Metal working – Method of mechanical manufacture – Prime mover or fluid pump making
Reexamination Certificate
1999-06-30
2001-07-24
Cuda Rosenbaum, I (Department: 3726)
Metal working
Method of mechanical manufacture
Prime mover or fluid pump making
C029S890129, C029S890132
Reexamination Certificate
active
06263569
ABSTRACT:
FIELD OF THE INVENTION
This invention relates generally to fuel injectors of the type that are used to inject fuel into the induction system of an internal combustion engine, and particularly to a standardized fuel injector configuration capable of accommodating multiple injector customers.
BACKGROUND OF THE INVENTION
Currently, fuel injectors are molded in several lengths, and multiple electrical plug designs are required for each of multiple customers. For each injector length, for example, there may be as many as five different connector or plug designs required by a multitude of customers. Each different plug design requires re-molding of the entire injector assembly, to incorporate the various plug designs. This not only costs excess dollars in extra molding tools, but also in electrical contact tooling.
Furthermore, for each different plug design, the injector must be assembled and tested individually, requiring much changeover time to be spent in both assembly and test areas of production. The multitude of connector or plug designs for each of a multitude of customers results in a statistical exercise of great magnitude, to properly assemble and test each separate design.
It is seen then that there exists a need for a standardized molded fuel injector geometry which comprises a standard post electrical plug assembly, capable of receiving multiple lengths and designs of plugs to accommodate multiple customers, which can be installed after assembly and testing of the standard fuel injector.
SUMMARY OF THE INVENTION
This need is met by the method of manufacturing and testing, for a plurality of customers, a standardized fuel injector geometry, in accordance with the present invention. Thus, any of a multitude of different electrical plug or cover designs can be ultrasonically welded in place on a standardized molded fuel injector geometry after final assembly or test processes are passed, thereby creating a customer-ready standardized fuel injector geometry. This eliminates re-molding of the entire injector assembly to accommodate each different plug design for each of a plurality of customers. The method of generating a standardized fuel injector and testing said standardized fuel injector for use by a plurality of customers allows for reduced process or equipment investment and a standard product geometry for the molded injector.
In accordance with one embodiment of the present invention, a method of manufacturing and testing a standardized fuel injector configuration for a plurality of customers is provided. Initially, a fuel injector is molded, the fuel injector having an inlet end and an outlet end. Passage of fuel through the fuel injector is controlled between the inlet end and the outlet end. The electrical terminal geometry to be molded with the electrically operated fuel injector is selected, and electrical current flow for the fuel injector is generated through the electrical terminals. The selected electrical terminal geometry is accessible for connection to any of a plurality of different connectors, which are independently molded. Test processes are conducted on the fuel injector and, subsequently, an independently molded post electrical plug is installed, encompassing the electrical terminals. The post electrical plug allows for connection to a mating connector, via which the injector is operated from an electronic engine control. The post electrical plug of the present invention is configured to accommodate multiple fuel injector geometries for a plurality of fuel injector customers.
It is an advantage of the present invention that a single mold design is provided for each injector length, with the standardized fuel injector geometry of the present invention being capable of accommodating multiple plug designs for a plurality of fuel injector customers.
For a full understanding of the nature and objects of the present invention, reference may be had to the following detailed description taken in conjunction with the accompanying drawings and the appended claims.
REFERENCES:
patent: 5155461 (1992-10-01), Teerman et al.
patent: 5157967 (1992-10-01), Wieczorek
patent: 5185919 (1993-02-01), Hickey
patent: 5625946 (1997-05-01), Wildeson et al.
patent: 5775599 (1998-07-01), Smith et al.
patent: 5937520 (1999-08-01), Earhart et al.
Cuda Rosenbaum I
Siemens Automotive Corporation
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