USING THE SAME

FIELD OF THE INVENTION

This invention generally relates to nozzle structures suitable for use in a fuel injector for an internal combustion engine. The invention is further applicable to fuel injectors incorporating such nozzle structures. This invention also relates to methods of making such nozzle structures, as well as methods of making fuel injectors incorporating such nozzle structures. The invention further relates to methods of using nozzle structures and fuel injectors in vehicles.

BACKGROUND

There are three basic types of fuel injector systems: port fuel injection (PFI), gasoline direct injection (GDI), and direct injection (DI). While PFI and GDI use gasoline as the fuel, DI uses diesel fuel. Efforts continue to further develop fuel injector nozzle structures and fuel injection systems containing the same so as to potentially increase fuel efficiency and reduce hazardous emissions of internal combustion engines, as well as reduce the overall energy requirements of a vehicle comprising an internal combustion engine.

SUMMARY OF THE INVENTION

The present invention is directed to fuel injector nozzle structures (including, e.g., nozzle plates, valve guides, and combinations thereof) and fuel injectors using the nozzle structures.

GDI engines can, as compared to PFI engines, reduce or avoid fuel wall film in the manifold, improve accuracy of air/fuel ratio during dynamics, reduce throttling losses of the gas exchange by stratified and homogeneous lean operation. As a result, GDI engines may offer improvements in fuel efficiency and reduction of C02, and HC emissions. In GDI engines, however, the fuel injector nozzle structure is in the combustion chamber of the engine. Therefore, when the piston compresses the air/fuel mixture and the spark plug ignites it; a significant amount of heat is generated, which can have damaging effects on the nozzle structure. In addition to high temperatures, the nozzle structure must be able to withstand the pressures generated in the combustion chamber, which can be as high as 200 bars. As a result, the injector nozzle structures for GDI engines are typically thicker, making it more difficult to produce a high quality weld (e.g., a laser weld) of the nozzle structure onto the injector body, welding ring

By making the inner port region thicker and the outer thinner, the nozzle structures described herein may be operatively adapted (e.g., dimensioned, configured or otherwise designed) so as to strike a balance of the above needs. As a result, laser welding of the welding ring of the nozzle structure to an injector body may be less likely to result in unacceptable deformation of the through-holes in the port region, both during welding and use in, e.g., a GDI engine. Maintaining integrity of the through-holes during and after welding of the nozzle structure to an injector body may improve performance of the fuel injector as compared to fuel injectors with through-holes deformed as a result of laser welding of a nozzle structure.

In a first aspect, one or more embodiments of the nozzle structures described herein may include a first face and a second face located on opposite sides of the nozzle structure, wherein the nozzle structure further comprises: a plurality of through-holes formed through the nozzle structure from the first face to the second face, wherein each through-hole of the plurality of through-holes comprises a first or inlet opening on the first face and a second or outlet opening on the second face; and a port region surrounded by a welding ring; wherein the port region contains the first and second openings of each through-hole of the plurality of through-holes; wherein the welding ring comprises an average welding ring thickness that comprises an average of the shortest distances between the first face and the second face of the nozzle structure as measured about a perimeter of the port region; wherein the shortest distance from the geometric center of the first opening of each of the through-holes to the second face of the nozzle structure is greater than the average welding ring thickness.

In a second aspect, one or more embodiments of a fuel injector as described herein may include: an injector body comprising an opening; an injector valve comprising a valve sealing surface facing the opening, wherein the injector valve is movable in the injector body towards and away from the opening such that the valve sealing surface moves towards and away from the opening; and a nozzle structure attached to the injector body over the opening, wherein the nozzle structure comprises a first face and a second face, wherein the first face and the second face are located on opposite sides of the nozzle structure, and wherein only one of the first face and the second face faces the injector valve. The nozzle structure further comprises: a plurality of through-holes formed through the nozzle structure from the first face to the second face, wherein each through-hole of the plurality of through-holes comprises a first or inlet opening on the first face and a second or outlet opening on the second face; and a port region surrounded by a welding ring, wherein the welding ring is attached to the injector body and the port region is suspended in the opening; wherein the port region contains the first and second openings of each through-hole of the plurality of through-holes; wherein the welding ring comprises an average welding ring thickness that comprises an average of the shortest distances between the first face and the second face of the nozzle structure as measured about a perimeter of the port region; wherein the shortest distance from the geometric center of the first opening of each of the through-holes to the second face of the nozzle structure is greater than the average welding ring thickness.

In one or more embodiments according to either of the first or second aspects, the port region of the first face of the nozzle structure comprises a continuously curved surface.

In one or more embodiments according to either of the first or second aspects, the port region of the second face of the nozzle structure comprises a continuously curved surface.

In one or more embodiments according to either of the first or second aspects, the port region of the first face of the nozzle structure comprises a flat surface.

