Fuel system components and methods of making the same

Abstract

A fuel system component for a fuel system, such as for a fuel injector, fuel cell, fuel pump, and / or fluid flow control device, is disclosed. The net shape of the fuel system component is formed by a cold-swaging process as a unitary single-piece metal body. The net shape of the fuel system component can include at least one internal passage formed by cold-swaging without machining or drilling the unitary metal body.

Description

Technical Field

[0001] This disclosure relates in general to fuel system components that can be used in fuel injectors, fuel cells, fuel pumps and / or fluid flow control devices, and more specifically, to fuel system components manufactured or made using a cold extrusion process. Background Technology

[0002] Fuel system components can be used with fuel injectors, fuel cells, fuel pumps, and / or fluid flow control devices. Fuel system components can serve as one or more parts in assemblies for devices such as, for example, fuel injectors, fuel pumps, fuel cells, and / or fluid flow control devices. Some fuel system components are used in fuel system devices to control fuel injection and / or flow under fuel pressure conditions. Therefore, it is desirable to manufacture such fuel system components using materials capable of operating under these conditions while also being able to be manufactured with desired dimensions, tolerances, roughness, and flatness.

[0003] Fuel system components can be manufactured by machining and assembling metal parts to form fuel system components with desired dimensions and finishes. The machining process involves the production time for each fuel system component to be produced, as well as energy input, material waste, and facility cleaning. Machining can also make it more difficult to control dimensions, tolerances, surface roughness, and flatness during production, while ensuring that the parts of the fuel system component meet perpendicularity and parallelism requirements. Furthermore, the raw materials used for machining fuel system components can be expensive in terms of raw material costs and the subsequent processing required to achieve the desired material hardness. Therefore, further improvements are still needed in this area.

[0004] Disclosure of exemplary embodiments To clearly, concisely, and accurately describe the exemplary embodiments of this disclosure, the ways and processes of making and using these embodiments, and to enable the implementation, making, and using of these exemplary embodiments, reference will now be made to certain exemplary embodiments, including those illustrated in the accompanying drawings, and these embodiments will be described using specific language. However, it should be understood that this does not constitute a limitation on the scope of the invention, and that the invention includes and protects such changes, modifications, and further applications of the exemplary embodiments that will be conceived by those skilled in the art. Summary of the Invention

[0005] The fuel system components according to this disclosure are manufactured using a cold extrusion process. The cold extrusion process involves extruding a metal blank into a single-piece, integral fuel system component having the desired configuration and dimensions for fuel system devices, such as fuel injectors, fuel cells, fuel pumps, and / or fluid flow control devices.

[0006] Fuel system components produced according to this disclosure include dimensional accuracy and net shape features produced at a faster rate, resulting in reduced costs, shorter manufacturing time, a cleaner working environment, and lower energy consumption compared to machining processes. Furthermore, fuel system components produced by cold extrusion have finer manufacturing tolerances than those produced by machining processes, and exhibit higher strength due to the cold working of the material below recrystallization temperatures. Fuel system components output from the cold extrusion process include final surfaces that do not require machining, grinding, polishing, and / or oxidation processes for finishing.

[0007] In one embodiment, a method is provided for manufacturing a fuel system component for use in conjunction with a fuel system. The method includes forming an integral metal body corresponding to the net shape of the fuel system component using a cold extrusion process. The integral metal body is formed during the cold extrusion process to extend from a first end to a second end and includes at least one channel extending at least partially through the integral metal body.

[0008] In one embodiment of this disclosure, an armature is provided comprising an integral metal body extruded as a single piece in a cold extrusion process. The integral metal body extends along a longitudinal axis between a first end and an opposing second end. The integral metal body includes a flange at the first end and a shaft extending from the flange. The shaft extends along the longitudinal axis from the flange to the second end of the integral metal body. A channel extends along the longitudinal axis and opens at both the first and second ends of the integral metal body.

[0009] In another embodiment of this disclosure, a method for manufacturing an armature for use in association with the actuation of a valve is provided. The method includes the step of forming an integral metal body using a cold extrusion process. The integral metal body is extruded to include: a flange at a first end of the integral metal body; a shaft extending along a longitudinal axis from the flange to an opposite second end of the integral metal body; and a channel extending along the longitudinal axis and opening at both the first and second ends of the integral metal body.

[0010] This invention is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an auxiliary means of limiting the scope of the claimed subject matter. Further embodiments, forms, objects, features, advantages, aspects, and benefits will become apparent from the following description and drawings. Attached Figure Description

[0011] The description herein refers to the accompanying drawings, wherein the same reference numerals in several views refer to the same parts, and wherein: Figure 1 This is a schematic diagram of a cold extrusion process for manufacturing various fuel system components according to this disclosure; Figure 2 This is a schematic flowchart of a method for forming various fuel system components using a cold extrusion process according to the present disclosure; Figure 3 It includes Figure 1 A cross-sectional view of a fuel injector for an internal combustion engine in one or more fuel system components. Figure 4 These are perspective views illustrating certain aspects of an armature according to an exemplary embodiment of the present disclosure; Figure 5 yes Figure 4 A frontal view of the armature in the middle; Figure 6 yes Figure 4 A longitudinal sectional view of the armature in the circuit; Figure 7 yes Figure 4 A magnified detailed view of a portion of the armature flange; Figure 8 yes Figure 4 A magnified detailed view of a portion of the armature's channel; Figure 9 This is a schematic diagram of a cold extrusion process for manufacturing armatures according to the present disclosure; and Figure 10 This is a schematic flowchart of a method for forming an armature using a cold extrusion process according to the present disclosure. Detailed Implementation

[0012] The following detailed description is taken in conjunction with the accompanying drawings, which are an integral part of the description and illustrate, by way of example, specific embodiments in which the present disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the present disclosure. It should be understood that other embodiments may be used and structural changes may be made without departing from the scope of the present disclosure. Therefore, the following detailed description should not be considered limiting, and the scope of the present disclosure is defined by the appended claims and their equivalents.

[0013] Figure 1 It is a schematic diagram of the process for manufacturing one or more fuel system components 30, 40, 50, 60, 70, and Figure 2 This is a flowchart of a method for manufacturing one or more fuel system components 30, 40, 50, 60, 70 using a cold extrusion process, according to the present disclosure. Figure 3 This is a detailed cross-sectional view of an embodiment of a fuel injector 100, showing exemplary specific implementations of fuel system components 30, 40, 50, 60, and 70 in the assembly of a particular fuel injector. Figures 4 to 8This is an illustration associated with an embodiment of the fuel system component 30 as an armature fuel system component 200 according to another aspect of this disclosure, and Figures 9 to 10 A cold extrusion process and method for manufacturing armature fuel system component 200 are shown.

