Armature and armature assembly for a valve in a fuel injector

Abstract

Disclosed are armatures and armature assemblies for use in connection with actuation of a valve, such as for a fuel injector, fuel cell, and / or fuel pump. The armature includes a body having a first end portion with a flange and a shaft extending from the flange to a second end portion of the body. The second end portion includes a configuration to slow the velocity of the armature during closing of the valve to reduce stress on one or more components of the valve when impacted by the armature. The armature can also or alternatively include a shaft configured to reduce end of injection delay.

Description

Technical Field

[0001] This disclosure relates in general to means for valves (such as valves for fuel injectors, fuel cells and / or fuel pumps), and more specifically to armatures and armature assemblies for use in such means. Background Technology

[0002] An armature can be used to actuate valves that use solenoids, such as those used in fuel injectors, fuel cells, fuel pumps, and / or fluid flow control devices. The armature can be controlled to move longitudinally between an open and closed position, thereby initiating and terminating fuel flow through the fuel injector. This movement causes an impact between the armature and one or more other components of the fuel injector, such as a check ball lift valve or other seat components.

[0003] The impact force depends on various factors, such as armature mass, preload on the armature, stroke length, and closing speed. The impact force induces stress in the armature, check ball lifter valve, and other components. Furthermore, the delay in cutting off fuel flow by closing the armature at the end of injection can cause fuel spray to interact with the cylinder liner, thereby increasing in-cylinder soot and emissions. Therefore, further improvements are needed in this area.

[0004] Disclosure of exemplary embodiments To clearly, concisely, and accurately describe the exemplary embodiments of this disclosure, their formulation and use, and to enable the practice, formulation, and use 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 limit the scope of the invention, and the invention includes and protects such changes, modifications, and further applications of the exemplary embodiments that can be conceived by those skilled in the art. Summary of the Invention

[0005] An armature and / or armature assembly for use in association with the actuation of a valve, such as for a fuel injector, fuel cell, and / or fuel pump, is disclosed. The armature includes a body having: a first end having a flange; and a shaft extending from the flange to a second end of the body.

[0006] In one embodiment, the second end of the body of the armature includes an end surface configured to slow the armature during closure. This speed reduction decreases the impact force and stress on one or more components of the valve upon impact.

[0007] In one embodiment, the shaft of the armature includes a configuration for increasing the armature closing speed. Increasing the armature closing speed reduces the delay in fuel injection initiation and / or injection termination.

[0008] In one embodiment of this disclosure, an armature and / or armature assembly is provided, the armature and / or armature assembly including an armature having a body extending along a longitudinal axis between a first end and an opposing second end. The body includes: a flange located 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 body. The body includes a channel extending along the longitudinal axis. The channel opens at both the first and second ends of the body. The second end of the body includes an end surface extending around the channel. The end surface projects radially outward from the shaft to slow the armature during closure.

[0009] In another embodiment of this disclosure, an armature and / or armature assembly is provided, comprising an armature having a body extending along a longitudinal axis between a first end and an opposing second end. The body includes: a flange located 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 body. The body includes a channel extending along the longitudinal axis. The channel opens at both the first and second ends of the body. The second end of the body includes an end surface extending around the channel. The shaft includes one or more circumferential grooves extending therearound, the one or more circumferential grooves being configured to receive fluid flow along the armature, thus giving the armature an increased shut-off speed, thereby reducing delays in injection initiation and / or injection termination.

[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 longitudinal sectional view illustrating certain aspects of a valve including an armature assembly according to an exemplary embodiment of the present disclosure.

[0012] Figure 2 yes Figure 1 A front view of the armature assembly.

[0013] Figure 3 yes Figure 2 An enlarged front view of the second end of the armature.

[0014] Figure 4 yes Figure 1 A longitudinal sectional view of an armature assembly in a valve having an armature of another embodiment.

[0015] Figure 5 Is Figure 1 A longitudinal sectional view of an armature assembly having an armature of another embodiment in a valve.

[0016] Figure 6 Is Figure 1 The valve has Figure 5 A longitudinal sectional view of the armature assembly of the armature and another embodiment of the check ball lift valve.

[0017] Figure 7 This is a front view of an armature according to another embodiment of the present disclosure.

[0018] Figure 8 yes Figure 1 The valve with Figure 7 A longitudinal sectional view of the armature assembly of the armature.

[0019] Figure 9 This is a longitudinal sectional view of the armature assembly in another embodiment.

[0020] Figure 10 This is a longitudinal sectional view of the armature in another embodiment.

[0021] Figure 11 This is a cross-sectional view of an example fuel injector for an internal combustion engine, which includes the armature assembly and armature of this disclosure. Detailed Implementation

[0022] 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.