In one or more embodiments according to either of the first or second aspects, the shortest distance from the geometric center of the first opening of each of the through- holes to the second face of the nozzle structure for all through-holes of the plurality of through-holes is the same.

In one or more embodiments according to either of the first or second aspects, the average welding ring thickness is 1 millimeter or less.

In one or more embodiments according to either of the first or second aspects, the shortest distance from the geometric center of the first opening of each of the through- holes to the second face of the nozzle structure is 2 millimeters or less.

In one or more embodiments according to either of the first or second aspects, the shortest distance from the geometric center of the first opening of each through hole of the plurality of through-holes to the second face of the nozzle structure is 100 micrometers or more.

In one or more embodiments according to either of the first or second aspects, each through-hole of the plurality of through-holes comprises a through-hole length measured from the geometric center of the first opening to a geometric center of the second opening along a centerline of the through-hole, wherein the centerline follows a geometric center of a cross-section of the through-hole, and wherein each through-hole of the plurality of through-holes comprises an average cross-sectional area measured transverse to the through-hole length, and further wherein an L/d ratio of the through-hole length to diameter of the average cross-sectional area for all of the through-holes of the plurality of through-holes is 0.1 or greater.

In one or more embodiments according to the second aspect, the plurality of through-holes in the nozzle structure are not deformed as a result of welding the welding ring to the injector body.

In one or more embodiments according to the second aspect, the face of the nozzle structure facing the injector valve comprises a nozzle sealing surface and wherein the injector valve comprises a valve sealing surface, wherein the nozzle sealing surface and the valve sealing surface seal the valve body when in contact with each other in the valve body.

In a third aspect, one or more embodiments of a fuel injection system may include a plurality of the nozzle structures or a plurality of the fuel injectors as described herein.

In a fourth aspect, one or more embodiments of methods of manufacturing a fuel injector nozzle as described herein may include: positioning a nozzle structure as described herein on an opening of a fuel injector body wherein the port region of the nozzle structure is suspended over the opening and the welding ring is in contact with the fuel injector body; and welding the nozzle structure to the injector body by directing laser energy at the welding ring.

In one or more embodiments of method according to the fourth aspect, the plurality of through-holes are not deformed after the welding.

The present invention is even further directed to fuel injection systems. In one exemplary embodiment, the fuel injection system comprises any one of the herein- disclosed nozzles or fuel injectors.

In another exemplary embodiment, the fuel injection system of the present invention comprises a fuel injection system of a vehicle, wherein the fuel injection system comprises:

The above summary is not intended to describe each embodiment or every implementation of the nozzle structures, fuel injectors, fuel injector systems and vehicles as described herein. Rather, a more complete understanding of the invention will become apparent and appreciated by reference to the following Detailed Description and claims in view of the accompanying figures of the drawing.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be more completely understood and appreciated in

consideration of the following detailed description of various embodiments of the invention in connection with the accompanying figures, in which:

FIG. 1 is a side view of one embodiment of an exemplary nozzle structure as described herein in the form of a nozzle plate;

FIG. 2 is a plan view of the nozzle plate of FIG. 1;

FIG. 3 is a side view of another embodiment of an exemplary nozzle structure as described herein;

FIGS. 4 and 5 are plan views of opposing faces of the nozzle structure of FIG. 3; FIG. 6 is a side view of another embodiment of an exemplary nozzle structure as described herein;

FIG. 7 is a plan view of another embodiment of an exemplary nozzle structure as described herein;

FIG. 8 is a side view of the nozzle structure of FIG. 7;

FIG. 9 is a side view of another embodiment of an exemplary nozzle structure as described herein;

FIG. 10 is a side view of another embodiment of an exemplary nozzle structure as described herein;

FIG. 11 is a side cross-sectional view of one embodiment of an exemplary nozzle structure as described herein in a fuel injector as described herein.

FIG. 12 is a schematic of one embodiment of an exemplary fuel injector system as described herein; and

FIG. 13 is a schematic of one embodiment of an exemplary vehicle comprising a fuel injector system as described herein.

DETAILED DESCRIPTION

In the following description, reference is made to the accompanying figures of the drawing which form a part hereof, and in which are shown, by way of illustration, specific embodiments. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention.

One embodiment of an exemplary nozzle structure in the form of a nozzle plate for a fuel injector comprising an injector valve as described herein is depicted in FIGS. 1 and 2. The nozzle plate 10 includes a first or inlet face 12 and a second exterior face 14 located on opposite sides of the nozzle plate 10. The nozzle plate 10 further includes a plurality of through-holes 20 formed through the nozzle plate 10 from the first face 12 to the second face 14. Each through-hole 20 of the plurality of through-holes 20 includes a first or inlet opening 21 on the first face 12 and a second or outlet opening 22 on the second face 14 of the nozzle plate 10.