[0014] While this disclosure describes specific configurations of fuel system components 30, 40, 50, 60, 70, 200 and / or fuel injector 100, one or more of these features described herein may be omitted, and other features are not excluded. The fuel system components 30, 40, 50, 60, 70, 200 of this disclosure can be used in any fuel injector, fuel cell, fuel pump, and / or fluid flow control device compatible with the features of this disclosure.

[0015] In embodiments of this disclosure, a method 90 is provided for manufacturing fuel system components 30, 40, 50, 60, 70, 200 for use in conjunction with a fuel system 101. Method 90 includes step 94 of forming integral metal bodies 32, 42, 52, 62, 72, 202 corresponding to the net shape of the fuel system components 30, 40, 50, 60, 70, 200 using a cold extrusion process. The integral metal bodies 32, 42, 52, 62, 72, 202 are formed during the cold extrusion process to extend from a first end 34, 44, 54, 64, 76, 206 to a second end 36, 46, 56, 66, 76, 212, and include at least one channel 38, 48, 58, 68, 78, 208 that at least partially extends through the integral metal bodies 32, 42, 52, 62, 72, 202.

[0016] In embodiments of this disclosure, the armature fuel system component 200 includes an integral metal body 202 that is extruded into a single piece in a cold extrusion process. The integral metal body 202 extends along a longitudinal axis 222 between a first end 206 and an opposing second end 212. The integral metal body 202 includes a flange 204 at one of the first end 206 and the second end 212, and a shaft 210 extending from the flange 204 to the other of the first end 206 and the second end 212. A channel 208 extends along the longitudinal axis 222 and opens at the first end 206 and the second end 212 of the integral metal body 202.

[0017] refer to Figure 1The diagram illustrates a cold extrusion method or process 10 for manufacturing fuel system components, such as one or more of fuel system components 30, 40, 50, 60, and 70 for fuel system 101. Process 10 includes step 14 of using a cold extrusion process on a billet or blank 12 of metallic material to form an integral metal body 32, 42, 52, 62, and / or 72 in the desired net shape of the fuel system components 30, 40, 50, 60, and 70.

[0018] As used herein, "net shape" refers to the extruded monolithic metal bodies 32, 42, 52, 62, and / or 72, which are produced from the cold extrusion process without machining or grinding the outer or inner surfaces of the extruded monolithic metal bodies 32, 42, 52, 62, and / or 72, and include the dimensions and surface finish of the corresponding fuel system components 30, 40, 50, 60, and / or 70. The extruded monolithic metal bodies 32, 42, 52, 62, and / or 72 may be heat-treated using a low-pressure carburizing process to provide a hardened layer on the finished fuel system components 30, 40, 50, 60, and 70.

[0019] The integral metal bodies 32, 42, 52, 62 and / or 72 are formed from the cold-extruded blank 12 extending from a first end of the integral metal bodies 32, 42, 52, 62 and / or 72 to opposite second ends of the integral metal bodies 32, 42, 52, 62 and / or 72. The integral metal bodies 32, 42, 52, 62 and / or 72 are also formed to include at least one channel forming an inner surface, which at least partially extends through the integral metal bodies 32, 42, 52, 62 and / or 72 during the cold extrusion of the blank 12.

[0020] In one embodiment, blank 12 is a block or cylinder of metal material having sufficient volume to form the corresponding fuel system components 30, 40, 50, 60, 70. In one embodiment, the metal material used for blank 12 is steel, such as stainless steel having a mixture of chromium and nickel alloys. In one embodiment, the material is 18CrNi8, which provides a low-cost, fatigue-resistant material that can be hardened using low-pressure carburizing heat treatment to provide the desired surface hardness to achieve a uniform surface depth. Other embodiments envision other types of metal materials that can be cold-extruded to form the fuel system components 30, 40, 50, 60, 70 according to this disclosure.

[0021] During operation 14, the blank 12 is inserted into the cold extruder 16. In one embodiment, the cold extruder 16 includes at least one die 20 and at least one press head 22 for extruding the blank 12 into and / or through the die 20. The die 20 and / or press head 22 may be configured to form a desired fuel system component 30, 40, 50, 60, 70 having one or more of the features discussed herein. At operation 18, the extruded blank 12 is output from the cold extruder 16 in the net shape of the desired fuel system component 30, 40, 50, 60, and / or 70.

[0022] refer to Figure 2 A method 90 is disclosed for forming fuel system components 30, 40, 50, 60, and / or 70 as a single integral body using a cold extrusion process (such as by using the cold extrusion process 10 discussed above). Method 90 includes an operation 92 of providing a blank or billet of material (such as blank 12) from which the desired fuel system components 30, 40, 50, 60, and / or 70 are formed. Method 90 also includes an operation 94 of extruding blank 12 into the net shape of the desired fuel system components 30, 40, 50, 60, and / or 70 using a cold extrusion process (such as by using a cold extrusion press 16) to form the fuel system components 30, 40, 50, 60, and / or 70.

[0023] In one embodiment, the integral metal bodies 32, 42, 52, 62, and 72 of the desired fuel system components 30, 40, 50, 60, and 70 are longitudinally extruded from a first end to an opposing second end. In one embodiment, the integral metal bodies 32, 42, 52, 62, and 72 are extruded to include at least one channel that extends completely or partially through the integral metal bodies 32, 42, 52, 62, and 72. The net shape of the fuel system components 30, 40, 50, 60, and 70 is formed by the extruded integral metal bodies 32, 42, 52, 62, and 72 without machining or drilling the outer surfaces of the bodies 32, 42, 52, 62, and 72 or the inner surfaces forming the channels therein.

[0024] Alternatively, a low-pressure carburizing heat treatment process can be used to surface harden the outer surfaces of the extruded integral metal bodies 32, 42, 52, 62, and 72, without the need for nitriding or further machining of the hardened surfaces. Therefore, a uniform surface depth is provided on the integral metal bodies 32, 42, 52, 62, and 72 to provide fuel system components 30, 40, 50, 60, and 70 that do not form a white layer.

[0025] Return to reference Figure 1 Fuel system component 30 is an example of an armature for the fuel injector 100, such as Figure 3As shown. The fuel system component 30 includes an integral metal body 32 forming the net shape of the armature, extending from a first end 34 to an opposing second end 36. The integral metal body 32 also includes a channel 38 extending longitudinally through the integral metal body 32, the channel opening at each of the first end 34 and the second end 36. In one embodiment, the integral metal body 32 includes a flange 32a at the first end 34 and a shaft 32b extending from the flange 32a to the second end 36. Exemplary embodiments of the armature fuel system component 30 are discussed herein with respect to the armature fuel system component 200.

