Valve with thin-film coating

A method of producing a fuel system component having a break-in coating, comprising:

• producing a valve body having a first substantially conical surface and a second substantially conical surface spaced apart from each other along a longitudinal axis of the valve body, the valve body being configured to repeatedly make and break contact with a first valve seat and a second valve seat during operation of the fuel system component;
• applying a first coating to the first substantially conical surface and the second substantially conical surface of the valve body;
• producing the first valve seat annularly disposed about the valve body proximate the first substantially conical surface, the first valve seat including a first surface and a second surface positioned radially outwards the first surface, the first surface and the second surface having a substantially conical shape, wherein the first surface makes a first angle with respect to the longitudinal axis and the second surface makes a second angle with respect to the longitudinal axis, the second angle being greater than the first angle when measured in a same direction;
• producing the second valve seat annularly disposed about the valve body proximate the second substantially conical surface, the second valve seat including a third surface and a fourth surface radially outwards the third surface, the third surface and the fourth surface having a substantially conical shape, wherein the third surface makes a third angle with respect to the longitudinal axis and the fourth surface makes a fourth angle with respect to the longitudinal axis, the fourth angle being greater than third angle;
• applying a second coating to the first surface of the first valve seat and the third surface of the second valve seat;
• and
• assembling the fuel system component such that (i) when the valve body contacts the first valve seat, the first substantially conical surface of the valve body contacts the first surface and not the second surface of the first valve seat, and (ii) when the valve body contacts the second valve seat, the second substantially conical surface of the valve body contacts the third surface and not the fourth surface of the second valve seat.

A fuel injector, comprising:

• a solenoid;
• a valve operated by the solenoid, the valve including:
• a valve body extending along a longitudinal axis of the fuel injector and including a first conical surface longitudinally spaced apart from a second conical surface, the first conical surface and the second conical surface including a first coating;
• and
• a first valve seat proximate the first conical surface and a second valve seat proximate the second conical surface, wherein the valve body is configured to move towards the solenoid to contact the first valve seat and away from the solenoid to contact the second valve seat during operation of the fuel injector, wherein at least one of the first valve seat and the second valve seat includes:
• a first surface having a substantially conical shape and including a second coating, the first surface making a first angle with respect to the longitudinal axis and having a width such that, when the valve body contacts the at least one of the first valve seat and the second valve seat, a force generated by the contact does not exceed a yield strength of the first coating and the second coating;
• a second surface positioned radially outwards the first surface and having a substantially conical shape, the second surface making a second angle with respect to the longitudinal axis, the second angle being greater than the first angle when measured in a same direction.