Delphi Technologies, Inc.

James Robert Molnar

Karl Jacob Haltiner, Jr

Robert B Perry

Otto Muller-Girard, Jr

Harrie William Bonnah, Ii

Michael Schneider

Peter Ronald Wendt

Timothy P Landschoot

Corrine A Volo

Paul S Von Bacho, Iii

Chester Henry Ciesinski

John David Vanderhenst

Todd A Bordewyk

Michael Brian Lavan

Jeffrey M Stuecken

A solenoid-type fuel injector assembly having at least one component formed of stabilized, solenoid-quality ferritic stainless steel. In a preferred embodiment, an austenitic fuel tube is laser-welded to an injector body and to a solenoid pole piece formed of the subject material. The stabilized, solenoid-quality ferritic stainless steel, preferably a free-machining grade thereof, comprises from about 10% to about 35% chromium, and at least one stabilizing element selected from the group consisting of titanium and columbium. Components thus formed are weldable, exhibit soft magnetic properties sufficiently strong for carrying a magnetic flux in a solenoid pole piece, have desired structural and mechanical properties, and reduce the susceptibility of a solenoid-type fuel injector to metallurgical sensitization and intergranular corrosive attack at weld sites.

Solenoid-type fuel injector assembly having stabilized ferritic stainless steel components

An engine fuel injector body is assembled using a furnace brazing method to provide structural and hermetic internal joints at interior locations with minimum size and processing. The method of assembling an injector with such an internal hermetic and structural joint may include the steps of providing an annular body member with an annular inner recess having an inner cylindrical surface, forming an annular end recess adjoining the cylindrical surface, fitting a tubular member into the inner recess of the body member with an outer surface of the tubular member engaging the cylindrical surface of the inner recess, placing a brazing ring in the end recess of the body member adjacent the tubular member, and furnace brazing the members together to form the internal hermetic and structural joint. Additional joints may be joined during the same brazing step.

Method of assembling a fuel injector body

A process of laser welding high carbon martensitic stainless steel components and austenitic stainless steel components by a stabilized ferritic stainless steel fusion zone modifier in the weld joint, and articles formed therefrom. The stabilized ferritic stainless steel fusion zone modifier comprises, in terms of weight percentage, from about 10% to about 35% chromium, and at least one element selected from the group consisting of no more than about 1.5% titanium and no more than about 1.5% columbium. The stabilized ferritic stainless steel fusion zone modifier present in the fusion zone inhibits and prevents solidification cracks and micro-fissures from forming in the weld joint, and assists immunity to environmental degradation.

Laser welding stainless steel components by stabilized ferritic stainless steel fusion zone modifiers

A method of assembly of a fuel injector having a valve plunger reciprocable in a guide tube for movement from a closed position engaging a valve seat to an open position engaging a valve stop by energizing of a solenoid coil to move the plunger against a biasing spring, wherein the method includes setting the valve stop at a position effective to establish the desired valve stroke, and fixing the valve stop to the guide tube by first laser spot welding the valve stop in the guide tube to fix the position of the valve stop without changing the set gap, and then laser seam welding the valve stop in the guide tube at an axial location beyond the spot welds, relative to a plunger-engagable end of the valve stop, to provide a hermetic seal around the valve stop.

Method of fuel injector assembly

A fuel injector for an engine includes a continuous endoskeletal injector tube enclosing an imperforate continuous passage for fuel flow from an inlet end to an outlet end of the tube. A valve seat, injection valve, tubular magnetic pole, biasing spring and adjusting sleeve are mounted within the tube, optionally with other elements, all being exposed to fuel in the passage defined by the tube. A solenoid coil and a magnetic body together with mounting components and seals are mounted on the exterior of the tube where they are protected from exposure to the fuel, which is restricted to passage within the continuous tube. The body, pole and armature form a magnetic flux concentrating path operative to attract the armature to the pole and open the valve when the coil is energized. The solenoid coil may be preassembled with its connector in a body forming a separate coil assembly for subsequent installation on the injector tube. During assembly, the tubular pole may be adjusted to set the desired stroke of the injection valve prior to fixing the pole in the tube. Various other features are also disclosed.

Engine fuel injector

An injector fuel injection valve is guided at the lower end by a plastic valve guide mounted in a nozzle containing a valve seat engagable by the valve element. The valve guide includes inwardly protruding annularly spaced ribs having inner guide surfaces and defining spaced flow channels. The guide surfaces engage the circular or spherical exterior of the valve element to guide the element to properly aligned seating against the conical valve seat. The plastic or polymeric valve guide is preferably molded in place within the cup shaped metal nozzle but, if desired, the valve guide may be separately molded and subsequently inserted or snapped in place within the nozzle. A second plastic valve guide may be provided for guiding the upper end of an associated armature. A plastic or polymeric ring is molded in place or otherwise mounted within a groove around the outer surface of the armature and engagable with a cylindrical tube disposed within a main body of the injector to which the injection nozzle is secured.

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Penfield, NY, United States of America

James Robert Molnar