[0026] Fuel system component 40 is an example such as a valve seat for a pilot valve of fuel injector 100. Fuel system component 40 includes an integral metal body 42 forming the clear shape of the valve seat, extending from a first end 44 to an opposing second end 46. The integral metal body 42 also includes a longitudinally extending channel 48 that opens at each of the first end 44 and the second end 46. In one embodiment, the integral metal body 42 includes a cylindrical flange 42a at the second end 46 and a smaller cylindrical shaft 42b extending from the flange 42a to the first end 34. In one embodiment, the first end 44 is configured as a valve seat, for example by including a concave shape, against which a ball valve can engage.

[0027] Fuel system component 50 is an example of a nozzle, such as a nozzle for a fuel injector 100. The fuel system component includes an integral metal body 52 forming the net shape of the nozzle, extending from a first end 54 to an opposing second end 56. The integral metal body 52 also includes a channel 58 extending longitudinally into the integral metal body 52. ​​In one embodiment, the integral metal body 52 includes a cylindrical proximal portion 52a at the first end 54, which is larger than a cylindrical distal portion 52b at the second end 56. In one embodiment, the channel 58 opens at the first end 54 and closes at the second end 56 by, for example, a convex hemispherical dome 52d.

[0028] like Figure 3As shown, in one embodiment, the channel 58 is larger in the proximal portion 52a than in the distal portion 52b to provide a desired fit with a corresponding portion of a needle valve-type fuel system component 70 located within the channel 58 and along its length. The integral metal body 52 may include an external shoulder 52c between the proximal and distal portions 52a and 52b, which is engaged by a nozzle retainer-type fuel system component 60. The integral metal body 52 may include an internal lip or shoulder 58c along the channel 58 between different sized portions of the channel 58. After extruding the integral metal body 52, a fuel nozzle 136 may be formed through a dome 52d at the second end 56 to inject fuel from the channel 58 during operation of the injector 100. The nozzle 136 may be formed by any suitable technique, including, for example, laser, drilling, and / or micromachining.

[0029] Fuel system component 60 is an example of a retainer, such as for retaining nozzle 50 on injector body 102 of fuel injector 100 or for retaining valve assembly 150, armature fuel system component 30, and / or valve seat fuel system component 40 within body 102 of fuel injector 100. Fuel system component 60 includes an integral metal body 62 forming the net shape of a retainer, extending from a first end 64 to an opposing second end 66. The integral metal body 62 also includes a longitudinally extending channel 68 that opens at the first end 64 and the second end 66. In one embodiment, the integral metal body 62 includes a cylindrical proximal portion 62a at the first end 64 that is larger than a cylindrical distal portion 62b at the second end 66.

[0030] Such as about Figure 3 The channel 68 discussed is larger in the proximal portion 62a than in the distal portion 62b to provide a desired fit with the corresponding portion of the nozzle 50 or valve assembly 150 located therein and to engage with the injector body 102. The integral metal body 62 may include an external shoulder 62c between the proximal portion 62a and the distal portion 62b. The channel 68 may include an internal lip or shoulder 68a between the different sized portions of the channel 68. After the integral metal body 62 is extruded, threads may be formed internally or externally at the first end 64 and / or at the second end 66 for mounting to the nozzle fuel system component 50, the injector body 102, or other parts or components of the fuel injector 100.

[0031] Fuel system component 70 is an example of a needle, such as that of a needle valve for a fuel injector 100. Fuel system component 70 includes an integral metal body 72 forming the net shape of the needle, extending from a first end 74 to an opposing second end 76. The integral metal body 72 also includes a proximal guide protrusion 72a and a distal guide protrusion 72b. A channel 78 extends obliquely through the integral metal body 72 at the distal guide protrusion 72b. The distal end 76 includes a needle tip 79 configured to engage a valve seat 142 formed within the nozzle fuel system component 50 to selectively stop and start fuel injection through the nozzle orifice 136 of the nozzle fuel system component 50.

[0032] refer to Figure 3 This illustration shows a cross-sectional view of an embodiment of a fuel injector 100 in a fuel system 101. In one embodiment, the fuel injector 100 is connected to a fuel distribution system 103, which may include a common rail, a fuel pump, a fuel source, and / or other components associated with the fuel system. The fuel injector 100 may include one or more of the fuel system components 30, 40, 50, 60, and 70 coupled to or within a fuel injector body 102.

[0033] In one embodiment, the fuel system component 30 is an armature fuel system component 30, which is configured similarly to the following reference. Figures 4 to 10 Further discussion of the armature fuel system component 200. Armature fuel system components 30, 200 can be used in conjunction with the valve assembly 150 of the fuel injector 100. The fuel injector 100 may include a valve seat fuel system component 40 used in conjunction with the valve assembly 150 within the fuel injector body 102. The fuel injector 100 may include a nozzle fuel system component 50 located at the distal end of the injector body 102.

[0034] The fuel injector 100 may also include one or more retainer fuel system components 60. For example, a retainer fuel system component 60 may be configured to be threaded into a proximal end of the injector body 102 to retain the valve assembly 150 within the fuel injector body 102. In another example, another fuel system component retainer 60 may be configured to be threaded into a distal end of the injector body 102 to retain the nozzle fuel system component 50 thereon.

[0035] The fuel injector 100 may also include a needle fuel system component 70. The needle fuel system component 70 is positioned in a passage 58 of the nozzle fuel system component 50 and a passage in the injector body 102, serving as a needle valve. The fuel injector 100 may also include a needle sleeve 106 and a needle seal 108 housed in the injector body 102. A plunger 112 may extend through the passage 58 of the armature fuel system components 30, 200.

[0036] Armature fuel system components 30 and 200 are configured to move vertically relative to the injector body 102 and the valve seat fuel system component 40 to facilitate the opening and closing of the valve assembly 150 of the fuel injector 100. A stator assembly 122, including a solenoid 148, is positioned directly above the armature fuel system components 30 and 200 such that when the solenoid 148 is active, the armature fuel system components 30 and 200 move to an upward position. When the solenoid 148 is inactive, the armature fuel system components 30 and 200 move to a downward position. An air gap provides distance between the stator assembly 122 and the armature fuel system components 30 and 200.