The nozzle plate 10 further includes a port region 16 surrounded by a welding ring 30. In the nozzle structures as described herein, the port region 16 on each of the first and face 12 and the second face 14 is the region of each respective face that contains all of the first and second openings 21 and 22 of each through-hole 20 of the plurality of through- holes 20 on that face. In other words, the port region 16 of the first face 12 of nozzle plate 10 is the smallest continuous area on the first face 12 that contains all of the first openings

21 of the through-holes 20. Similarly, the port region 16 of the second face 14 of nozzle plate 10 is the smallest continuous area on the second face 14 that contains all of the second openings 22 of the through-holes 20.

The welding ring 30 has an average welding ring thickness 32 that comprises an average of the shortest distances between the first face 12 and the second face 14 of the nozzle plate 10 as measured about a perimeter of the port region 16. Further, the shortest distance from the geometric center of the first opening 21 of each of the through-holes 20 on the first face 12 to the second face 14 of the nozzle plate 10, represented by reference number 29 in FIG. 1, is greater than the average welding ring thickness 32.

Although the port region 16 contains at least the first and second openings 21 and

22 of all of the through-holes 20, in one or more embodiments of the nozzle structures described herein, the nozzle structure may include a larger region of increased thickness as compared to the surrounding welding ring 30. Nozzle plate 10 is one example of such a design because the port region 16 could be increased to include the entire thicker portion of the nozzle plate 10 that is surrounded by the thinner welding ring 30.

One optional feature of the nozzle structures described herein found in nozzle plate 10 is that the port region 16 of the first face 12 of the nozzle plate 10 comprises a flat surface. In one or more embodiments of the nozzle structures described herein, the port region 16 of the first face 12 and the port region 16 of the second face 14 are flat surfaces arranged parallel with each other.

Another optional feature of the nozzle structures described herein found in nozzle plate 10 is that the shortest distance 29 from the geometric center of the first opening 21 of each of the through-holes 20 to the second face 14 of the nozzle plate 10 for all through- holes 20 of the plurality of through-holes 20 is the same.

Still another optional feature of the nozzle structures described herein found in nozzle plate 10 is that the shortest distance 29 from the geometric center of the first opening 21 of each of the through -holes 20 to the second face 14 of the nozzle plate 10 for any through-hole 20 of the plurality of through-holes 20 differs from an average of the shortest distances 29 of the plurality of through-holes 20 by no more than + 10% of the average.

In one or more embodiments of the nozzle structures described herein, the shortest distance from the geometric center of the first opening of each of the through-holes to the second face of the nozzle structure is 2 millimeters or less, or, alternatively, 1.2

millimeters or less. In one or more embodiments of the nozzle structures described herein, the shortest distance from the geometric center of the first opening of each of the through- holes to the second face of the nozzle structure is 800 micrometers or less.

In one or more embodiments of the nozzle structures described herein, the shortest distance from the geometric center of the first opening of each through hole of the plurality of through-holes to the second face of the nozzle structure is 100 micrometers or more. In one or more embodiments of the nozzle structures described herein, the shortest distance from the geometric center of the first opening of each through hole of the plurality of through-holes to the second face of the nozzle structure is 200 micrometers or more. In one or more embodiments of the nozzle structures described herein, the shortest distance from the geometric center of the first opening of each through hole of the plurality of through-holes to the second face of the nozzle structure is 250 micrometers or more.

In one or more embodiments of the nozzle structures described herein, the average welding ring thickness 32 is 1 millimeter or less. In one or more embodiments of the nozzle structures described herein, the average welding ring thickness 32 is 500 micrometers or less.

In one or more embodiments of the nozzle structures described herein, the average welding ring thickness 32 is 100 micrometers or more. In one or more embodiments of the nozzle structures described herein, the average welding ring thickness 32 is 200 micrometers or more. In one or more embodiments of the nozzle structures described herein, the average welding ring thickness 32 is 250 micrometers or more.

The nozzle structures described herein may, in one or more embodiments, be characterized in terms of ratios of the length of the through-holes to the cross-sectional diameter of the through-holes, i.e. the L/d ratio (where the "diameter" for a non-circular through-hole in such a ratio is the diameter of a circle having the same cross-sectional area as the non-circular through-hole). In one or more embodiments, each through-hole of the plurality of through-holes comprises a through-hole length measured from the geometric center of the first opening to a geometric center of the second opening along a centerline of the through-hole. The centerline follows a geometric center of a cross-section of the through-hole. Each through-hole of the plurality of through-holes comprises an average L/d ratio along its length. The average L/d ratio for all of the through-holes of the plurality of through-holes is, in one or more embodiments, 0.1 or greater. In one or more alternative embodiments, the average L/d ratio for all of the through-holes of the plurality of through- holes is 0.1 or greater, 0.2 or greater, 0.3 or greater, 0.4 or greater, 0.5 or greater, 0.6 or greater, 0.7 or greater, 0.8 or greater, 0.9 or greater, or 1.0 or greater. At the upper end of the range, the average L/d ratio may, in one or more embodiments, be 100 or less, 95 or less, 90 or less, 85 or less, 80 or less, 75 or less, 70 or less, 65 or less, 60 or less, 55 or less, 50 or less, 45 or less, 40 or less, 35 or less, 30 or less, 25 or less, 20 or less, 15 or less, 10 or less, or 5 or less.

