Fuel injector for internal combustion engine and corresponding method of manufacture

A method for manufacture of a fuel injector for an internal-combustion engine, having a hollow body in which an electromagnet is housed for controlling a metering valve for the injection, the electromagnet comprising a magnetic core, an electric coil and two plugs electrically connected to said coil, said core having an annular slot for housing said coil, and two holes for the passage of said plugs, the method comprising the steps of:

• (a) providing a bobbin for said coil having a C-shaped section, said bobbin having two appendages, each designed to receive a first end portion of the corresponding plug;
• (b) winding said coil on said bobbin and inserting the first end portion of the corresponding plug into each appendage;
• (c) inserting said bobbin into said core with said coil and said plugs;
• (d) providing a mould to form a block of non-magnetic material to englobe at least part of said core, said appendages of the bobbin, and said plugs;
• (e) providing said core in said mould with said bobbin said plugs;
• (f) providing a core in said mould to form a gap between an outer surface of said coil and said annular slot;
• (g) injecting a non-magnetic plastic material into said mould;
• and
• (h) separating said block thus formed from said core and from said mould.

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

• a hollow body;
• an electromagnet housed in the hollow body for controlling a metering valve, the electromagnet comprising a magnetic core, an electric coil wound on a bobbin, and two plugs electrically connected to said coil, said core having an annular slot for housing said coil and two holes for receiving said plugs, the bobbin having a C-shaped section and two appendages, each appendage supporting a first end portion of one of said two plugs;
• said bobbin, said coil, and said plugs inserted within said core, defining a gap between an outer surface of said coil and said annular slot in said core;
• and
• a block of non-magnetic, plastic material englobing at least a portion of said core, said bobbin appendages, and said plugs.