Modular fuel injector having a low mass, high efficiency electromagnetic actuator and having an integral filter and o-ring retainer assembly

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

• a valve group subassembly that is independently operable and testable prior to assembly in a fuel injector, the valve group subassembly including:
• a tube assembly having a longitudinal axis extending between a first end and a second end, the tube assembly including a magnetic pole piece having a first face and having a first generally planar surface area;
• 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 having a second face disposed from the first face by a gap, the second face having a second generally planar surface area smaller than the first surface area;
• 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 located at the first end of the tube assembly, the filter having a retaining portion, wherein the filter has a cup shape including an open filter end and a closed filter end;
• an O-ring circumscribing the first end of the tube assembly, the retaining portion of the filter maintaining the O-ring proximate the first end of the tube assembly;
• and
• a first attaching portion;
• and
• a coil group subassembly that is independently operable and testable prior to assembly in a fuel injector, the 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, the tube assembly including a magnetic pole piece having a first face having a first surface area;
• 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 having a second face disposed from the first face by a gap, the second face having a second surface area smaller than the first surface area;
• 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 located at the first end of the tube assembly, the filter having retaining portion;
• an O-ring circumscribing the first end of the tube assembly, the retaining portion of the filter maintaining the O-ring proximate the first end of the tube assembly;
• 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;
• and
• 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 that is independently operable and testable prior to assembly in a fuel injector, the valve group subassembly including:
• a tube assembly having a longitudinal axis extending between a first end and a second end, the tube assembly including:
• an inlet tube having a first inlet tube end and a second inlet tube end having a first face and having a first generally planar surface area;
• a non-magnetic shell having a first shell end connected to the second inlet tube end at a first connection and further having a second shell end;
• and
• a valve body having a first valve body end connected to the second shell end at a second connection and further having a second valve body 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 face disposed from the first face by a gap, the second face having a second generally planar surface area smaller than the first generally planar surface area;
• 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 located at the first end of the tube assembly, the filter having a retaining portion;
• an O-ring circumscribing the first end of the tube assembly, the retaining portion of the filter maintaining the O-ring proximate the first end of the tube assembly;
• and
• a first attaching portion;
• and
• a coil group subassembly that is independently operable and testable prior to assembly in a fuel injector, the 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 that is independently operable and testable prior to assembly in a fuel injector, the valve group subassembly including:
• a tube assembly having a longitudinal axis extending between a first end and a second end, the tube assembly including:
• an inlet tube having a first inlet tube end and a second inlet tube end having a first face and having a first surface area;
• a non-magnetic shell having a first shell end connected to the second inlet tube end at a first connection and further having a second shell end;
• and
• a valve body having a first valve body end connected to the second shell end at a second connection and further having a second valve body 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 face disposed from the first face by a gap, the second face having a second surface area smaller than the first surface area;
• 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 located at the first end of the tube assembly, the filter having a retaining portion, wherein the filter has a cup shape including an open filter end and a closed filter end;
• an O-ring circumscribing the first end of the tube assembly, the retaining portion of the filter maintaining the O-ring proximate the first end of the tube assembly;
• and
• a first attaching portion;
• and
• a coil group subassembly that is independently operable and testable prior to assembly in a fuel injector, the 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, the tube assembly including:
• an inlet tube having a first inlet tube end and a second inlet tube end having a first face having a first surface area;
• a non-magnetic shell having a first shell end connected to the second inlet tube end at a first connection and further having a second shell end;
• and
• a valve body having a first valve body end connected to the second shell end at a second connection and further having a second valve body 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 face disposed from the first face by a gap, the second face having a second surface area smaller than the first surface area;
• 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 located at the first end of the tube assembly, the filter having retaining portion;
• an O-ring circumscribing the first end of the tube assembly, the retaining portion of the filter maintaining the O-ring proximate the first end of the tube assembly;
• 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;
• and
• 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.