Caterpillar Inc.

Lucas Industries Public Limited Company

Lucas Industries Limited

James J Streicher

David E Martin

Dana Ray Coldren

Jeffrey R Ries

Marvin P Schneider

Stephen Robert Lewis

Glen F Forck

Matthew S Touvelle

Prabhakar Ramalingam

Matthew Bredesen

Amy Shalaine Johanson

Thomas R Springer

Van A Flamion

David V Teel

Clifford J Rebello

A method for coupling a valve member to an armature member includes coupling the valve member to a surface of a bore of the armature member. The valve member contacts the armature member over less than an entire axial thickness of the surface of the bore of the armature member. The method further includes aligning the armature member to a desired alignment and securing the valve member to the armature member at the desired alignment.

Valve coupling system

The present invention relates to fuel injectors having a free floating plunger. Traditional tappet assemblies include a plunger that is mechanically coupled to the tappet, and therefore, cannot be uncoupled over a portion of its movement during an injection event. In the event of a plunger seizure in a traditional tappet assembly, the tappet spring can be prevented from expanding, which can cause major valve train and engine damage. In addition, because the plunger in traditional tappet assemblies is moved to its upward position under the action of the tappet spring, the fuel passages can depressurize if fuel cannot refill the fuel pressurization chamber as quickly as the plunger retracts, causing cavitation bubbles. Therefore, the present invention utilizes a plunger that is not mechanically coupled to the tappet and can uncouple from the tappet during the injection event to address these and other problems related to plunger wear and failure.

Free floating plunger and fuel injector using same

Inclusion of a direct control needle valve in fuel injectors can allow for independent control of injection pressure and timing. Engineers have learned that it is desirable to position the control valve assembly in close proximity to the needle valve member to improve response time. However, by placing the control valve assembly in a central portion of the fuel injector, at least one fluid passage must often be routed through the electrical actuator included in the valve assembly. The present invention seeks to address this problem by providing a direct control valve assembly for a fuel injector that directs fluid around the electrical actuator without increasing the size of the fuel injector. Thus, the present invention includes an electrical actuator having an actuator centerline that is oriented at an angle, which is preferably perpendicular, with respect to a centerline of the fuel injector.

Compact valve assembly and fuel injector using same

A fuel injector includes a tappet assembly mounted on an injector body. At least one of the tappet assembly and the injector body define a retention opening therethrough. A retention member is positioned in the retention opening and concealed by at least one of the tappet assembly and the injector body. The tappet assembly is moveable with respect to the injector body an unadjustable displacement distance between an advanced position and an extended position. The height of the retention opening is less than the unadjustable displacement distance.

Tappet retention for a fuel injector

A fuel injector includes an injector body defining a terminal passage extending between a solenoid cavity and an outer surface. A solenoid assembly is press fit attached to the injector body and received in the solenoid cavity. The solenoid assembly includes a bobbin sandwiched between an upper magnetic flux carrier and a lower magnetic flux carrier. At least one of the flux carriers is plastically deformed when the solenoid assembly is attached to the injector body. A terminal assembly has an external terminal, an electrical conductor and a sealing member surrounding a portion of the electrical conductor. A portion of the electrical conductor and the sealing member are received in the terminal passage. A clamp is in contact with the outer surface of the injector body and the terminal assembly.

Fuel injector with solenoid and terminal assemblies

A valve assembly includes a first body with a first conical valve seat and a locating bore centered about a first axis. A second body is press fit attached to the first body and has a second conical valve seat with a second axis positioned in opposition to the first conical valve seat. An elongated valve member with a centerline has an upper conical valve surface and a lower conical valve surface trapped between the first conical valve seat and the second conical valve seat. A guide portion of the elongated valve member moves in a guide bore defined by one of the first body and the second body. The first axis, the second axis and the centerline are concentrically linked via the press fit attachment of the second body in the locating bore of the first body. The valve assembly is preferably utilized as a needle control valve assembly in a fuel injector.

Valve assembly with concentrically linked components and fuel injector

A fuel injector includes a barrel having an insert recess therein within which an insert is disposed. A facing surface of the insert is located opposite a base surface of the recess and forms a passage interconnecting a high pressure fuel passage and a valve bore. High pressure intersecting bores are thus avoided, leading to a reduction in structural failures.

Fuel injector having a press-in valve seat

A fuel injector solenoid includes an armature through which a high pressure fuel passage extends. Because the fuel passage is disposed within the armature, the solenoid can be made larger, thereby permitting greater armature forces to be developed.

Fuel injector solenoid utilizing an apertured armature

A fuel injector includes a center tube, a first valve separate from the center tube and surrounding a first end of the center tube and a second valve also separate from the center tube and surrounding a second end thereof. A solenoid is actuable to independently move the first and second valves and thereby control the application of fluid pressures to first and second ends of a check assembly, in turn to control injection of fuel into an associated engine cylinder.

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Pontiac, IL, United States of America

James J Streicher