbore, the throughbore defining at least a portion of the fluid path through the fluid injector. An actuator unit is disposed within the fluid injector and engages a second end of the calibration filter tube. A valve assembly operatively couples to the actuator unit. A position of the calibration filter tube within the tube sets an opening force of the valve assembly. A cap member has a sidewall defining an inner space receiving the filter, and the sidewall contacts and attaches to the first end of the calibration filter tube.
    Type: Application
    Filed: September 14, 2017
    Publication date: March 14, 2019
    Applicant: Continental Automotive Systems, Inc.
    Inventors: Josh Lee Hatfield, Stephen C. Bugos, Keith Aaron Shaw
  • Publication number: 20190078487
    Abstract: A reductant delivery unit includes a fluid injector having a fluid inlet for receiving a reductant, and a fluid outlet disposed for discharging the reductant, the fluid injector defining a fluid path from the fluid inlet to the fluid outlet. The fluid injector further includes a tube having an end disposed at the fluid inlet of the fluid injector, the tube configured to pass reductant along the fluid path. A cup covers the end of the tube, including a sidewall and an axial end portion. A compressible seal member is disposed within the cup between the end of the tube and the axial end portion of the cup, the seal member occupying a volume so as to reduce an amount of space for reductant between the tube and the cup.
    Type: Application
    Filed: September 14, 2017
    Publication date: March 14, 2019
    Applicant: Continental Automotive Systems, Inc.
    Inventors: Josh Lee Hatfield, Stephen C. Bugos
  • Publication number: 20180058291
    Abstract: An injector having at least one heat dissipation element used for providing a highly conductive path for transferring heat away from a valve portion of an injector. In one embodiment, the heat dissipation element is a cylindrical element, or conductive plug, in contact with the injector valve body and the injector housing. In one embodiment, the heat dissipation element is a plurality of cooling fins, each being in direct contact with the injector housing. The fins may be used in combination with the cylindrical element to serve as an additional heat evacuation conduction path, allowing the heat to be dissipated by convection through the large surface area provided by the fins. The cylindrical element may be made of copper, but it is also within the scope of the invention that any suitable thermally conductive material may be used.
    Type: Application
    Filed: August 23, 2016
    Publication date: March 1, 2018
    Applicant: Continental Automotive Systems, Inc.
    Inventors: Stephen C. Bugos, Willem Nicolaas Van Vuuren
  • Patent number: 9777859
    Abstract: A sealing device which is used as part of an injector in a reductant delivery unit (RDU), where the RDU is part of a selective catalytic reduction (SCR) system for injecting diesel exhaust fluid (DEF) into an exhaust system, used for controlling exhaust emissions. This invention improves the purging efficiency of the RDU, in addition to improving the sealing performance of the unit by reducing the fluid volume to be evacuated from the injector, and provides an additional sealing barrier to reduce the sealing load of the existing sealing elements. An additional sealing device having a ring seal and a stopper element (also referred to as a “plug”) is pressed into the upper valve body of the injector, which results in a reduced fluid volume that is left behind after a purging event, due to the reduced initial volume at the beginning of the purge.
    Type: Grant
    Filed: November 19, 2012
    Date of Patent: October 3, 2017
    Assignee: Continental Automotive Systems, Inc.
    Inventors: Willem Nicolaas van Vuuren, Stephen C Bugos
  • 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: 9587603
    Abstract: A compact fuel pressure regulator (10) includes a housing (12) with an interior (13) communicating and inlet opening (16) and an outlet opening (20). The housing defines a valve seat surface (26) in the interior. A cover (22) is provided at an end of the housing and is disposed in the interior. The cover includes a through-hole (24) therein that communicates the outlet opening with the interior. A valve structure (28) is movable within the interior to control fuel flow between the inlet opening and outlet opening. A spring (30) is engaged between the valve structure and the cover so that when pressure of fuel at the inlet opening is greater than a force of the spring, the fuel pushes the valve structure against the bias of the spring and away from the valve seat surface so that fuel flows around a periphery of the valve structure to the outlet opening.
    Type: Grant
    Filed: September 1, 2011
    Date of Patent: March 7, 2017
    Assignee: Continental Automotive Systems, Inc.
    Inventors: Mahesh N. Hanjagi, Stephen C. Bugos
  • 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: 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: 9115624
    Abstract: A valve structure (20?) is provided for insertion into a boss (22?). The boss includes a threaded bore (46) and at least one key slot (48) therein. The valve structure includes a valve (26) constructed and arranged to control fluid flow, a fitting (24) surrounding at least a portion of the valve with the fitting having external threads (28) for mating with the threaded bore, and anti-rotate structure (34) between the valve and the fitting. The anti-rotate structure is constructed arranged such that when the fitting is rotated into threaded engagement with the boss, at least a portion of the anti-rotate structure engages a surface defining the key slot in the boss, thereby preventing rotation of the valve, with the fitting clamping on the anti-rotate structure and thus the valve.
    Type: Grant
    Filed: July 29, 2011
    Date of Patent: August 25, 2015
    Assignee: Continental Automotive Systems, Inc.
    Inventor: Stephen C. Bugos
  • Patent number: 9074511
    Abstract: A reductant delivery unit for selective catalytic reduction (SCR) after-treatment for vehicles includes a fluid injector having a fluid inlet and a fluid outlet. The fluid inlet receives a source of urea solution. An injector flange is coupled directly with an end of the fluid injector and has a flange outlet in fluid communication with the fluid outlet of the fluid injector. The flange outlet is associated with an exhaust gas flow path upstream of a SCR catalytic converter with the fluid injector controlling injection of urea solution into the exhaust gas flow path. Internal surface structure that defines the flange outlet includes a conical surface joined with at least one radius surface. The radius surface is constructed and arranged to resist formation of deposits on the internal surface structure due to break down of the urea solution.
    Type: Grant
    Filed: November 16, 2012
    Date of Patent: July 7, 2015
    Assignee: Continental Automotive Systems, Inc.
    Inventors: Willem Nicolaas Van Vuuren, Stephen C. Bugos
  • 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