Direct injection fuel injector spray nozzle and method

A spray nozzle assembly for a direct injection fuel injector, said assembly comprising:

• a nozzle body having an axial bore extending from an inlet end and having a conical guide seat adjacent an outlet end, the guide seat extending to a reduced nozzle opening communicating with an outwardly angled conical valve seat that opens through the outlet end;
• a swirler seated against the conical guide seat;
• a valve guide adjacent the swirler;
• a pintle valve having a pintle extending through and radially guided for reciprocating motion in the valve guide and a conical valve head with an outwardly angled conical surface engagable with the valve seat;
• a spring urging the valve in a closing direction toward the valve seat;
• and
• magnetic means operable to move the valve against the spring and open the valve a small amount that creates a predetermined conical gap between the valve head and the valve seat for the passage of fuel therethrough in a thin conical sheet;
• the valve guide engaging the axial bore and centering the pintle valve on a common axis with the valve seat and the bore, the valve guide defining at least one longitudinal fuel passage between the guide and the bore and extending to the swirler;
• the swirler forming an annular wall between the guide and the guide seat and including a plurality of swirler holes therethrough, the wall defining an annular inlet between the swirler and the bore, and an annular swirl chamber between the swirler and the pintle, the annular inlet communicating with said at least one longitudinal fuel passage to deliver fuel to the swirler holes and the swirler holes being angled to open tangentially into the swirl chamber to direct fuel delivered thereto into a toroidal motion in the swirl chamber;
• the swirl holes and the conical gap being sized relative to other fuel passages in the assembly to provide nearly all of the fuel pressure drop through the nozzle assembly when the valve is open for fuel flow.