[0037] The upper portion of the passage 68 of the upper retainer fuel system component 60 at the upper end of the injector body 102 receives armature fuel system components 30 and 200, plunger 112, armature spring 118, spring disc 120, and stator assembly 122. The lower portion of the passage 68 of the retainer fuel system component 60 receives shaft portion 42b or valve seat fuel system component 40. The injector body 102 receives the upper portion of needle fuel system component 70, needle sleeve 106, needle seal 108, valve seat fuel system component 40, and check ball 126.

[0038] The fuel injector 100 provides a lower pressure environment for the fuel injector 100 in the region above and along the channel 68 of the upper retainer fuel system component 60, relative to the high-pressure environment below the check ball 126. The stator assembly 122 is secured within the channel 68 and held in place by the upper retainer fuel system component 60. The bottom surface of the stator assembly 122 is precisely calibrated to the upper surface of the armature fuel system components 30, 200. At the other end of the armature fuel system components 30, 200 is a check ball retainer 130, which supports the armature fuel system components 30, 200 by abutment engagement.

[0039] The intermediate segment of plunger 112 includes an angled shoulder 113 disposed on the upper surface of armature fuel system components 30, 200, which interconnects such that plunger 112 moves along with armature fuel system components 30, 200 in an upward direction. Armature spring 118 is biased against flanges 32a, 204 of armature fuel system components 30, 200, and biases armature fuel system components 30, 200 and plunger 112 in an upward direction. Armature fuel system components 30, 200 include channels 38, 208 that receive a shaft 115 passing through the plunger 112. The outer diameter of shaft 115 is sizing and configured to provide a tight or mating fit relative to the inner diameter of channels 38, 208 while still allowing sliding movement of plunger 112. This tight fit / matching fit allows for relative sliding movement while suppressing fuel leakage between the outer diameter of the shaft 115 of the plunger 112 and the inner diameter of the channels 38, 208.

[0040] The lower portion of the fuel injector body 102 includes an inner cavity that houses the proximal portion of the needle fuel system component 70, needle sleeve 106, needle seal 108, valve seat fuel system component 40, and check ball 126. The inner cavity of the fuel injector body 102 also houses a needle spring 134 that biases the needle fuel system component 70 in a downward direction and applies a closing spring force to the needle fuel system component 70, thereby preventing fuel from escaping through the injector orifice 136. The needle seal 108 includes a control hole 138 integrated within the needle seal 108 to allow fuel to enter the needle seal 108 when the proximal end of the needle fuel system component 70 is positioned within the needle seal 108. The needle seal 108 is disposed above the needle fuel system component 70 and includes an end point terminating the adjacent needle sleeve 106.

[0041] The lower surface of the valve seat fuel system component 40 abuts against the top surface of the needle seal 108, while the upper surface of the valve seat fuel system component 40 is positioned directly below the armature spring 118. The valve seat fuel system component 40 also includes a valve seat central channel 48 that extends longitudinally from the lower end 46 of the valve seat fuel system component 40 toward the upper end 44.

[0042] The needle fuel system component 70 moves longitudinally up and down within the injector body 102 to selectively initiate and deactivate fuel injection from the injector body 102. The distal second end 76 of the needle fuel system component 70 is located at the distal portion of the nozzle fuel system component 50, which defines a needle valve seat 142 that positions the tip 79 of the needle fuel system component 70 between fuel injection events. For example, during a fuel injection event using the fuel system 100, the needle fuel system component 70 is lifted from the needle seat 142, allowing fuel to be injected into an engine cylinder (not shown).

[0043] The injector body 102 also includes a fuel inlet port 144 configured to supply fuel into the interior of the injector body 102. A cross-drilled fluid passage 78 in the needle fuel system component 70 also facilitates fuel flow throughout the interior of the injector body 102. A control port 138 guides fuel upward flow along the seat passage 48. When the coil 121 is de-energized and the solenoid 148 is inactive, the check ball 126 is sealingly engaged with the seat fuel system component 40. The check ball 126 also functions as a movable valve member and thus moves to disengage from the sealing engagement with the seat fuel system component 40. When the check ball 126 is sealingly engaged with the seat fuel system component 40, fuel from the nozzle fuel system component 50 and the interior of the injector body 102 is prevented from flowing proximally through passage 48. When fuel is supplied to the cavity of the injector body 102 and the check ball 126 is sealed to the valve seat fuel system component 40, the cavity of the injector body 102 becomes a high-pressure volume. When the check ball 126 acts as a movable valve component and moves to disengage from the sealed engagement with the valve seat fuel system component 40, the high-pressure fuel flows upward along the valve seat central passage 48 through the valve seat fuel system component 40 and into the passage 68 of the upper retainer fuel system component 60.

[0044] Fuel injector 100 utilizes a needle fuel system component 70 in a normally closed position. When the needle fuel system component 70 is in the normally closed position, coil 121 is de-energized and solenoid 148 is inactive. Fuel injector 100 also includes a plunger return spring 151 that applies a downward spring force, causing plunger 112 and armature fuel system components 30, 200 to exert a downward force on check ball retainer 130, thereby securing and holding check ball 126 in a sealing engagement with valve seat fuel system component 40. Pressurized fuel is continuously supplied to the interior of injector body 102.

[0045] When coil 121 is de-energized, fuel from the inner cavity of injector body 102 is prevented from entering channel 68, thus the inner cavity of injector body 102 becomes highly pressurized. Due to the downward pressure of the fuel supply acting on needle fuel system component 70, a large downward hydraulic pressure pushes needle fuel system component 70 downwards. Needle spring 134 is also positioned within the inner cavity of injector body 102 and compressed around the upper end 74 of needle fuel system component 70, such that when solenoid 148 is inactive, the high-pressure fuel and the downward spring force on needle fuel system component 70 both serve to secure needle fuel system component 70 against needle valve seat 142 formed by integral metal body 52 in channel 58 of nozzle 50. Secure needle fuel system component 70 against needle valve seat 142 prevents high-pressure fuel from exiting fuel injector 100 through injector nozzle 136 of nozzle fuel system component 50.

[0046] In an example use of the armature fuel system components 30, 200 in the fuel injector 100, flange 204 is positioned below solenoid 148 and coil 121. Plunger 112 includes a shaft portion disposed within and received by channels 38, 208 of the armature fuel system components 30, 200 to form an interconnection, such that plunger 112 moves along with the armature fuel system components 30, 200 in an upward direction. Armature spring 118 is biased against flanges 32a, 204 to bias the armature fuel system components 30, 200 and plunger 112 in an upward direction.