In one or more embodiments of the nozzle structures described herein, the shortest distance from the geometric center of the first opening of each of the through-holes to the second face of the nozzle structure is greater than the average welding ring thickness. In one or more embodiments, a ratio of the shortest distance from the geometric center of the first opening of each of the through-holes to the second face of the nozzle structure to the average welding ring thickness is 100 or less, 95 or less, 90 or less, 85 or less, 80 or less, 75 or less, 70 or less, 65 or less, 60 or less, 55 or less, 50 or less, 45 or less, 40 or less, 35 or less, 30 or less, 25 or less, 20 or less, 15 or less, 10 or less, 5 or less, 4 or less, 3 or less, or 2 or less, but not as low as 1 or less than 1.

Another embodiment of an exemplary nozzle structure as described herein in the form of a nozzle plate is depicted in FIGS. 3-5. The nozzle plate 110 includes a first face 112, second face 114, and welding ring 130. The port region 116 is defined by a broken line on each of the first and second faces 112 and 114, although, as discussed herein, the port region 116 may encompass the portion of the nozzle plate 110 located within the inner boundary 134 of the welding ring 130. The port region 116 may also be the smallest area that contains all of the openings on each face 112 and 114 of the nozzle plat 110. The exemplary port region 116 of the second face 114 of the nozzle plate 110 comprises a continuously curved surface. As used herein, a "continuously curved surface" is a surface that does not include steps, shoulders, or other planar or ruled surfaces.

Another embodiment of an exemplary nozzle structure as described herein in the form of a nozzle plate as described herein is depicted in FIG. 6. The nozzle plate 210 includes a first face 212, second face 214, and welding ring 230. The port region of the first face 212 of the nozzle plate 210 comprises a continuously curved surface. In this embodiment, the second face 214 of the nozzle plate 210 also comprises a continuously curved surface.

Another embodiment of an exemplary nozzle structure as described herein in the form of a nozzle plate as described herein is depicted in FIGS. 7 and 8. The nozzle plate 310 includes a first face 312, second face 314, and welding ring 330. The port region of the second face 314 of the nozzle plate 310 containing the through-holes 320 comprises a continuously curved surface and a flat surface.

Another embodiment of an exemplary nozzle structure as described herein in the form of a nozzle plate as described herein is depicted in FIG. 9. The nozzle plate 410 includes a first face 412, second face 414, and welding ring 430. The port region of the first face 412 of the nozzle plate 410 containing the openings of the through-holes 420 comprises a flat surface and the second face 414 containing the openings of the through- holes 420 comprises a continuously curved surface.

Another optional feature depicted in the embodiment of nozzle plate 410 are counter-bores 424 formed in the through-holes 420 from the second face 414 of the nozzle plate 410. Counter-bores such as, e.g., counter-bores 424, may be used to provide different characteristics in the fluid emitted from through-holes in nozzle plates as described herein.

Also depicted in connection with nozzle plate 410 is a measurement indicating that the shortest distance 429 from the geometric center of the first opening 421 of a through- hole 420 on the first face 412 of the nozzle plate 410 to the second face 414 of the nozzle plate 410. The illustrative embodiment depicted in FIG. 9 illustrates the concept that the shortest distance from the geometric center of the first opening 421 of through-hole 420 on the first face 412 of the nozzle plate 410 to the second face 414 of the nozzle plate 410 is not necessarily measured through the through-hole 420 itself. Rather, the measurement of distance 429 may be taken along a line that does not extend through the through-hole of the opening 421 from which it is measured.

The welding ring 430 of illustrative nozzle plate 410 has an average welding ring thickness 432 that comprises an average of the shortest distances between the first face 412 and the second face 414 of the nozzle plate 410 as measured about a perimeter of the port region. As described above in more detail with respect to nozzle plate 10, the port region on each face 412 and 414 of the nozzle plate 410 would include the openings of the through-holes on that face. For example, the port region on the first face 412 of nozzle plate 410 is the smallest continuous area on the first face 412 that would contain the first openings 421 of through-holes 420. Further, the shortest distance from the geometric center of the first opening 421 of each of the through-holes 20 on the first face 412 to the second face 414 of the nozzle plate 410, represented by reference number 429 in FIG. 9, is greater than the average welding ring thickness 432.

Still another embodiment of an exemplary nozzle structure as described herein in the form of a nozzle plate as described herein is depicted in FIG. 10. The nozzle plate 510 includes a first face 512, second face 514, and welding ring 530. The port region of the first face 512 of the nozzle plate 510 containing the openings 521a, 521b, and 521c of the through-holes 520a, 520b, and 520c (respectively) comprises a flat surface and the second face 514 containing the openings 522a, 522b, 522c, and 522c' of the through-holes 520a, 520b, and 520c comprises a continuously curved surface.

