Claims
- 1. A fuel injection system for an internal combustion engine comprising:
a fuel injector having an injector housing with first and second opposing portions with an injector passage extending between said first and second portions, and a valve disposed in said injector passage for selectively permitting fuel to flow from said first portion to said second portion; a fuel rail having a fuel passage having a first opening receiving said first portion with said injector passage in fluid communication with said fuel passage; an intake manifold having a second opening receiving said second portion; and a polymer layer extending from said fuel rail and said intake manifold about at least a portion of said fuel injector sealing said first and second portions respectively to said fuel rail and said intake manifold for preventing fuel from leaking from the fuel injection system.
- 2. The system according to claim 1, wherein said layer forms said fuel rail and defines said fuel passage.
- 3. The system according to claim 1, wherein said layer forms said intake manifold.
- 4. The system according to claim 1, wherein said intake manifold includes an upper portion having a plenum with a plurality of apertures, and a lower portion secured to said upper portion having a plurality of individual passageways with said each of said plurality of apertures in fluid communication with a corresponding one of said plurality of passageways and said second portion of said injector in one of said passageways.
- 5. The system according to claim 1, wherein fuel rail includes a cavity and said injector includes electrical contacts extending into said cavity, said system further including wires disposed within said cavity connected to said contacts and a seal enclosing said wires within said cavity.
- 6. The system according to claim 5, wherein seal is plastic molded into said cavity.
- 7. The system according to claim 5, wherein said wires is a ribbon including a plurality of wires adjoining one another.
- 8. The system according to claim 5, wherein said contacts includes first and second contacts and said wires includes first and second wires respectively including first and second individual connectors independent of one another respectively connected to said first and second contacts.
- 9. The system according to claim 1, wherein said layer is unitary extending from said fuel rail to said intake manifold substantially enclosing said fuel injector and interconnecting said fuel rail with said intake manifold.
- 10. A fuel injection system for an internal combustion engine comprising:
a fuel injector having an injector housing with first and second opposing portions with an injector passage extending between said first and second portions, and a valve disposed in said injector passage for selectively permitting fuel to flow from said first portion to said second portion; a fuel rail having a fuel passage having a first opening receiving said first portion with said injector passage in fluid communication with said fuel passage; and a polymer layer extending from said fuel rail about at least a portion of said fuel injector sealing said first portion to said fuel rail for preventing fuel from leaking from the fuel injection system.
- 11. The system according to claim 10, further including an intake manifold having a second opening receiving said second portion, said polymer layer extending from said intake manifold about at least a portion of said fuel injector sealing said second portion to said intake manifold for preventing fuel from leaking from the fuel injection system.
- 12. The system according to claim 10, further including an intake manifold having a passageway with a second opening removably receiving said second portion with said injector passage in fluid communication with said fuel passage, and a seal arranged between said fuel rail and said second opening.
- 13. The system according to claim 10, wherein said layer forms said fuel rail and defines said fuel passage.
- 14. The system according to claim 10, wherein fuel rail includes a cavity and said injector includes electrical contacts extending into said cavity, said system further including wires disposed within said cavity connected to said contacts and a seal enclosing said wires within said cavity.
- 15. The system according to claim 14, wherein seal is plastic molded into said cavity.
- 16. The system according to claim 14, wherein said wires is a ribbon including a plurality of wires adjoining one another.
- 17. The system according to claim 14, wherein said contacts includes first and second contacts and said wires includes first and second wires respectively including first and second individual connectors independent of one another respectively connected to said first and second contacts.
- 18. A method of forming a fuel injection system comprising the steps of:
a) providing a fuel injector; b) molding a polymer material about a portion of the fuel injector; and c) forming a fuel rail with the polymer material.
- 19. The method according to claim 18, further including step d) molding the polymer material about another portion of the fuel injector; and e) forming an intake manifold with the polymer material.
- 20. The method according to claim 18, wherein step a) includes providing a fuel injector with electrical contacts, and c) includes creating a cavity in the fuel rail receiving the electrical contacts.
- 21. The method according to claim 20, further including step d) arranging wires in the cavity and connecting the wires to the electrical contacts.
- 22. The method according to claim 21, further including step e) molding a plastic into the cavity and enclosing the wires.
RELATED APPLICATIONS
[0001] This application claims priority to provisional application No. 60/242,870, filed Oct. 24, 2000.
Provisional Applications (1)
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Number |
Date |
Country |
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60242870 |
Oct 2000 |
US |