[0023] Figures 1 to 6 This is an example associated with armature 100 and / or armature assembly 101 according to certain embodiments of this disclosure. Figures 7 to 8 This is an example associated with armature 150 and / or armature assembly 151 according to another embodiment of this disclosure. Figure 9 This is an example associated with armature 350 and / or armature assembly 351 according to another embodiment of this disclosure, and Figure 10 This is an example associated with an armature 450 according to another embodiment of the present disclosure. Figure 11 This is a detailed cross-sectional view of an embodiment of fuel injector 200, illustrating exemplary specific implementations of armatures 100, 150, 350, 450 and / or armature assemblies 101, 151, 351 in valve 250 of a particular fuel injector. While this disclosure describes specific configurations of fuel injector 200, armatures 100, 150, 350, 450 and / or armature assemblies 101, 151, 351, one or more of these features described in this disclosure may be omitted, and other features and applications are not excluded. The armatures 100, 150, 350, 450 and / or armature assemblies 101, 151, 351 of this disclosure can be used with any fuel injector, fuel cell, fuel pump and / or flow control valve that is compatible with them.

[0024] As shown in these figures, in embodiments of this disclosure, Figures 1 to 3 The armature 100 includes a body 102 extending along a longitudinal axis L between a first end 104 and an opposing second end 106. The body 102 includes a flange 108 located at the first end 104 and a shaft 110 extending from the flange 108. The flange 108 extends radially outward from the shaft 110. The shaft 110 extends along the longitudinal axis L from the distal end of the flange 108 to the second end 106 of the body 102. The body 102 includes a channel 112 extending along the longitudinal axis L. The channel 112 opens at both the first end 104 and the second end 106 of the body 102.

[0025] The second end 106 of the body 102 includes an end surface 114 extending around the channel 112. The end surface 114 is formed at least partially by a circumferential protrusion 116 projecting radially outward from the axis 110 at the second end 106. In an embodiment, the end surface 114 is planar and orthogonal to the longitudinal axis L, but other configurations and / or orientations are not excluded. In an embodiment, the end surface 114 is annular, with its inner diameter formed by the channel 112 and its outer diameter D. ES The third diameter D3 is larger than that of the shaft 114 adjacent to the second end 106.

[0026] In embodiments of this disclosure, armature 100 is equipped with armature assembly 101. Armature assembly 101 includes armature 100 and check ball lift valve 230. Check ball lift valve 230 includes a check ball 226 that is positioned against pilot seat 224 to close a central seat passage 240 that allows fluid to flow through when open. Check ball lift valve 230 also includes a plate 228 located between check ball 226 and end surface 114. End surface 114 of armature 100 contacts plate 228 to position check ball 226 against pilot seat 224, thereby closing central seat passage 240.

[0027] The flange 108 of the body 102 includes an outer edge 120 forming a circular shape. The flange 108 projects radially outward from the channel 112, and the shaft 110 extends axially from the distal end of the flange 108. In an embodiment, the flange 108 is disk-shaped and the shaft 110 is cylindrical, and the channel 112 extends longitudinally through the flange 108 and the shaft 110 and is centered along the longitudinal axis L.

[0028] In one embodiment, the flange 108 includes an outer diameter defined by an outer edge 120, which is larger than a maximum outer diameter portion defined by the outer surface 132 of the shaft 110. The flange 108 includes a plurality of slots 122 extending through the flange 108. Each of the plurality of slots 122 extends radially inward from the outer edge 120 of the flange 108 to a terminal end 124 of a corresponding slot among the plurality of slots 122.

[0029] In one embodiment, the plurality of slots 122 are four slots 122 spaced at equal angles around the flange 108. In another embodiment, the flange 108 may include a plurality of axially extending perforations to facilitate fluid flow through the flange 108, such as by reducing drag forces during closing and pressure spikes in the squeezed membrane during opening. The perforations on the flange 108 help reduce pressure rise on the top of the armature 100 during opening, thus helping to reduce injection initiation delay. The perforations also reduce drag forces during both opening and closing movements, thereby helping to reduce both injection initiation delay and / or injection termination delay. In another embodiment, the flange 108 may have a tapered thickness as it extends radially outward to reduce the mass of the armature 100 and facilitate movement of the armature 100 during valve opening and closing operations.

[0030] In one embodiment, the shaft 110 of the body 102 includes an outer surface 132 extending from the flange 108 to the second end 106. The outer surface 132 of the shaft 110 extends from the second end 106 of the body 102 to the distal end face 132 of the flange 108. In another embodiment, the outer surface 132 of the shaft 110 has a stepped surface profile along a portion of the length of the shaft 110.

[0031] In one embodiment, the stepped surface profile of the outer surface 132 of the shaft 110 includes a first shaft portion 134 adjacent to the flange 108 and having a first outer diameter D1. The stepped surface profile also includes a second shaft portion 136 adjacent to the first shaft portion 134. The second shaft portion 136 includes a second outer diameter D2, which is smaller than the first outer diameter D1. The stepped surface profile of the outer surface 132 of the shaft 110 includes a third shaft portion 138 adjacent to the second shaft portion 136. The third shaft portion 138 extends to a circumferential protrusion 116 of the body 102. The third shaft portion 138 has a third outer diameter D3, which is smaller than the second outer diameter D2 and also smaller than the diameter D of the end surface 114. ES .