It should be noted that the through holes 520a, 520b, and 520c have different features to illustrate the concept that nozzle structures as described herein may include through-holes that are different from each other in one or more respects. For example, through-hole 520a follows a curved path from the first face 512 to the second face 514 while through-hole 520b follows a straight path from the first face 512 to the second face 514. In another variation, through-hole 520c includes two openings 522c and 522c' at the second face 514.

The nozzle structures described herein may, in one or more embodiments, be used in fuel injectors of fuel injector systems. One embodiment of an exemplary nozzle structure as described herein in the form of a nozzle plate 610 attached to an injector body 650 of a fuel injector is depicted in FIG. 11. The injector body 650 comprises an opening 652, an injector valve 660 facing the opening 652. The injector valve 660 is movable in the injector body 650 towards and away from the opening as indicated by the arrow located below the injector valve 660 such that the valve sealing surface 662 moves towards and away from the opening 652.

The embodiment of exemplary nozzle plate 610 depicted in FIG. 11 is attached to the injector body 650 over the opening 652. The nozzle plate 610 comprises a first face 612 and a second face 614 located on opposite sides of the nozzle plate 610. Only one of the first face 612 and the second face 614 faces the injector valve 660. In the depicted embodiment, the first face 612 of the nozzle plate 610 faces the injector valve 660, although it should be understood that the second face 614 of the nozzle plate 610 could alternatively face the injector valve 660.

As with the other nozzle plates described herein, nozzle plate 610 includes a plurality of through-holes 620 formed through the nozzle plate 610 from the first face 612 to the second face 614, wherein each through-hole 620 comprises a first or inlet opening 621 on the first face 612 and a second or outlet opening 622 on the second face 614. The port region (i.e., the region containing the openings of the through-holes on the first and second faces 612 and 614) surrounded by a welding ring 630 is suspended over the opening. As discussed herein, the welding ring 630 comprises an average welding ring thickness that comprises an average of the shortest distances between the first face 612 and the second face 614 of the nozzle plate 610 as measured about a perimeter of the port region. Further, the shortest distance from the geometric center of the first opening 621 of each of the through-holes 620 to the second face 614 of the nozzle plate 610 is greater than the average welding ring thickness.

The welding ring 630 is attached to the injector body 650. On the left side of the fuel injector, the welding ring 630 and the injector body 650 are shown as being attached by a side weld 654 formed at the junction of the welding ring 630 and the injector body 650 on the side of the injector body 650. Welding energy (e.g., a laser beam, etc.) may be directed at that junction along the direction of the arrow pointing at the junction to form the side weld 654. Alternatively, or in addition to the side weld 654, attachment of the nozzle plate 610 may be accomplished using a top weld 656 formed by directing energy at the second face 614 of the nozzle plate (e.g., in the direction of the arrow pointing at top weld 656).

Because the welding ring 630 of the nozzle plate 610 is thinner than the port region, the plurality of through-holes 620 in the nozzle plate 610 are not deformed as a result of welding the welding ring 630 to the injector body 650. In other words, the shapes and dimensions of the through-holes 620 are not changed after welding from their pre- welding shapes and dimensions.

Another optional feature depicted in connection with FIG. 11 is that the face of the nozzle plate 610 facing the injector valve 660 (first face 612 in the depicted embodiment) comprises a nozzle sealing surface 618 and the injector valve 660 comprises a valve sealing surface 662, wherein the nozzle sealing surface 618 and the valve sealing surface 662 seal the injector body 650 when in contact with each other in the injector body 650 such that fluid cannot pass through the through-holes of the nozzle plate 610.

Further, although not shown in the figures, any of the herein-described nozzle structures may further comprise one or more alignment surface features that enable (1) alignment of nozzle structure (i.e., in the x- y plane) relative to a fuel injector body and (2) rotational alignment/orientation of nozzle structure (i.e., a proper rotational position within the x-y plane) relative to a fuel injector body. The one or more alignment surface features may aid in positioning nozzle structure and nozzle through-holes therein. The one or more alignment surface features on nozzle structure may be present along one or both faces of the nozzle structure, the periphery of the nozzle structure, or any combination of one or both faces and the periphery of the nozzle structures. Further, the one or more alignment surface features on nozzle structure may comprise, but are not limited to, a visual marking, an indentation within nozzle structure, a raised surface portion along nozzle structure, or any combination of such alignment surface features.

The nozzle structures as described herein may include a port region and welding ring that are portions of a one-piece, completely integral article (e.g., a molded, electroformed, etc. article). In one or more alternative embodiments, portions of the nozzle structures described herein may be manufactured as separate articles joined together using any suitable technique or combination of techniques, e.g., pressing (using interference fits), welding, adhesives, etc.

