Abstract: A fuel injector (10) includes an inlet tube (20). A valve body (12) is associated with the inlet tube to define a fuel passage (23). A valve seat (14) is associated with the valve body and defines an outlet opening (18). An armature (42) is movable with respect to the valve body between a first position and a second position. The armature is associated with a closure member (18) that opens and closes the outlet opening. An electromagnetic coil (40) is energizable to provide magnetic flux that moves the armature between the first and second positions to control fuel flow through the outlet opening. A heat exchanger (50) is provided in the inlet tube and a secondary coil (46) is energizable to provide a magnetic field to inductively heat the heat exchanger and thus fuel prior to exiting the outlet opening.

Abstract: A valve seat (16?) for a fuel injector (10) includes a main body (27) having a proximal and a distal end with at least one orifice (24) extending through the main body. A seating surface (22) is provided on the main body to receive a closure member (20) of a fuel injector such that when the closure member engages the seating surface, the at least one orifice is closed. A guide surface (36) is provided on the main body to guide movement of the closure member. An annular wall (26) extends in a cantilever manner from the main body at the distal end thereof and defines an outer peripheral portion of the valve seat. The wall is constructed and arranged to deform during welding at the wall so as to isolate effects of the welding from the seating surface and the guide surface.

Abstract: A fuel injector apparatus and method for use in a fuel injection system of an internal combustion engine that includes a body, a valve seat, closure member, and an orifice plate. The valve seat comprises the intersection of two angled surfaces before assembly of the fuel injector. During assembly of the fuel injector, a member presses against the edge of the sealing surface of the valve seat to create an oblique third sealing surface or sealing band that is coined into the valve seat. The sealing band provides an improved seal between the valve closure member and the valve seat which operates to prevent leakages of fuel in the fuel injector.

Abstract: A fuel injector apparatus and method is provided for use in a fuel injection system of an internal combustion engine that includes a body, a valve seat, closure member, and an orifice plate. The valve seat comprises the intersection of two angled surfaces with a radius before assembly of the fuel injector. During assembly of the fuel injector, a member presses against the radius edge of the sealing surface of the valve seat to create an oblique third sealing surface or sealing band that is coined into the valve seat. The sealing band provides an improved seal between the valve closure member and the valve seat which operates to prevent leakages of fuel in the fuel injector.

Abstract: A valve seat (16?) for a fuel injector (10) includes a main body (27) having a proximal and a distal end with at least one orifice (24) extending through the main body. A seating surface (22) is provided on the main body to receive a closure member (20) of a fuel injector such that when the closure member engages the seating surface, the at least one orifice is closed. A guide surface (36) is provided on the main body to guide movement of the closure member. An annular wall (26) extends in a cantilever manner from the main body at the distal end thereof and defines an outer peripheral portion of the valve seat. The wall is constructed and arranged to deform during welding at the wall so as to isolate effects of the welding from the seating surface and the guide surface.

Abstract: A fuel injector apparatus and method for use in a fuel injection system of an internal combustion engine that includes a body, a valve seat, closure member, and an orifice plate. The valve seat comprises the intersection of two angled surfaces before assembly of the fuel injector. During assembly of the fuel injector, a member presses against the edge of the sealing surface of the valve seat to create an oblique third sealing surface or sealing band that is coined into the valve seat. The sealing band provides an improved seal between the valve closure member and the valve seat which operates to prevent leakages of fuel in the fuel injector.

Abstract: A fuel injector apparatus and method is provided for use in a fuel injection system of an internal combustion engine that includes a body, a valve seat, closure member, and an orifice plate. The valve seat comprises the intersection of two angled surfaces with a radius before assembly of the fuel injector. During assembly of the fuel injector, a member presses against the radius edge of the sealing surface of the valve seat to create an oblique third sealing surface or sealing band that is coined into the valve seat. The sealing band provides an improved seal between the valve closure member and the valve seat which operates to prevent leakages of fuel in the fuel injector.

Abstract: A fuel injector apparatus and method is provided for use in a fuel injection system of an internal combustion engine that includes a body, a valve seat, closure member, and an orifice plate. The valve seat comprises the intersection of two angled surfaces with a radius before assembly of the fuel injector. During assembly of the fuel injector, a member presses against the radius edge of the sealing surface of the valve seat to create an oblique third sealing surface or sealing band that is coined into the valve seat. The sealing band provides an improved seal between the valve closure member and the valve seat which operates to prevent leakages of fuel in the fuel injector.

Abstract: A fuel injector apparatus and method for use in a fuel injection system of an internal combustion engine that includes a body, a valve seat, closure member, and an orifice plate. The valve seat comprises the intersection of two angled surfaces before assembly of the fuel injector. During assembly of the fuel injector, a member presses against the edge of the sealing surface of the valve seat to create an oblique third sealing surface or sealing band that is coined into the valve seat. The sealing band provides an improved seal between the valve closure member and the valve seat which operates to prevent leakages of fuel in the fuel injector.

Abstract: A fuel injector (10) includes an inlet tube (20). A valve body (12) is associated with the inlet tube to define a fuel passage (23). A valve seat (14) is associated with the valve body and defines an outlet opening (18). An armature (42) is movable with respect to the valve body between a first position and a second position. The armature is associated with a closure member (18) that opens and closes the outlet opening. An electromagnetic coil (40) is energizable to provide magnetic flux that moves the armature between the first and second positions to control fuel flow through the outlet opening. A heat exchanger (50) is provided in the inlet tube and a secondary coil (46) is energizable to provide a magnetic field to inductively heat the heat exchanger and thus fuel prior to exiting the outlet opening.