[0032] The second end portion 106 includes an end surface 114 extending about the longitudinal axis L. The end surface 114 is formed on the distal side of the circumferential protrusion 116, opposite to the check ball lift valve 230. The end surface 114 provides a radially outward protrusion from the outer surface 132 of the shaft 110 to reduce the closing speed of the armature 100.

[0033] During the closure of valve 250, as armature 100 displaces distally, fluid is pressurized between end surface 114 and plate 228, such as... Figure 3 As indicated by arrow P in the diagram, the pressurized fluid provides resistance to the closing of the armature 100 and reduces its closing speed. Because the area of ​​the end surface 114 is larger than the cross-sectional area of ​​the shaft 110 at the third shaft portion 138, the armature closing speed is reduced compared to an arrangement that eliminates the circumferential protrusion 116 and extends the third diameter D3 to the end surface 114. This reduced armature closing speed decreases the impact forces and stresses on the armature 100, plate 228, ball check valve 226, and pilot seat 224.

[0034] refer to Figure 4 An embodiment of the armature 100 is shown, in which the end surface 114 is formed by a circumferential protrusion 116', which is a cylindrical sleeve press-fitted or otherwise secured to the shaft 110. Figures 1 to 3 In one embodiment, the circumferential protrusion 116 is integrated with the main body 102 to form a single-piece, integrated armature main body 102.

[0035] refer to Figure 5 An embodiment of the armature 100 is shown, in which the mass of the body 102 is reduced by forming a circumferential groove 140 around the first shaft portion 134. Furthermore, the length of the circumferential protrusion 116 along the longitudinal axis L is minimized, while providing sufficient material to form an end surface diameter D. ES The end surface 114, and maintain the structural integrity of the body 102 at the second end 106.

[0036] exist Figures 1 to 5 In the embodiment, the diameter D of the end surface 114 ES The diameter D of the check ball lift valve 230 is larger than that of the check ball lift valve. P .exist Figure 6 In the middle, the diameter D of the check ball lift valve 230 P Increase to match the diameter D of the end surface 114 ES Corresponding in size. In the embodiment, diameter D P Equal to diameter D ES Diameter D P The increase in the force will increase the extrusion force, thereby reducing the closing speed and travel depth of the armature 100.

[0037] Figures 7 to 8 Another embodiment of the armature assembly 151 is shown, which has an armature 150 for use in connection with the actuation of valve 250. Armature 150 is similar to armature 100, but does not include a circumferential protrusion at the second end 156. Instead, armature 150 includes a plurality of circumferential grooves 164 along shaft 160, as discussed further below. Figure 8 As shown, the circumferential groove 164 receives the fluid flow F during the actuation of the armature 150 from the first end 154 and the second end 156. The circumferential groove 164 allows for faster opening and closing speeds, which reduces the delay in injection start and / or injection end.

[0038] Armature 150 includes a body 152 extending along a longitudinal axis L between a first end 154 and an opposing second end 156. Body 152 includes a flange 158 at the first end 154. Shaft 160 extends from flange 158 along the longitudinal axis L from flange 158 to the second end 156 of body 152. Body 152 also includes a channel 162 for plunger 212 extending along the longitudinal axis L. Channel 162 opens at the first end 154 and the second end 156 of body 152. Shaft 160 includes a plurality of circumferential grooves 164 extending therearound.

[0039] A plurality of circumferential grooves 164 are longitudinally spaced apart from each other along the shaft 160 and positioned adjacent to the second end 156 of the body 152 to receive fluid flow thereby improving the closing speed of the armature 150. In the illustrated embodiment, the plurality of circumferential grooves 164 includes two circumferential grooves 164 that are longitudinally spaced apart from each other on the shaft 160.

[0040] The body 152 of the armature 150 includes an outer surface 172 extending from a second end 156 of the body 152 to a flange 158. The outer surface 172 has a stepped surface profile including a first axial portion 174 adjacent to the flange 158, the first axial portion having a first outer diameter D1. The outer surface 172 has a second axial portion 176 adjacent to the first axial portion 174. The second axial portion 176 has a second outer diameter D2 smaller than the first outer diameter D1. The outer surface 172 has a third axial portion 178 adjacent to the second axial portion 176. The third axial portion 178 extends from the second axial portion 176 to the second end 156 of the body 152. A plurality of circumferential grooves 164 are all located on the third axial portion 178.