In one or more embodiments, a plurality of the fuel injectors using the nozzle structures as described herein may be used in an engine such as, e.g., a GDI or a PFI engine. One embodiment of an exemplary fuel injector system is depicted in FIG. 12. The depicted fuel injector system may include, inter alia, a fuel injector 701 (incorporating one or more nozzle structures 710 as described herein), fuel source/tank 704, fuel pump 703, fuel filter 702, fuel injector electrical source 705, and internal combustion engine 706. FIG. 13 is a schematic depicting the internal combustion engine 706 of FIG. 12 in a vehicle 800, wherein the internal combustion engine 706 includes one or more fuel injectors including one or more of the nozzle structures described herein.

The nozzle structures disclosed herein can be fabricated of any suitable weldable material or materials such as, e.g., silver, passivated silver, gold, rhodium, aluminum, enhanced reflectivity aluminum, copper, indium, nickel, chromium, tin, and alloys thereof. The process of manufacturing the nozzle structures described herein may include the construction of molds using multiphoton, such as two photon, processes like those disclosed in International Patent Application Publications WO 2011/014607 and WO 2012/106512. In particular, multiphoton processes can be used to fabricate various microstructures, which can at least include one or more hole forming features. Such hole forming features can, in turn, be used as molds to fabricate through-holes for use in nozzle structures as described herein.

Microstructured articles are described herein that may, in one or more

embodiments, be suitable for use as nozzle structures (including, e.g., nozzle plates, valve guides, nozzle plate and valve guide structures, and other structural combinations) used in fuel injector nozzles. It should be understood that the term "nozzle" or "nozzle structure", as used herein, may have a number of different meanings in the art. For example, U.S. Patent Publication No. 2009/0308953 Al (Palestrant et al.), discloses an "atomizing nozzle" which includes a number of elements, including an orifice insert 24 and an occluder chamber 50. The understanding and definition of "nozzle structure" put forth herewith may, for example, include such structure like the orifice insert 24 of Palestrant et al. along with a portion, most or all of the structure corresponding to the chamber 50. In general, the nozzle structure of the current description can be understood as including the structure of an atomizing spray system from which the spray is ultimately emitted, see e.g., Merriam Webster's dictionary definition of nozzle ("a short tube with a taper or constriction used (as on a hose) to speed up or direct a flow of fluid." Further

understanding may be gained by reference to U.S. Patent No. 5,716,009 (Ogihara et al.) issued to Nippondenso Co., Ltd. (Kariya, Japan). In this reference, again, fluid injection "nozzle" is defined broadly as the multi-piece valve element 10 ("fuel injection valve 10 acting as fluid injection nozzle. . ." - see col. 4, lines 26-27 of Ogihara et al.). The current definition and understanding of the term "nozzle structure" as used herein would relate, e.g., to first and second orifice plates 130 and 132, valve body 26, and potentially sleeve 138 (see Figs. 14 and 15 of Ogihara et al.), for example, which are located immediately proximate the fuel spray. Similar structures that may be referred to as "nozzle structure", as described herein, is disclosed in U.S. Patent No. 5,127, 156 (Yokoyama et al.) to Hitachi, Ltd. (Ibaraki, Japan). There, the nozzle 10 is defined separately from elements of the attached and integrated structure, such as " swirl er" 12 (see Fig. 1). Such separate elements may be formed, in part or completely, as one unitary structure. The above- described structures may be included when the term "nozzle structure" is referred to throughout the remainder of the description and claims.

The nozzle structures described herein may comprise (or consist essentially of or consist of) any one of the disclosed nozzle features or any combination of two or more of the disclosed nozzle features. In addition, although not shown in the figures and/or described in detail herein, the nozzle structures described herein may further comprise one or more nozzle features disclosed in (1) International Patent Application Publication WO 2014/022646 ("GDI Fuel Injectors with Non-Coined Three-Dimensional Nozzle Outlet Face"); (2) International Patent Application Publication WO 2014/022624 ("Targeting of Fuel Output by Off- Axis Directing of Nozzle Output Streams"); (3) International Patent Application Publication WO 2014/022650 ("Fuel Injector Nozzles with at Least One Multiple Inlet Port and/or Multiple Outlet Port"); and (4) International Patent Application Publication WO 2014/022631 ("Fuel Injectors with Improved Coefficient of Fuel

Discharge").

The nozzle structures described herein may be formed using any method as long as the resulting nozzle structures have one or more combinations of the features as described herein. Although the methods of making nozzle structures as described herein are not limited to the methods disclosed in International Patent Publication No. WO 2012/106512, nozzle structures as described herein may be formed using the methods as disclosed in International Patent Publication No. WO 2012/106512 (see, in particular, the method steps described in reference to FIGS. 1 A-1M).