[0047] In one embodiment, armature fuel system components 30, 200 are configured to move axially within the fuel injector 100 or other device as part of a valve assembly 150 to facilitate the opening and closing of the valve assembly 150. Figure 3 In an exemplary embodiment, a stator assembly 122 including a solenoid 148 may be positioned directly above the armature fuel system components 30, 200, such that when the solenoid 148 is active, the armature fuel system components 30, 200 move to an upward position. When the solenoid 148 is inactive, the armature fuel system components 30, 200 move to a downward position. For example, an air gap may provide distance between the stator assembly 122 and the armature fuel system components 30, 200. The second ends 36, 212 of the armature fuel system components 30, 200 may be supported by a check ball retainer 130. An armature spring 118 may be biased against flanges 32a, 204 to bias the armature fuel system components 30, 200 and the plunger 112 in an upward direction.

[0048] refer to Figures 4 to 8 Further details of one embodiment of an armature fuel system component 200 are shown. The armature fuel system component 200 includes a flange 204 extending radially outward from and perpendicular to a shaft 210. The flange 204 includes a circularly formed outer edge 226, wherein the flange 204 extends radially outward from a channel 208, and the shaft 210 extends axially from one side of the flange 204. In one embodiment, the flange 204 is disc-shaped, and the shaft 210 is cylindrical, and the channel 208 extends longitudinally through the flange 204 and the shaft 210.

[0049] In one embodiment, flange 204 includes an outer diameter defined by outer edge 226, which is 1.7 to 2.3 times the maximum outer diameter portion defined by the outer surface of shaft 210. In one embodiment, the outer diameter of flange 204 is 3.5 to 4.0 times the minimum outer diameter portion of shaft 210. In one embodiment, flange 204 includes an outer diameter defined by outer edge 226, which is at least 2 times the maximum outer diameter portion defined by the outer surface of shaft 210. In one embodiment, flange 204 includes an outer diameter that is 3.5 times the minimum outer diameter portion of shaft 210.

[0050] Flange 204 includes a plurality of slots 228 extending through flange 204. Each of the plurality of slots 228 extends radially inward from the outer edge 226 of flange 204 to the terminal 230 of a corresponding slot in the plurality of slots 228. In one embodiment, the plurality of slots 228 are four slots 228 spaced at equal angles around flange 204.

[0051] In one embodiment, flange 204 includes an end surface at a first end 206 of integral metal body 202, the end surface including an outer end face portion 244 surrounding channel 208. Flange 204 also defines a recessed end face portion 236 at the first end 206, the recessed end face portion being radially outwardly spaced from the outer end face portion 244. The recessed end face portion 236 is connected to the outer end face portion 244 via a recessed bent transition section 246. The outer end face portion 244 includes a groove 238 extending around an opening of channel 208 at the first end 206 of integral metal body 202. In one embodiment, flange 204 includes a second face 240 opposite to the recessed end face portion 236. The second face 240 faces the second end 212 and extends radially outwardly from shaft 210.

[0052] In one embodiment, flange 204 includes a first flange portion 232 extending radially outward from shaft 210, the first flange portion having a first thickness t1 between a recessed end face 236 and a second face 240. Flange 204 also includes a second flange portion 234 between adjacent pairs of slots 228. The second flange portion 234 extends radially outward from the first flange portion 232 to the outer edge 226 of flange 204. The second flange portion 234 gradually thins from the first thickness t1 to a second, smaller thickness t2 between the recessed end face 236 and the second face 240 at the outer edge 226 of flange 204. The use of slots 228 and / or the gradually thinning second flange portion 234 reduces the mass of flange 204 and facilitates movement of armature fuel system components 200 during valve opening and closing operations.

[0053] Flange 204 includes a plurality of holes 242, each extending axially through a recessed end face portion 236 and a second face 240. Each of the plurality of holes 242 is located between a corresponding pair of slots in the plurality of slots 228. In the illustrated embodiment, the holes 242 are cylindrical, but other shapes of the holes 242 are also contemplated.

[0054] In one embodiment, the holes 242 are spaced equidistant from each other at an angle A1 around the flange 204. In another embodiment, four holes 242 are provided, spaced 90 degrees apart at an angle A1. Similarly, the slots 228 may be spaced equidistantly at the same angle A1, but are positioned such that each hole 242 is positioned between a corresponding pair of slots 228. Other embodiments envision fewer than four holes 242 and / or slots 228, or more than four holes 242 and / or slots 228.

[0055] In one embodiment, orifice 242 is a diffuser orifice that can influence fluid flow during all travel points of armature fuel system component 200. During travel of armature fuel system component 200 toward first end 206, fluid compression occurs on outer end face portion 244 and recessed end face portion 236, potentially leading to high-pressure spikes. The presence of diffuser orifice 242, recessed end face portion 236, and / or slot 228 helps diffuse the pressure spikes on the compression film during armature travel, and thus increases the velocity of armature fuel system component 200.

[0056] During the movement of the armature fuel system component 200 toward the second end 212, fluid (such as fuel) flows from the second face 240 of the flange 204 to the outer end face portion 244 and the recessed end face portion 236 via the diffuser hole 242, thereby reducing hydraulic resistance on the armature fuel system component 200 and increasing speed.

[0057] In one embodiment, channel 208 includes a first diameter D1 adjacent to the second end 212 of the integral metal body 202 and a second diameter D2 along a majority of the length of channel 208 between the first end 206 and the second end 212 of the integral metal body 202. The first diameter D1 of channel 208 is larger than the second diameter D2 of channel 208. In one embodiment, a lip 250 connects a transition segment of diameter D1 to diameter D2. In one embodiment, lip 250 is oriented at an angle A2 relative to the longitudinal axis 222, as... Figure 8 As shown.

[0058] In one embodiment, the channel 208 includes a transition portion 248. The transition portion 248 may include a truncated cone shape that transitions from a second diameter D2 to an opening in the outer end face portion 244 of the channel 208 at a first end 206 of the integral metal body 202. In one embodiment, the transition portion 248 flares outward to create a wider opening at the outer end face portion 244 that is larger than the diameter D2, such as... Figure 7 The expansion angle F is shown in the figure.

[0059] In one embodiment, the shaft 210 of the integral metal body 202 includes an outer surface 252 extending from the flange 204 to a second end 212. The outer surface 252 extends from the second end 212 of the integral metal body 202 to a second face 240 of the flange 204. In one embodiment, the outer surface 252 has a stepped surface profile along the length of the shaft 210 adjacent to a portion of the flange 204.