[0041] In an embodiment, each circumferential groove 164 includes a cylindrical portion 166 and a frustoconical portion 168. The frustoconical portion 168 provides a transition from the outer surface 172 of the shaft 160 to the cylindrical portion 166 of the corresponding circumferential groove 164. The frustoconical portion 168 extends from the cylindrical portion 166 of the corresponding circumferential groove 164 toward a second end 156 of the body 152 to the outer surface 172. Furthermore, each circumferential groove 164 includes a lip 170 that extends from the cylindrical portion 166 of the circumferential groove to the outer surface 172 of the shaft 160. In an embodiment, the lip 170 is orthogonal to the longitudinal axis L, the frustoconical portion 168 is inclined relative to the longitudinal axis L, and the cylindrical portion 166 is parallel to the longitudinal axis L.

[0042] Figure 9 Another embodiment of the armature assembly 351 is shown, which has an armature 350 for use in connection with the actuation of valve 250. The armature 350 is similar to armature 100, but does not include a circumferential protrusion at the second end 356. Instead, the armature 350 includes a shaft 360 that has no external grooves or protrusions at the distal ends of a first shaft portion 368 and a second shaft portion 370. As shown, the first shaft portion 368 extends distally from flange 358 to the second shaft portion 370, and the shaft 360 includes a smooth shaft portion 372 that extends distally from the second shaft portion 370 to the second end 356. The smooth shaft portion 372 lacks any outwardly extending protrusions or radially inwardly recesses formed thereon or therein.

[0043] Armature 350 includes a body 352 extending along a longitudinal axis L between a first end 354 and an opposing second end 356. Body 352 includes a flange 358 at the first end 354. A shaft 360 extends from flange 358 along the longitudinal axis L to the second end 356 of body 352. Body 352 also includes a channel 362 for plunger 212 extending along the longitudinal axis L. Channel 362 opens at both the first end 354 and the second end 356 of body 352.

[0044] In the illustrated embodiment, channel 362 includes a first proximal portion 364 that fits snugly around plunger 212, and a second distal portion 366 along a smooth axis portion 372, the latter being wider than the proximal portion 364 in distance from plunger 212. Due to the wider inner diameter ID of distal portion 366 and the absence of any outwardly extending circumferential protrusions at the second end 356, the surface area at the second end 356 of armature 350 is smaller. In this embodiment, the ratio of plunger length L1 to inner diameter ID is 2. The reduced mass and the reduced compressive force on armature 350 shorten the overtravel time of armature 350.

[0045] Figure 10 Another embodiment of an armature 450 is illustrated for use in connection with the actuation of valve 250. Armature 450 is similar to armature 350, but includes a bore 470 in shaft 460. Armature 450 includes a body 452 extending along a longitudinal axis L between a first end 454 and an opposing second end 456. Body 452 includes a flange 458 at the first end 454. Shaft 460 extends from flange 458 along the longitudinal axis L from flange 458 to the second end 456 of body 452. Body 452 also includes a channel 462 for plunger 212 extending along the longitudinal axis L. Channel 462 opens at the first end 454 and the second end 456 of body 452. Channel 462 includes a first proximal portion 464 that fits tightly around plunger 212, and a second distal portion 466 having an inner diameter ID spaced wide from plunger 212.

[0046] In one embodiment, at the distal portion 466 of channel 462, a pair of holes 470 are provided on opposite sides of shaft 460. In a specific embodiment, the diameter of the holes 470 is 1 mm. Other embodiments envision other numbers and / or sizes of the holes 470 in shaft 460. The holes 470 provide a reduction in mass and overtravel time for armature 450. The holes 470 can be implemented in any armature embodiment discussed herein.

[0047] Furthermore, the armature 450 is shown as two separate pieces fixed to each other. The first armature 450 includes a shaft 480 comprising a shaft 460 and a shaft flange 482 located at a first end 454. The second armature 450 includes a flange 484 comprising a flange 458 and a shaft portion 486 extending from the flange 458 around a proximal portion of the shaft 480 toward a distal end. The shaft flange 482 is located within a recess 488 in the flange 484 at the first end 454. Several other embodiments envision an armature provided as a three-piece assembly.

[0048] refer to Figure 11 A cross-sectional view illustrating an embodiment of a fuel injector 200 having exemplary armature assemblies 101, 151, 351 and armatures 100, 150, 350, 450 is shown, the exemplary armature assemblies and the armatures being employed in association with a valve 250 of the fuel injector 200. The fuel injector 200 generally includes an injector body 202, an elongated needle valve 204, a needle sleeve 206, a needle seal 208, an armature 100 or 150 or 350 or 450, and a plunger 212 extending through a channel 112 or 162 through the armature 100 or 150 or 350 or 450. The injector body 202 includes an upper chamber 214 and a lower chamber 216 for receiving multiple components therein, as would be conceived by those skilled in the art utilizing the benefits and insights of this disclosure.