RELATED APPLICATIONS:

The nozzle structures, fuel injectors and methods as discussed herein may be, in one or more embodiments, used in combination with the methods of manufacturing nozzle structures as discussed in and/or the nozzle structures described in the following copending applications: METHOD OF ELECTROFORMING MICROSTRUCTURED ARTICLES, U.S. Provisional Application No. 62/438,567, filed on December 23, 2016 (Attorney Docket No. 78371US002) and, MAKING NOZZLE STRUCTURES ON A STRUCTURED SURFACE, U.S. Provisional Application No. 62/438,561, filed on December 23, 2016 (Attorney Docket No. 77312US002).

ILLUSTRATIVE EMBODIMENTS:

1. A nozzle structure (e.g., a nozzle plate) comprising a first face and a second face located on opposite sides of the nozzle structure, wherein the nozzle structure further comprises:

a plurality of through-holes formed through the nozzle structure from the first face to the second face, wherein each through-hole of the plurality of through-holes comprises a first opening on the first face and a second opening on the second face; and

a port region surrounded by a welding ring;

wherein the port region contains the first and second openings of each through- hole of the plurality of through-holes;

wherein the welding ring comprises an average welding ring thickness that comprises an average of the shortest distances between the first face and the second face of the nozzle structure as measured about a perimeter of the port region;

wherein the shortest distance from the geometric center of the first opening of each of the through-holes to the second face of the nozzle structure is greater than the average welding ring thickness.

2. A fuel injector comprising:

an injector body comprising an opening;

an injector valve comprising a valve sealing surface facing the opening, wherein the injector valve is movable in the injector body towards and away from the opening such that the valve sealing surface moves towards and away from the opening; and

a nozzle structure (e.g., a nozzle plate) attached to the injector body over the opening, wherein the nozzle structure comprises a first face and a second face, wherein the first face and the second face are located on opposite sides of the nozzle structure, and wherein only one of the first face and the second face faces the injector valve, wherein the nozzle structure further comprises:

a plurality of through-holes formed through the nozzle structure from the first face to the second face, wherein each through-hole of the plurality of through-holes comprises a first opening on the first face and a second opening on the second face; and a port region surrounded by a welding ring, wherein the welding ring is attached to the injector body and the port region is suspended in the opening; wherein the port region contains the first and second openings of each through-hole of the plurality of through-holes;

wherein the welding ring comprises an average welding ring thickness that comprises an average of the shortest distances between the first face and the second face of the nozzle structure as measured about a perimeter of the port region;

wherein the shortest distance from the geometric center of the first opening of each of the through-holes to the second face of the nozzle structure is greater than the average welding ring thickness.

3. A nozzle structure or a fuel injector according to embodiment 1 or 2, wherein the port region of the first face of the nozzle structure comprises a continuously curved surface.

4. A nozzle structure or a fuel injector according to any one of embodiments 1 to 3, wherein the port region of the second face of the nozzle structure comprises a

continuously curved surface.

5. A nozzle structure or a fuel injector according to any one of embodiments 1 to 4, wherein the port region of the first face of the nozzle structure comprises a flat surface.

6. A nozzle structure or a fuel injector according to any one of embodiments 1 to 5, wherein the shortest distance from the geometric center of the first opening of each of the through-holes to the second face of the nozzle structure for all through-holes of the plurality of through-holes is the same.

7. A nozzle structure or a fuel injector according to any one of embodiments 1 to 5, wherein the shortest distance from the geometric center of the first opening of each of the through-holes to the second face of the nozzle structure for any through-hole of the plurality of through-holes differs from an average of the shortest distances of the plurality of through-holes by no more than + 10% of the average. 8. A nozzle structure or a fuel injector according to any one of embodiments 1 to 7, wherein the port region of the first face and the port region of the second face are flat surfaces arranged parallel with each other. 9. A nozzle structure or a fuel injector according to any one of embodiments 1 to 8, wherein the average welding ring thickness is 1 millimeter or less, or 500 micrometers or less.

10. A nozzle structure or a fuel injector according to embodiment 9, wherein the average welding ring thickness is 100 micrometers or more, 200 micrometers or more, or 250 micrometers or more.

11. A nozzle structure or a fuel injector according to any one of embodiments 1 to 10, wherein the shortest distance from the geometric center of the first opening of each of the through-holes to the second face of the nozzle structure is 2 millimeters or less, or 1.2 millimeters or less, or 800 micrometers or less.

12. A nozzle structure or a fuel injector according to any one of embodiments 1 to 11, wherein the shortest distance from the geometric center of the first opening of each through hole of the plurality of through-holes to the second face of the nozzle structure is 100 micrometers or more, 200 micrometers or more, or 250 micrometers or more.

