Modular fuel injector having interchangeable armature assemblies and having an integral filter and dynamic adjustment assembly

A fuel injector for use with an internal combustion engine, the fuel injector comprising:

• a valve group subassembly including:
• a tube assembly having a longitudinal axis extending between a first end and a second end;
• a seat secured at the second end of the tube assembly, the seat defining an opening;
• an armature assembly disposed within the tube assembly, the armature assembly including:
• a first armature assembly end having a magnetic portion, the first armature assembly end includes at least one opening extending therethrough, each of the at least one opening has a center and a plurality of transverse radii extending from the center, each of the plurality of transverse radii having different lengths and a second armature assembly end having a sealing portion;
• a member biasing the armature assembly toward the seat;
• a filter assembly located in the tube assembly, the filter assembly engaging the member and adjusting a biasing force of the member;
• and
• a first attaching portion;
• and
• a coil group subassembly including:
• a solenoid coil operable to displace the armature assembly with respect to the seat;
• and
• a second attaching portion fixedly connected to the first attaching portion.

A fuel injector for use with an internal combustion engine, the fuel injector comprising:

• a valve group subassembly including:
• a tube assembly having a longitudinal axis extending between a first end and a second end;
• a seat secured at the second end of the tube assembly, the seat defining an opening;
• an armature assembly disposed within the tube assembly, the armature assembly including:
• a first armature assembly end having a magnetic portion and
• a second armature assembly end having a sealing portion;
• a member biasing the armature assembly toward the seat;
• a filter assembly located in the tube assembly, the filter assembly engaging the member and adjusting a biasing force of the member;
• and
• a first attaching portion;
• and
• a coil group subassembly including:
• a solenoid coil operable to displace the armature assembly with respect to the seat;
• and
• a second attaching portion fixedly connected to the first attaching portion;
• a housing module having:
• a first insulator portion generally surrounding the second end of the inlet tube;
• and
• a second insulator portion generally surrounding the first end of the inlet tube, the second insulator portion being bonded to the first insulator portion.

A fuel injector for use with an internal combustion engine, the fuel injector comprising:

• a valve group subassembly including:
• a tube assembly having a longitudinal axis extending between a first end and a second end;
• a seat secured at the second end of the tube assembly, the seat defining an opening;
• an armature assembly disposed within the tube assembly, the armature assembly including:
• a first armature assembly end having a magnetic portion;
• a second armature assembly end having a sealing portion;
• and
• an armature tube interposed between and connecting the magnetic portion and the sealing portion;
• a member biasing the armature assembly toward the seat;
• a filter assembly located in the tube assembly, the filter assembly engaging the member and adjusting a biasing force of the member;
• and
• a first attaching portion;
• and
• a coil group subassembly including:
• an overmold;
• a solenoid coil operable to displace the armature assembly with respect to the seat;
• a housing having a first portion and a second portion, the first portion encased within the overmold, the first portion surrounding a portion of the solenoid coil, and the second portion forming a flange so as to retain a member that substantially prohibits fluid communication between the flange and the overmold;
• and
• a second attaching portion fixedly connected to the first attaching portion.

A fuel injector for use with an internal combustion engine, the fuel injector comprising:

• a valve group subassembly including:
• a tube assembly having a longitudinal axis extending between a first end and a second end;
• a seat secured at the second end of the tube assembly, the seat defining an opening;
• an armature assembly disposed within the tube assembly, the armature assembly including:
• a first armature assembly end having a magnetic portion, the armature tube includes at least one opening extending therethrough, each of the at least one opening has a center and a plurality of transverse radii extending from the center, and each of the plurality of transverse radii having different lengths;
• a second armature assembly end having a sealing portion;
• and
• an armature tube interposed between and connecting the magnetic portion and the sealing portion;
• a member biasing the armature assembly toward the seat;
• a filter assembly located in the tube assembly, the filter assembly engaging the member and adjusting a biasing force of the member;
• and
• a first attaching portion;
• and
• a coil group subassembly including:
• a solenoid coil operable to displace the armature assembly with respect to the seat;
• and
• a second attaching portion fixedly connected to the first attaching portion.

A fuel injector for use with an internal combustion engine, the fuel injector comprising:

• a valve group subassembly including:
• a tube assembly having a longitudinal axis extending between a first end and a second end;
• a seat secured at the second end of the tube assembly, the seat defining an opening;
• an armature assembly disposed within the tube assembly, the armature assembly including:
• a first armature assembly end having a magnetic portion;
• a second armature assembly end having a sealing portion;
• an armature tube interposed between and connecting the magnetic portion and the sealing portion;
• and
• an intermediate portion coupled between the magnetic portion and the sealing portion, the intermediate portion adapted to magnetically decouple the magnetic portion and the sealing portion;
• a member biasing the armature assembly toward the seat;
• a filter assembly located in the tube assembly, the filter assembly engaging the member and adjusting a biasing force of the member;
• and
• a first attaching portion;
• and
• a coil group subassembly including:
• a solenoid coil operable to displace the armature assembly with respect to the seat;
• and
• a second attaching portion fixedly connected to the first attaching portion.

A fuel injector for use with an internal combustion engine, the fuel injector comprising:

• a valve group subassembly including:
• a tube assembly having a longitudinal axis extending between a first end and a second end;
• a seat secured at the second end of the tube assembly, the seat defining an opening;
• an armature assembly disposed within the tube assembly, the armature assembly including:
• a first armature assembly end having a magnetic portion;
• a second armature assembly end having a sealing portion;
• and
• an armature tube interposed between and connecting the magnetic portion and the sealing portion;
• a member biasing the armature assembly toward the seat;
• a filter assembly located in the tube assembly, the filter assembly engaging the member and adjusting a biasing force of the member;
• and
• a first attaching portion;
• and
• a coil group subassembly including:
• a solenoid coil operable to displace the armature assembly with respect to the seat;
• a second attaching portion fixedly connected to the first attaching portion;
• a housing module having:
• a first portion generally surrounding the second end of the inlet tube;
• and
• a second portion generally surrounding the first end of the inlet tube, the second portion being bonded to the first portion.

A method of assembling a fuel injector, comprising:

• providing a fuel injector comprising:
• a valve group subassembly having a first end and a second end, the valve group subassembly including:
• a tube assembly having a longitudinal axis extending between a first end and a second end;
• a seat secured at the second end of the tube assembly, the seat defining an opening;
• an armature assembly disposed within the tube assembly, the armature assembly including:
• a first armature assembly end having a magnetic portion and
• a second armature assembly end having a sealing portion;
• a member biasing the armature assembly toward the seat;
• an adjusting tube located in the tube assembly, the adjusting tube engaging the member and adjusting a biasing force of the member;
• a filter assembly located in the tube assembly, the filter assembly engaging the member and adjusting a biasing force of the member;
• and
• a first attaching portion;
• and
• a coil group subassembly including:
• an overmold;
• a solenoid coil operable to displace the armature assembly with respect to the seat;
• a housing having a first portion and a second portion, the first portion encased within the overmold, the first portion surrounding a portion of the solenoid coil, and the second portion forming a flange so as to retain a member that substantially prohibits fluid communication between the flange and the overmold;
• and
• a second attaching portion fixedly connected to the first attaching portion;
• inserting the coil group subassembly over the valve group subassembly.