[0049] Armatures 100, 150, 350, and 450 are configured to move vertically within the injector body 202 to facilitate the opening and closing of valve 250 of the fuel injector 200. A stator assembly 222, including solenoid 248, may be positioned directly above armatures 100, 150, 350, and 450 such that when solenoid 248 is active, armatures 100, 150, 350, and 450 move to an upward position. When solenoid 248 is inactive (e.g., at the end of injection), armatures 100, 150, 350, and 450 move to a downward position. An air gap (e.g., air gap 232) provides distance between the stator assembly 222 and armatures 100, 150, 350, and 450. As discussed above, armatures 100, 350, and 450 may be configured to slow their closing speed, and / or armature 150 may be configured to reduce injection end delay.

[0050] The inner cavity of the upper chamber 214 of the injector body 202 receives the armature 100, 150, 350, or 450, plunger 212, armature spring 218, and stator assembly 222. The inner cavity of the lower chamber 216 receives the needle valve 204, needle sleeve 206, needle seal 208, pilot valve seat 224, and check ball 226. The upper chamber 214 provides a low-pressure environment for the fuel injector 200 relative to the high-pressure environment below the check ball 226. The stator assembly 222 is secured within the upper chamber 214 and held in place by a retainer. The bottom surface of the stator assembly 222 is precisely calibrated from the upper surfaces of the armatures 100, 150, 350, and 450. At the other end of armatures 100, 150, 350, and 450 is a check ball lift valve 230, which supports armatures 100, 150, 350, and 450 via abutment engagement.

[0051] The intermediate segment of plunger 212 includes a shoulder 213 disposed on the upper surface of armature 100, the shoulder being interconnected such that plunger 212 moves along with armatures 100, 150, 350, 450 in an upward direction. Armature spring 218 is biased against flanges 108, 158, 358, 458 of armatures 100, 150, 350, 450, and biased in an upward direction against armatures 100, 150, 350, 450 and plunger 212. Armatures 100, 150, 350, 450 include channels 112, 162, 362, 462, which receive the shaft 215 of plunger 212 passing through them. The outer diameter and configuration of the shaft 215 are designed to provide a tight or mating fit with at least a portion of the inner diameters of channels 112, 162, 362, and 462 while still allowing sliding movement of the plunger 212. This tight / matting fit, while allowing relative sliding movement, suppresses fuel leakage between the outer diameter of the shaft 215 of the plunger 212 and the inner diameters of channels 112, 162, 362, and 462.

[0052] A lower chamber 216, including an inner cavity, houses a needle valve 204, a needle sleeve 206, a needle seal 208, a pilot valve seat 224, and a check ball 226. This inner cavity also houses a needle spring 234 that biases the needle valve 204 in a downward direction and applies a closing spring force to the needle valve 204, thereby preventing fuel from leaving through the injector orifice 236. The needle seal 208 includes a control orifice 238 integrated within the needle seal 208 to receive fuel into the needle seal 208, with the proximal end of the needle valve 204 located within the needle seal 208. The needle seal 208 is positioned above the needle valve 204 and includes an end point terminating adjacent to the needle sleeve 206.

[0053] The lower end surface of the pilot valve seat 224 abuts against the top surface of the needle seal 208, while the upper end surface of the pilot valve seat 224 is positioned directly below the armature spring 218. The pilot valve seat 224 also includes a seat center channel 240 that extends longitudinally from the lower end of the pilot valve seat 224 toward the upper end.

[0054] The needle valve 204 moves longitudinally up and down within the injector body 202 to selectively initiate and deactivate fuel injection from the injector body 202. The distal end 217 of the needle valve 204 is located at the distal portion of the injector body 202, which defines a needle valve seat 242 that receives the tip 219 of the needle valve 204 between fuel injection events. For example, during a fuel injection event, the needle valve 204 rises from the needle seat 242, thereby injecting fuel into an engine cylinder (not shown).

[0055] The lower chamber 216 also includes a fuel inlet port 244 configured to supply fuel to the inner chamber of the lower chamber 216. A cross-drilled fluid passage (not shown) may be provided in the needle valve 204 and facilitate fuel flow through the lower chamber 216. A control port 238 is used to direct fuel upward through the valve seat center passage 240. When the coil 221 is de-energized and the solenoid 248 is inactive, the check ball 226 is sealingly engaged with the pilot valve seat 224. The check ball 226 also functions as a movable valve member, allowing it to move out of the sealing engagement with the pilot valve seat 224. When the check ball 226 is sealingly engaged with the pilot valve seat 224, fuel from the lower chamber 216 is prevented from entering the upper chamber 214. When fuel is supplied to the lower chamber 216 and the check ball 226 is sealingly engaged with the pilot valve seat 224, the inner chamber of the lower chamber 216 becomes a high-pressure space. When the check ball 226 is used as a movable valve component and moves to disengage from the sealed engagement with the pilot valve seat 224, high-pressure fuel flows upward through the pilot valve seat 224 into the valve seat center passage 240 and into the inner cavity of the upper chamber 214.

