Abstract: A seal arrangement for a needle valve in a fuel injector (100) includes a nozzle housing (122) forming an outer cavity (216) and defining a needle valve seat (218). A plurality of nozzle openings (204) are formed in the nozzle housing (122) and arranged symmetrically around its centerline at a first radial distance (R1). An outer needle valve (104) is reciprocally mounted in the outer cavity (216) and has a seat portion (224) arranged to abut the needle valve seat (218) when the outer needle valve (104) is seated or closed. A first ledge (502) formed on the seat portion (224) of the outer needle valve (104) sealably contacts the needle valve seat (218) along a first line contact seal (220) and a second ledge (508) formed on the seat portion (224) of the outer needle valve (104) sealably contacts the needle valve seat (218) along a second line contact seal (222).

Abstract: An engine system includes an intake system, an internal combustion engine, and an exhaust system. The internal combustion engine includes a fuel droplet generator, and a fuel injector configured to inject fuel directly into a combustion chamber of the internal combustion engine.

Abstract: A method to set a small air gap by improving the parallelism between the armature and the stator assembly includes attaching a guide sleeve to a pole piece and grinding the surfaces on the guide sleeve and the pole piece after the attaching step to improve parallelism. By decoupling the armature assembly from a valve member in a fuel injector assembly, an improved parallel orientation between the armature assembly and the stator assembly can be achieved by grinding the outer surface of the guide sleeve perpendicular to the planar bottom surface of the stator assembly in a single chucking. When the solenoid is energized, the armature is at a final air gap with the flux piece parallel to the bottom surface of the armature and the armature not in contact with the valve member.

Abstract: A seal arrangement for a needle valve in a fuel injector (100) includes a nozzle housing (122) forming an outer cavity (216) and defining a needle valve seat (218). A plurality of nozzle openings (204) are formed in the nozzle housing (122) and arranged symmetrically around its centerline at a first radial distance (RI). An outer needle valve (104) is reciprocally mounted in the outer cavity (216) and has a seat portion (224) arranged to abut the needle valve seat (218) when the outer needle valve (104) is seated or closed. A first ledge (502) formed on the seat portion (224) of the outer needle valve (104) sealably contacts the needle valve seat (218) along a first line contact seal (220) and a second ledge (508) formed on the seat portion (224) of the outer needle valve (104) sealably contacts the needle valve seat (218) along a second line contact seal (222).

Abstract: An engine system includes an intake system, an internal combustion engine, and an exhaust system. The internal combustion engine includes a fuel droplet generator, and a fuel injector configured to inject fuel directly into a combustion chamber of the internal combustion engine.

Abstract: An apparatus and method for injecting fuel into a cylinder of an engine which includes a fuel injector and a tip located on the fuel injector. The tip and fuel injector are located about a common longitudinal axis and includes a sac portion having a sac chamber, an outer sac surface, and at least one nozzle passage extending from an inner end located in the sac chamber to an outer end located at the outer sac surface, the at least one nozzle passage being at a fixed angle from the longitudinal axis along a central axis. The tip also includes an end surface located substantially adjacent to and parallel with the at least one nozzle passage and extending beyond the outer end of the at least one nozzle passage, and a curvilinear surface located on at least one of the end surface and the outer sac surface and configured such that a portion of fuel being injected through the at least one nozzle passage is directed to follow the curvilinear surface away from the central axis.

Abstract: An apparatus and method for injecting fuel into a cylinder of an engine which includes a fuel injector and a tip located on the fuel injector. The tip and fuel injector are located about a common longitudinal axis and includes a sac portion having a sac chamber, an outer sac surface, and at least one nozzle passage extending from an inner end located in the sac chamber to an outer end located at the outer sac surface, the at least one nozzle passage being at a fixed angle from the longitudinal axis along a central axis. The tip also includes an end surface located substantially adjacent to and parallel with the at least one nozzle passage and extending beyond the outer end of the at least one nozzle passage, and a curvilinear surface located on at least one of the end surface and the outer sac surface and configured such that a portion of fuel being injected through the at least one nozzle passage is directed to follow the curvilinear surface away from the central axis.

Abstract: A fuel injector comprising a body and an injector tip is provided. The injector tip includes a barrel having a first end, a second end, an outer wall and a cavity extending from the first end toward the second end. An end portion is disposed at the second end, the end portion includes a sac portion and an end surface. A radius or chamfer is interposed the end surface and the outer wall. A plurality of nozzles are disposed in the sac portion at a predetermined angle and the end surface is defined substantially parallel to the plurality of nozzles.