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 apparatus and method is provided for use in a fuel injection system of an internal combustion engine that includes a body, a valve seat, closure member, and an orifice plate. The valve seat comprises the intersection of two angled surfaces with a radius before assembly of the fuel injector. During assembly of the fuel injector, a member presses against the radius edge of the sealing surface of the valve seat to create an oblique third sealing surface or sealing band that is coined into the valve seat. The sealing band provides an improved seal between the valve closure member and the valve seat which operates to prevent leakages of fuel in the fuel injector.

Abstract: A fuel injector has a housing extending along a longitudinal axis between an inlet and an outlet. A seat assembly is disposed in a body proximate the outlet. The seat assembly includes a flow portion and a securement portion. The flow portion extends along the longitudinal axis between a first surface and an orifice disk retention surface at a first length. The flow portion has a seat orifice extending therethrough and an orifice disk coupled to the orifice disk retention surface so that the orifice plate is aligned in a fixed spatial axial orientation with respect to the flow portion. The securement portion extends along the longitudinal axis away from the orifice disk retention surface at a second length greater than the first length. A method of maintaining a fixed spatial axial orientation and dimensional symmetry of at least one of the seat and orifice disk in the body is disclosed.

Abstract: A power module for a fuel injection unit is shown and described. The power module includes a housing that has a plurality of first and second housing portions spaced apart along a first axis. Each of the first housing portions is formed to enclose each of a plurality electromagnetic coil subassemblies spaced apart along the first axis. Each of the second housing portions connects the plurality of first housing portions together along the first axis and includes a wall with at least one inflection portion with respect to the first axis. A fuel injector module is also shown and described. The fuel injector module includes the power module and a plurality of valve group subassemblies. Each of the valve group subassemblies is disposed in respective first housing portions of the module and secured thereto via a securement. Various methods relating to the power module and fuel injector module are described.

Abstract: A modular fuel injector that includes a coil group subassembly and a valve group subassembly. The coil group subassembly is independently testable. The valve group subassembly is independently testable and includes a tube assembly having a longitudinal axis extending between a first tube end and a second tube end, and a seat assembly disposed in the tube assembly proximate the second tube end. The seat assembly includes a flow portion and a securement portion. The flow portion extends along the longitudinal axis between a first surface and an orifice disk retention surface at a first length. The flow portion has a seat orifice extending therethrough and an orifice disk coupled to the orifice disk retention surface so that the orifice plate is aligned in a fixed spatial orientation with respect to the flow portion. The securement portion extends along the longitudinal axis away from the orifice disk retention surface at a second length greater than the first length.

Abstract: A fuel pressure regulator is disposed in a socket in a fuel rail and retained therein by means of a one-piece metal retention clip which has a flat forked blade portion that is inserted through a slot in the socket sidewall to span the socket in overlying relation to a flange extending around the outside of the cylindrical body of the pressure regulator so as to capture the pressure regulator in the socket and which also has a resilient body-clasping portion in the form of a pair of opposing spring fingers that are cantilevered on and spaced axially of the flat forked blade portion by means of a joining portion of the clip and that come to resiliently embrace the body of the pressure regulator as the forked blade portion comes to span the socket.

Abstract: A number of electrically-operated fuel injectors are mounted in a fuel rail assembly, and electrical circuit connections to the injectors are provided by an electrical connector which contains a flexible strip onto a lengthwise edge of which are disposed electrical outlet terminals for making connection of individual conductor paths on the strip to the individual injectors. Electrical inlet terminals are also disposed on the strip to provide for connection to a source of signals for operating the injectors.

Abstract: A metal tube, such as an inlet, outlet, return, or cross-over tube, is connected to a non-metallic fuel rail by means of a tubular sleeve that has one axial end embedded in the fuel rail coaxial with the hole with which the tube is in communication and its other axial end non-embedded. Non-metallic fuel rail material lines the interior of the sleeve from the innermost point of its embedded end to a point that stops short of the outermost point of its non-embedded end. The tube is sealed to this liner, and is prevented from coming out by a retainer, such as a crimp, retention ring or snap ring, that extends radially from the sleeve to overlap a flange that extends around the outside of the tube. The sleeve constitutes an insert onto which the fuel rail is molded during the process of fabricating the fuel rail. A plug of the mold closes off the outer end of the sleeve during molding.

Abstract: Improvements for imparting hysteresis, or dampening, to the shaft of a pedal assembly for an electronic throttle actuation system so that the feel of the pedal simulates the feel of a strictly mechanical system. Pads are resiliently urged against a disk in one embodiment, the disk being affixed to the pedal shaft. In another embodiment, metal rings are resiliently urged against friction rings on the disk.

Abstract: An accelerator control apparatus for mounting in a motor vehicle for a "drive-by-wire" system. The apparatus provides a bias spring means to generate the "feel" of an accelerator pedal to the vehicle operator, a compression spring means provides frictional forces preventing extraneous pedal actuation and pedal sensor switch means for indicating the rotation position of the accelerator pedal from a first or normal position to any second position.