[0056] Fuel injector 200 utilizes a needle valve 204 in a normally closed position. When needle valve 204 is in the normally closed position, coil 221 is de-energized and solenoid 248 is inactive. Fuel injector 200 also includes a plunger return spring 251 that applies a downward spring force, causing plunger 212 and armatures 100, 150 to exert a downward force on check ball lift valve 230, thereby securing check ball 226 and maintaining it in a sealing engagement with pilot seat 224. Pressurized fuel is continuously supplied to the interior of lower chamber 216.

[0057] When coil 221 is de-energized, fuel from lower chamber 216 is prevented from entering upper chamber 214, thus creating high pressure within lower chamber 216. Due to the downward pressure of the fuel supply acting on needle valve 204, a greater downward hydraulic pressure pushes needle valve 204 downwards. Needle spring 234 is also located within lower chamber 216 and is compressed around the upper end of needle valve 204, such that when solenoid 248 is not activated, both the high-pressure fuel and the downward spring force on needle valve 204 hold needle valve 204 against needle valve seat 242. Holding needle valve 204 against needle valve seat 242 prevents high-pressure fuel from leaving fuel injector 200 through injector orifice 236.

[0058] In an example application of the armatures 100, 150, 350, and 450 in the fuel injector 200, flanges 108, 158, 358, and 458 are located below the solenoid 248 and coil 221. The plunger 212 includes a shaft portion disposed within and received by channels 112, 162, 362, and 462 of the armatures 100, 150, 350, and 450 to form an interconnection, such that the plunger 212 moves along with the armatures 100, 150, 350, and 450 in an upward direction. An armature spring 218 is biased against the flanges 108, 158, 358, and 458 to bias the armatures 100, 150, 350, and 450 and the plunger 212 in an upward direction.

[0059] In embodiments, armatures 100, 150, 350, and 450 are configured to move axially within a fuel injector or other device as part of a valve assembly to facilitate the opening and closing of valves (such as valve 250 of fuel injector 200). Figure 11 In the illustrated embodiment, the stator assembly 222, including the solenoid 248, may be positioned directly above the armatures 100, 150, 350, 450, such that when the solenoid 248 is active, the armatures 100, 150, 350, 450 move to an upward position. When the solenoid 248 is inactive, the armatures 100, 150, 350, 450 move to a downward position. An air gap (such as, for example, air gap 232) provides the distance between the stator assembly 222 and the armatures 100, 150, 350, 450. The end surfaces located at the second ends 106, 156, 356, 456 of the armatures 100, 150, 350, 450 may be supported by a check ball lift valve 230. Armature spring 218 can be biased against flanges 108 and 158 to bias armatures 100, 150, 350, 450 and plunger 212 in an upward direction.

[0060] Various aspects of this disclosure are contemplated. According to a first aspect, an armature assembly is provided for use in association with the actuation of a valve. The armature assembly includes: an armature including a body extending along a longitudinal axis between a first end and an opposing second end. The body includes: a flange located 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 body. The body also includes a channel extending along the longitudinal axis. The channel opens at both the first and second ends of the body. The second end of the body includes an end surface extending around the channel. The end surface projects radially outward from an outer surface of the shaft to reduce the closing speed of the armature.

[0061] In one embodiment, the body includes a circumferential protrusion extending along an axis around the second end of the body. The end surface is formed on the circumferential protrusion.

[0062] In one embodiment, the circumferential protrusion includes: an end surface diameter surrounding the longitudinal axis; and a length extending from the end surface along a portion of the longitudinal axis.

[0063] In one embodiment, the axis of the body includes an outer surface. The outer surface extends from the second end of the body to the flange. The outer surface has a stepped surface profile.

[0064] In one 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, the second shaft portion has a second outer diameter, and the third shaft portion has a third outer diameter smaller than the second outer diameter. The end surface diameter is larger than the third outer diameter.

[0065] In one embodiment, the first shaft portion includes a circumferential groove extending therearound.

[0066] In an embodiment, the diameter of the end surface and the second diameter are equal to each other.

[0067] In one embodiment, the armature assembly includes a check ball lift valve located at the second end of the armature. The armature is movable to displace the end surface away from the check ball lift valve to open the valve, and is also movable to displace the end surface into contact with the check ball lift valve to close the valve.

[0068] In one embodiment, the end surface has an end surface diameter, and the check ball lift valve has a lift valve diameter. The end surface diameter is larger than the lift valve diameter.

[0069] In one embodiment, the end surface has an end surface diameter, and the check ball lift valve has a lift valve diameter. The end surface diameter is equal to the lift valve diameter.

[0070] In this embodiment, the end surface is planar.

[0071] According to another aspect of this disclosure, an armature is provided for use in connection with the actuation of a valve. The armature includes a body extending along a longitudinal axis between a first end and an opposing second end. The body includes: a flange located 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 body. The body also includes a channel extending along the longitudinal axis. The channel opens at both the first and second ends of the body. The second end of the body includes an end surface extending around the channel. The end surface is formed by a circumferential protrusion located at the second end of the shaft, the circumferential protrusion projecting radially outward from an outer surface of the shaft.