[0060] In one embodiment, the stepped surface profile of the outer surface 252 of the shaft 204 includes a first shaft portion 254 adjacent to the flange 204 and having a first outer diameter OD1. The stepped surface profile also includes a second shaft portion 256 adjacent to the first portion 254. The second shaft portion 256 includes a second outer diameter OD2 smaller than the first outer diameter OD1. The stepped surface profile of the outer surface 252 of the shaft 204 includes a third shaft portion 258 adjacent to the second shaft portion 256. The third shaft portion 258 extends to a second end 212 of the integral metal body 202. The third shaft portion 258 has a third outer diameter OD3 smaller than the second outer diameter OD2.

[0061] In one embodiment, a first fillet 260 connects the second surface 240 to the first shaft portion 254, a second fillet 262 connects the first shaft portion 254 to the second shaft portion 256, and a third fillet 264 connects the second shaft portion 256 to the third shaft portion 258. In one embodiment, each of the first fillet 260, the second fillet 262, and the third fillet 264 includes a concave bend to provide a non-angular transition between the shaft portions 254, 256, and 258.

[0062] refer to Figure 9 A schematic diagram of a cold extrusion process 600 for extruding an armature fuel system component 200 is shown. Process 600 includes a billet or blank 602 of material. In one embodiment, the blank 602 is a block or cylinder of metal material having sufficient volume to form the armature fuel system component 200. In one embodiment, the metal material used for the blank 602 is steel, such as low-carbon steel.

[0063] Other embodiments envision other types of metallic materials that can be cold-extruded to form the armature fuel system component 200. In one embodiment, the integral metal body 202 is formed into a net shape including the armature fuel system component 200 by cold-extruded a blank of stainless steel material having a mixture of chromium and nickel alloys. In one embodiment, the stainless steel material is 18CrNi8.

[0064] During operation 604, a blank 602 is inserted into a cold extrusion press 606. In one embodiment, the cold extrusion press 606 includes at least one die 610 and at least one pressure head 612 for extruding the blank 602 into and / or through the die. The die 610 and / or pressure head 612 may be configured to form an integral metal body 202 of the armature fuel system component 200 having one or more of the features discussed above. At operation 608, the extruded blank 602 is output from the cold extrusion press 606 in the net form of the armature fuel system component 200.

[0065] refer to Figure 10 A method 700 is disclosed for forming an armature fuel system component 200 into a single integral body using a cold extrusion process (such as by using the cold extrusion process 600 discussed above). Method 700 includes an operation 702 of providing a blank or billet of material (such as blank 602) from which the armature fuel system component 200 is formed. Method 700 further includes an operation 704 of forming the armature fuel system component 200 using a cold extrusion process (such as by using a cold extrusion press 606) to extrude the blank 602 into an integral metal body 202 corresponding to the net shape of the armature fuel system component 200.

[0066] In one embodiment, the integral metal body 202 is pressed from a first end 206 to an opposing second end 212 along a longitudinal axis 222. In another embodiment, the integral metal body 202 is pressed from a second end 212 to an opposing first end 206 along a longitudinal axis 222.

[0067] Various aspects of this disclosure are contemplated. According to one aspect of this disclosure, a method of manufacturing a fuel system component for use in conjunction with a fuel system includes forming an integral metal body corresponding to the net shape of the fuel system component using a cold extrusion process. The integral metal body is formed during the cold extrusion process to extend from a first end to a second end and includes at least one channel extending at least partially through the integral body.

[0068] In one embodiment, forming the integral metal body includes forming an armature fuel system component or a valve seat fuel system component, wherein the net shape includes a flange at one of the first end or the second end and a shaft extending from the flange.

[0069] The shaft extends along a longitudinal axis from the flange to the other of the first or second end of the integral metal body. The clear shape also includes at least one channel extending along the longitudinal axis. The channel opens at the first and second ends of the integral metal body.

[0070] In one embodiment, forming the integral metal body includes forming a fuel injector nozzle fuel system component, wherein the net shape includes the at least one channel extending along the longitudinal axis, wherein the at least one channel opens at a first end of the integral metal body and closes at a second end of the integral metal body. The method further includes forming one or more nozzles through the second end of the integral metal body, such that the one or more nozzles extend from the outside of the integral metal body to the at least one channel.

[0071] In one embodiment, forming the integral metal body includes forming a retainer fuel system component, in which the net shape includes the at least one channel extending along the longitudinal axis and opening at a first end and a second end of the integral metal body. The at least one channel is configured to receive at least a portion therein of one or more additional fuel system components.

[0072] In one embodiment, the method includes forming one or more auxiliary fuel system components by cold extruding a metal blank into a net shape. The one or more auxiliary fuel system components are used for at least one of a nozzle, valve seat, armature, retainer, and needle of a fuel injector.

[0073] In one embodiment, forming the integral metal body includes forming an elongated needle fuel system component for a fuel injector, wherein the clear shape of the elongated needle fuel system component for the fuel injector includes at least one channel extending laterally through the integral metal body.

[0074] In one embodiment, forming the integral metal body comprises forming the net shape by cold extruding a blank of stainless steel material having a mixture of chromium and nickel alloys. In another embodiment, the stainless steel material is 18CrNi8.

[0075] In one embodiment, the method includes hardening the monolithic metal body with a low-pressure carburizing heat treatment.

[0076] In one embodiment, forming the integral metal body includes forming the at least one channel in the net shape of the integral metal body without drilling or machining the integral metal body.

[0077] According to another aspect of this disclosure, an armature is provided for use in conjunction with the actuation of a valve. The armature includes an integral metal body that has been extruded as a single piece in a cold extrusion process. The integral metal body extends along a longitudinal axis between a first end and an opposing second end. The integral metal body includes a flange at the first end and a shaft extending from the flange. The shaft extends along the longitudinal axis from the flange to the second end of the integral metal body. Additionally, a channel extends along the longitudinal axis and opens at both the first and second ends of the integral metal body.

[0078] In one embodiment, the flange extends radially outward from the channel, and the shaft extends along the channel.

[0079] In another embodiment, the channel includes a first diameter adjacent to a second end of the integral metal body, and a second diameter along a majority of the length of the channel between the first and second ends of the integral metal body. The first diameter of the channel is larger than the second diameter of the channel.

[0080] In another embodiment, the central channel includes a transition section having a truncated conical shape, which extends from the second diameter to an opening of the central channel at the first end of the integral metal body.

[0081] In one embodiment, the shaft of the integral metal body includes an outer surface. The outer surface extends from a second end of the integral metal body to the flange, and the outer surface has a stepped surface profile.