[0072] According to another aspect of this disclosure, an armature is provided for use in association with the actuation of a valve. The armature includes a body extending along a longitudinal axis between a first end and an opposing second end. The body includes: a flange located 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 body. The body includes a channel extending along the longitudinal axis. The channel opens at both the first and second ends of the body. The channel includes a first proximal portion and a second distal portion, the inner diameter of the second distal portion being larger than the inner diameter of the first proximal portion of the channel.

[0073] In one embodiment, the shaft includes at least one hole extending through the shaft into the channel.

[0074] In one embodiment, the shaft includes a shaft portion extending from the second end toward the first end. The shaft portion does not include any protrusions projecting outward therefrom or radially formed grooves therein.

[0075] In one embodiment, the length of the plunger within the channel is a ratio of 2 to the inner diameter of the second distal portion of the channel.

[0076] In one embodiment, the body is formed of a shaft including the shaft and a flange including the flange. The flange and the shaft are separate components, and the shaft is supported in a recess in the flange.

[0077] According to another aspect of this disclosure, an armature is provided for use in association with valve actuation. The armature includes a body extending along a longitudinal axis between a first end and an opposing second end. The body includes: a flange located 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 body. A channel extends along the longitudinal axis through the body. The channel opens at both the first and second ends of the body. The shaft includes a plurality of circumferential grooves extending therearound it. The plurality of circumferential grooves are longitudinally spaced from each other along the shaft adjacent to the second end of the body to receive fluid flow thereby increasing the closing speed of the armature.

[0078] In one embodiment, the axis of the body includes an outer surface. The outer surface extends from the second end of the body to the flange. The outer surface has a stepped surface profile.

[0079] In one embodiment, the stepped surface profile of the outer surface of the shaft includes: a first shaft portion adjacent to the flange; and a second shaft portion adjacent to the first shaft portion. The first shaft portion has a first outer diameter and the second shaft portion has a second outer diameter. The second outer diameter is smaller than the first outer diameter. The stepped surface profile also includes a third shaft portion adjacent to the second shaft portion. The third shaft portion extends from the second shaft portion to the second end of the body. The plurality of circumferential grooves are located on the third shaft portion.

[0080] In one embodiment, each circumferential groove in the circumferential groove includes a cylindrical portion and a frustoconical portion. The frustoconical portion provides a transition from the outer surface of the shaft to the cylindrical portion of the circumferential groove.

[0081] In one embodiment, the truncated cone portion extends from the cylindrical portion of the corresponding circumferential groove toward the second end of the body.

[0082] In one embodiment, each circumferential groove in the circumferential groove includes a lip that extends from the cylindrical portion of the circumferential groove to the outer surface of the shaft.

[0083] In one embodiment, the lip is orthogonal to the longitudinal axis, and the truncated cone portion is inclined relative to the longitudinal axis.

[0084] In one embodiment, the plurality of circumferential grooves includes two circumferential grooves.

[0085] While exemplary embodiments of the present disclosure have been illustrated and described in detail in the accompanying drawings and the foregoing description, these embodiments should be considered exemplary rather than limiting. It should be understood that only specific exemplary embodiments have been shown and described, and protection is intended for all changes and modifications falling within the spirit of the claimed invention. It should be understood that while the use of terms such as preferred, preferred, or more preferred in the foregoing description indicates that the features so described may be more desirable, this may not be necessary, and embodiments lacking these may be contemplated as being within the scope of the invention, 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 otherwise 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 otherwise.

Claims

1. An armature assembly for use in association with the actuation of a valve, the armature assembly comprising: An armature, the armature including a body extending along a longitudinal axis between a first end and an opposing second end, the body comprising: Flange, the flange being located at the first end; A shaft extending from the flange and along the longitudinal axis from the flange to the second end of the body; A channel extending along the longitudinal axis, the channel opening at the first and second ends of the body, wherein the second end of the body includes an end surface extending around the channel and projecting radially outward from the outer surface of the shaft to reduce the closing speed of the armature.

2. The armature assembly of claim 1, wherein the body includes a circumferential protrusion extending about the axis at the second end of the body, and the end surface is formed on the circumferential protrusion.

3. The armature assembly of claim 2, wherein the circumferential protrusion comprises: End surface diameter, the end surface diameter being surrounding the longitudinal axis; and The length extends from the end surface along the longitudinal axis along a portion of the axis.

4. The armature assembly according to claim 2, wherein: The shaft of the body includes an outer surface; The outer surface extends from the second end of the body to the flange; and The outer surface has a stepped surface profile.

5. The armature assembly of claim 4, wherein the stepped surface profile of the outer surface of the shaft comprises: A first shaft portion, the first shaft portion being adjacent to the flange, the first shaft portion having a first outer diameter; A second shaft portion is adjacent to the first shaft portion, and the second shaft portion has a second outer diameter, wherein the second outer diameter is smaller than the first outer diameter; and A third shaft portion is adjacent to the second shaft portion and extends from the second shaft portion to the circumferential protrusion. The third shaft portion has a third outer diameter that is smaller than the second outer diameter, and the diameter of the end surface is larger than the third outer diameter.

6. The armature assembly of claim 5, wherein the first shaft portion includes a circumferential groove extending therearound.

7. The armature assembly of claim 5, wherein the end surface diameter and the second diameter are equal to each other.

8. The armature assembly of claim 1, the armature assembly comprising a check ball lift valve located at a second end of the armature, wherein the armature is movable to displace the end surface away from the check ball lift valve to open the valve, and is movable to displace the end surface to contact the check ball lift valve to close the valve.

9. The armature assembly of claim 8, wherein the end surface has an end surface diameter, and the check ball lift valve has a lift valve diameter, and the end surface diameter is larger than the lift valve diameter.

10. The armature assembly of claim 8, wherein the end surface has an end surface diameter, and the check ball lift valve has a lift valve diameter, and the end surface diameter is equal to the lift valve diameter.

11. The armature assembly of claim 1, wherein the end surface is planar.

12. An armature for use in association with the actuation of a valve, the armature comprising: The body, extending along a longitudinal axis between a first end and an opposing second end, comprises: Flange, the flange being located at the first end; A shaft extending from the flange and along the longitudinal axis from the flange to the second end of the body; A channel extending along the longitudinal axis, the channel opening at a first end and a second end of the body, wherein the second end of the body includes an end surface extending around the channel, the end surface being formed by a circumferential protrusion located at the second end of the shaft, the circumferential protrusion projecting radially outward from the outer surface of the shaft.

13. An armature for use in association with the actuation of a valve, the armature comprising: A body extending along a longitudinal axis between a first end and an opposing second end, the body comprising: Flange, the flange being located at the first end; A shaft extending from the flange and along the longitudinal axis from the flange to the second end of the body; and A channel extending along the longitudinal axis, the channel opening at the first end and the second end of the body, wherein the channel includes a first proximal portion and a second distal portion, the inner diameter of the second distal portion being larger than the inner diameter of the first proximal portion of the channel.

14. The armature of claim 13, wherein the shaft includes at least one hole extending through the shaft to the channel.

15. The armature of claim 13, wherein the shaft includes a shaft portion extending from the second end toward the first end, the shaft portion not including any protrusions projecting outward therefrom or any grooves formed therein radially.

16. The armature of claim 13, wherein the length of the plunger within the channel is in a ratio of 2 to the inner diameter of the second distal portion of the channel.

17. The armature of claim 13, wherein the body is formed by a shaft including the shaft and a flange including the flange, the flange and the shaft being separate members, and the shaft being supported in a recess of the flange.

18. An armature for use in association with the actuation of a valve, the armature comprising: A body extending along a longitudinal axis between a first end and an opposing second end, the body comprising: Flange, the flange being located at the first end; A shaft extending from the flange and along the longitudinal axis from the flange to the second end of the body; and A channel extending along the longitudinal axis, the channel opening at the first and second ends of the body, wherein the axis includes a plurality of circumferential grooves extending therearound, the plurality of circumferential grooves being longitudinally spaced from each other along the axis adjacent to the second end of the body to receive fluid flow thereby improving the closing speed of the armature.

19. The armature according to claim 18, wherein: The shaft of the body includes an outer surface; The outer surface extends from the second end of the body to the flange; and The outer surface has a stepped surface profile.

20. The armature of claim 19, wherein the stepped surface profile of the outer surface of the shaft comprises: A first shaft portion, the first shaft portion being adjacent to the flange, the first shaft portion having a first outer diameter; A second shaft portion is adjacent to the first shaft portion, and the second shaft portion has a second outer diameter, wherein the second outer diameter is smaller than the first outer diameter; and A third axial portion, adjacent to the second axial portion, extending from the second axial portion to the second end of the body, wherein the plurality of circumferential grooves are located on the third axial portion.

21. The armature of claim 18, wherein each circumferential groove in the circumferential groove comprises a cylindrical portion and a truncated conical portion, the truncated conical portion providing a transition from the outer surface of the shaft to the cylindrical portion of the circumferential groove.

22. The armature of claim 21, wherein the truncated conical portion extends from the cylindrical portion of the corresponding circumferential groove toward the second end of the body.

23. The armature of claim 21, wherein each of the circumferential grooves includes a lip extending from the cylindrical portion of the circumferential groove to the outer surface of the shaft.

24. The armature of claim 23, wherein the lip is orthogonal to the longitudinal axis, and the truncated cone portion is inclined relative to the longitudinal axis.

25. The armature of claim 18, wherein the plurality of circumferential grooves comprises two circumferential grooves.

Images