[0082] In another embodiment, the stepped surface profile of the outer surface of the shaft includes a first shaft portion adjacent to the flange, a second shaft portion adjacent to the first shaft portion, and a third shaft portion adjacent to the second shaft portion. The first shaft portion has a first outer diameter, and the second shaft portion has a second outer diameter smaller than the first outer diameter. The third shaft portion extends from the second shaft portion to a second end of the integral metal body, and the third shaft portion has a third outer diameter smaller than the second outer diameter.

[0083] In one embodiment, the flange includes a plurality of slots. Each of the plurality of slots extends radially inward from the outer edge of the flange to the end of a corresponding slot in the plurality of slots.

[0084] In another embodiment, the flange includes a first flange portion having a first thickness extending radially outward from the shaft, and a second flange portion extending radially outward from the first flange portion to the outer edge of the flange. The second flange portion gradually thins from the first thickness to a second, smaller thickness at the outer edge of the flange.

[0085] In another embodiment, the plurality of slots includes four slots positioned at equal angles around the flange.

[0086] In another embodiment, the flange defines an outer end face portion and a recessed end face portion at a second end of the integral metal body. The outer end face portion includes a groove extending around an opening of the channel at a first end of the integral metal body.

[0087] In another embodiment, the flange includes a second face opposite the recessed end face portion. The second face extends radially outward from the axis. The flange includes a plurality of holes. Each of the plurality of holes extends axially through the recessed end face portion and the second face.

[0088] In another embodiment, each of the plurality of holes is located between a corresponding pair of slots in the plurality of slots.

[0089] According to another aspect of this disclosure, a method of manufacturing an armature for use in conjunction with the actuation of a valve includes forming an integral metal body using a cold extrusion process. The integral metal body is formed to include: a flange at a first end of the integral metal body; a shaft extending along a longitudinal axis from the flange, wherein the shaft extends to a second end of the integral metal body opposite the first end; and a channel extending along the longitudinal axis and opening at both the first and second ends of the integral metal body.

[0090] In one embodiment, the channel includes a first diameter adjacent to a second end of the integral metal body, and a second diameter extending along a majority of the length of the central channel between the first and second ends of the integral metal body. The first diameter of the channel is larger than the second diameter of the channel. A transition section having a truncated conical shape extends from the second diameter to the opening of the channel at the second end of the integral metal body.

[0091] In one embodiment, the integral metal body is formed during a cold extrusion process to provide a plurality of slots to the flange. Each of the plurality of slots extends radially inward from the outer edge of the flange to the end of a corresponding slot in the plurality of slots.

[0092] In one embodiment, the integral metal body is formed in a cold extrusion process to provide the flange with a first flange portion having a first thickness extending radially outward from the shaft and a second flange portion extending radially outward from the first flange portion to the outer edge of the flange. The second flange portion gradually thins from the first thickness to a second, smaller thickness at the outer edge of the flange.

[0093] In one embodiment, the integral metal body is formed during a cold extrusion process to provide an outer end face portion and a recessed end face portion to the flange at a first end of the integral metal body. The recessed end face portion extends radially outward from the recessed end face portion. The outer end face portion includes a groove extending around an opening of the channel at the first end of the integral metal body.

[0094] In another embodiment, the integral metal body is formed during a cold extrusion process to provide the flange with a second face opposite to the recessed end face portion and a plurality of holes. The second face extends radially outward from the axis, and each of the plurality of holes extends axially through the recessed end face portion and the second face.

[0095] In one embodiment, the integral metal body is formed in a cold extrusion process to include an outer surface extending from a second end of the integral metal body to the flange on a shaft. The outer surface has a stepped surface profile, including a first shaft portion adjacent to the flange, a second shaft portion adjacent to the first shaft portion, and a third shaft portion extending from the second shaft portion to the second end. The first shaft portion has a first outer diameter, the second shaft portion has a second outer diameter smaller than the first outer diameter, and the third shaft portion has a third outer diameter smaller than the second outer diameter.

[0096] In another embodiment, the integral metal body is formed during a cold extrusion process to include a first fillet between the flange and the first shaft portion, a second fillet between the first shaft portion and the second shaft portion, and a third fillet between the second shaft portion and the first shaft portion.

[0097] Although illustrative embodiments of this disclosure have been described in detail in the accompanying drawings and foregoing description, they should be considered illustrative rather than restrictive. It should be understood that only certain exemplary embodiments have been shown and described, and all changes and modifications within the spirit and scope of the claimed invention are intended to be protected. It should be understood that while the use of terms such as preferred, preferably, or more preferred in the above description indicates that the features described so far may be more desirable, this may not be necessary, and embodiments lacking these may be contemplated as being within the scope of the invention, as defined by the appended claims. When reading the claims, the use of terms such as “a,” “an,” “at least one,” or “at least a portion” is not intended to limit the claims to only one object unless expressly stated to the contrary in the claims. When the terms “at least a portion” and / or “a portion” are used, the item may include a portion and / or the entire item unless the contrary is explicitly stated.

Claims

1. A method for manufacturing a fuel system component for use in conjunction with a fuel system, the method comprising: An integral metal body corresponding to the net shape of the fuel system component is formed using a cold extrusion process. The integral metal body is formed during the cold extrusion process to extend from a first end to a second end and includes at least one channel that extends at least partially through the integral body.

2. The method of claim 1, wherein forming the integral metal body includes forming an armature fuel system component or a valve seat fuel system component, wherein the net shape of the armature fuel system component or the valve seat fuel system component includes: A flange at one of the first or second ends; A shaft extending from the flange, the shaft extending along a longitudinal axis from the flange to the other of the first end or the second end of the integral metal body; as well as The at least one channel extending along the longitudinal axis opens at the first and second ends of the integral metal body.

3. The method of claim 1, wherein forming the integral metal body includes forming a fuel injector nozzle fuel system component, wherein the net shape of the fuel injector nozzle fuel system component includes the at least one channel extending along a longitudinal axis, wherein the at least one channel opens at a first end of the integral metal body and closes at a second end of the integral metal body, and the method includes: One or more nozzles are formed through the second end of the integral metal body, such that the one or more nozzles extend from the outside of the integral metal body to the at least one channel.

4. The method of claim 1, wherein forming the integral metal body includes forming a retainer fuel system component, wherein the net shape of the retainer fuel system component includes the at least one channel extending along a longitudinal axis and opening at a first end and a second end of the integral metal body, wherein the at least one channel is configured to receive at least a portion of one or more additional fuel system components therein.

5. The method of claim 4, further comprising forming the one or more auxiliary fuel system components by cold extruding a metal blank into a net shape, wherein the one or more auxiliary fuel system components include at least one of a nozzle, a valve seat, an armature, and a needle for a fuel injector.

6. The method of claim 1, wherein forming the integral metal body includes forming an elongated needle fuel system component for a fuel injector, wherein the net shape of the elongated needle fuel system component for the fuel injector includes the at least one channel extending laterally through the integral metal body.

7. The method according to any one of claims 1 to 6, wherein forming the integral metal body comprises forming the net shape by cold extrusion of a stainless steel blank having a mixture of chromium and nickel alloys.

8. The method according to claim 7, wherein the stainless steel material is 18CrNi8.

9. The method according to any one of claims 1 to 6, the method comprising hardening the integral metal body by low-pressure carburizing heat treatment.

10. The method according to any one of claims 1 to 6, wherein forming the integral metal body comprises forming the at least one channel in the net shape of the integral metal body without drilling or machining the integral metal body.

11. An armature for use in conjunction with the actuation of a valve, the armature comprising: A monolithic metal body, which is extruded into a single piece in a cold extrusion process, extends along a longitudinal axis between a first end and an opposite second end, and the monolithic metal body comprises: The flange at the first end; A shaft extending from the flange, the shaft extending along the longitudinal axis from the flange to the second end of the integral metal body; and A channel that extends along the longitudinal axis and opens at the first and second ends of the integral metal body.

12. The armature of claim 11, wherein the flange extends radially outward from the channel, and the shaft extends along the channel.

13. The armature of claim 12, wherein the channel comprises: The first diameter adjacent to the second end of the integral metal body; A second diameter, the second diameter being along a large portion of the length of the channel between the first end and the second end of the integral metal body; and The first diameter of the channel is larger than the second diameter of the channel.

14. The armature of claim 13, wherein the central channel includes a transition section having a truncated conical shape, the transition section extending from the second diameter to an opening of the central channel at the first end of the integral metal body.

15. The armature according to claim 11, wherein: The shaft of the integral metal body includes an outer surface; The outer surface extends from the second end of the integral metal body to the flange; and The outer surface has a stepped surface profile.

16. The armature of claim 15, wherein the stepped surface profile of the outer surface of the shaft comprises: A first shaft portion adjacent to the flange, the first shaft portion having a first outer diameter; A second shaft portion adjacent to the first shaft portion, the second shaft portion having a second outer diameter, wherein the second outer diameter is smaller than the first outer diameter; and A third shaft portion adjacent to the second shaft portion, the third shaft portion extending from the second shaft portion to the second end of the integral metal body, the third shaft portion having a third outer diameter smaller than the second outer diameter.

17. The armature of claim 11, wherein the flange includes a plurality of slots, each of the plurality of slots extending radially inward from the outer edge of the flange to the end of a corresponding slot in the plurality of slots.

18. The armature of claim 17, wherein the flange comprises: A first flange portion extending radially outward from the shaft, the first flange portion having a first thickness; and A second flange portion extends radially outward from the first flange portion to the outer edge of the flange, and the second flange portion gradually thins from the first thickness to a second smaller thickness at the outer edge of the flange.

19. The armature of claim 18, wherein the plurality of slots comprises four slots positioned at equal angles around the flange.

20. The armature of claim 18, wherein the flange defines an outer end face portion and a recessed end face portion at the second end of the integral metal body, the outer end face portion including a groove extending around the opening of the channel at the first end of the integral metal body.

21. The armature according to claim 20, wherein: The flange includes a second face opposite to the recessed end face portion, and the second face extends radially outward from the axis; and The flange includes a plurality of holes, each of which extends axially through the recessed end face portion and the second face.

22. The armature of claim 21, wherein each of the plurality of holes is located between a corresponding pair of slots in the plurality of slots.

23. A method of manufacturing an armature for use in conjunction with the actuation of a valve, the method comprising: An integral metal body is formed using a cold extrusion process, the integral metal body comprising: a flange at a first end of the integral metal body; a shaft extending from the flange along a longitudinal axis to a second end of the integral metal body opposite to the first end; and a channel extending along the longitudinal axis and opening at both the first and second ends of the integral metal body.

24. The method of claim 23, wherein forming the integral metal body comprises forming the channel by the cold extrusion process to include: The first diameter adjacent to the second end of the integral metal body; The second diameter is a portion of the length of the central channel between the first end and the second end of the integral metal body; The first diameter of the channel is larger than the second diameter of the channel; as well as It has a truncated conical transition section that extends from the second diameter to the opening of the channel at the second end of the integral metal body.

25. The method of claim 23, wherein forming the integral metal body includes forming the flange having a plurality of slots during the cold extrusion process, such that each of the plurality of slots extends radially inward from the outer edge of the flange to the end of a corresponding slot in the plurality of slots.

26. The method of claim 23, wherein forming the integral metal body includes forming the flange of the integral metal body during the cold extrusion process to include: A first flange portion extending radially outward from the shaft, the first flange portion having a first thickness; and A second flange portion extends radially outward from the first flange portion to the outer edge of the flange, and the second flange portion gradually thins from the first thickness to a second smaller thickness at the outer edge of the flange.

27. The method of claim 23, wherein forming the integral metal body includes forming the flange of the integral metal body during the cold extrusion process to include: The outer end face portion and the recessed end face portion at the first end of the integral metal body; The recessed end face portion extends radially outward from the recessed end face portion; Furthermore, the outer end face portion includes a groove extending around the opening at the first end of the integral metal body surrounding the channel.

28. The method of claim 27, wherein forming the integral metal body includes forming the flange of the integral metal body during the cold extrusion process to include: A second surface opposite to the recessed end face portion, the second surface extending radially outward from the axis; and A plurality of holes, each of which extends axially through the recessed end face portion and the second face.

29. The method of claim 23, wherein forming the integral metal body includes forming an outer surface of the integral metal body during the cold extrusion process to extend from the second end of the integral metal body to the flange, the outer surface forming a stepped surface profile, the stepped surface profile comprising: A first shaft portion adjacent to the flange, the first shaft portion having a first outer diameter; A second shaft portion adjacent to the first shaft portion, the second shaft portion having a second outer diameter smaller than the first outer diameter; and A third shaft portion extending from the second shaft portion to the second end, the third shaft portion having a third outer diameter smaller than the second outer diameter.

30. The method of claim 29, wherein forming the integral metal body comprises forming the integral metal body during the cold extrusion process to include: The first fillet between the flange and the first shaft portion; A second fillet between the first shaft portion and the second shaft portion; and A third fillet between the second shaft portion and the first shaft portion.

Images