13. A nozzle structure or a fuel injector according to any one of embodiments 1 to 12, wherein each through-hole of the plurality of through-holes comprises a through-hole length measured from the geometric center of the first opening to a geometric center of the second opening along a centerline of the through-hole, wherein the centerline follows a geometric center of a cross-section of the through-hole, and wherein each through-hole of the plurality of through-holes comprises an average cross-sectional area measured transverse to the through-hole length, and further wherein an L/d ratio of the through-hole length to diameter of the average cross-sectional area for all of the through-holes of the plurality of through-holes is 0.1 or greater , 0.2 or greater, or 0.3 or greater. 14. A nozzle structure or a fuel injector according to embodiment 13, wherein the L/d ratio for all of the through-holes of the plurality of through-holes is 100 or less, 50 or less, or 20 or less. 15. A nozzle structure or a fuel injector according to any one of embodiments 1 to 14, wherein the port region and the welding ring of the nozzle structure are a one-piece, completely integral article.

16. A fuel injector according to any one of embodiments 2 to 15, wherein the plurality of through-holes in the nozzle structure are not deformed as a result of welding the welding ring to the injector body.

17. A fuel injector according to any one of embodiments 2 to 16, wherein the face of the nozzle structure facing the injector valve comprises a nozzle sealing surface and wherein the injector valve comprises a valve sealing surface, wherein the nozzle sealing surface and the valve sealing surface seal the valve body when in contact with each other in the valve body.

18. A gasoline direct injection system comprising a plurality of the nozzle structures according to any one of embodiments 1 to 15 or a plurality of the fuel injectors according to any one of embodiments 2 to 19.

19. An engine comprising the gasoline direct injection system according to

embodiment 18.

20. A vehicle comprising the gasoline direct injection system according to

embodiment 18.

21. A port fuel injection system comprising a plurality of the nozzle structures or a plurality of the fuel injectors according to any one of embodiments 1 to 15 or a plurality of the fuel injectors according to any one of embodiments 2 to 17.

22. An engine comprising the port fuel injection system according to embodiment 21. 23. A vehicle comprising the port fuel injection system according to embodiment 21.

24. A method comprising:

positioning a nozzle structure according to any one of embodiments 1 to 17 on an opening of a fuel injector body wherein the port region of the nozzle structure is suspended over the opening and the welding ring is in contact with the fuel injector body; and

welding the nozzle structure to the injector body by directing laser energy at the welding ring.

25. A method according to embodiment 24, wherein the plurality of through-holes are not deformed after the welding.

26. A method according to any one of embodiments 24 to 25, wherein an injector valve is located in the injector body and configured to move towards and away from the opening, and wherein only one of the first face and the second face of the nozzle structure faces the injector valve.

27. A method according to any one of embodiments 24 to 26, wherein the face of the nozzle structure facing the injector valve comprises a nozzle sealing surface and wherein the injector valve comprises a valve sealing surface, wherein the nozzle sealing surface and the valve sealing surface seal the valve body when in contact with each other in the valve body. It should be understood that although the above-described nozzles, nozzle structures, fuel injectors, fuel injector systems, and methods are described as "comprising" one or more components, features or steps, the above-described nozzles, nozzle structures, fuel injectors, fuel injector systems, and methods may "comprise," "consists of," or "consist essentially of any of the above-described components and/or features and/or steps of the nozzles, nozzle structures, fuel injectors, fuel injector systems, and methods.

Consequently, where the present invention, or a portion thereof, has been described with an open-ended term such as "comprising," it should be readily understood that (unless otherwise stated) the description of the present invention, or the portion thereof, should also be interpreted to describe the present invention, or a portion thereof, using the terms "consisting essentially of or "consisting of or variations thereof as discussed below.

As used herein, the terms "comprises," "comprising," "includes," "including," "has," "having," "contains", "containing," "characterized by" or any other variation thereof, are intended to encompass a non-exclusive inclusion, subject to any limitation explicitly indicated otherwise, of the recited components. For example, a nozzle, nozzle structure, fuel injector, fuel injector system, and/or method that "comprises" a list of elements (e.g., components or features or steps) is not necessarily limited to only those elements (or components or features or steps), but may include other elements (or components or features or steps) not expressly listed or inherent to the nozzle, nozzle structure, fuel injector, fuel injector system, and/or method.

As used herein, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a" or "the" component may include one or more of the components and equivalents thereof known to those skilled in the art. Further, the term "and/or" means one or all of the listed elements or a combination of any two or more of the listed elements.

Further, the term "comprises" and variations thereof do not have a limiting meaning where these terms appear in the accompanying description. Moreover, "a," "an," "the," "at least one," and "one or more" are used interchangeably herein.

As used herein, the transitional phrases "consists of and "consisting of exclude any element, step, or component not specified. For example, "consists of or "consisting of used in a claim would limit the claim to the components, materials or steps specifically recited in the claim except for impurities ordinarily associated therewith (i.e., impurities within a given component). When the phrase "consists of or "consisting of appears in a clause of the body of a claim, rather than immediately following the preamble, the phrase "consists of or "consisting of limits only the elements (or components or steps) set forth in that clause; other elements (or components) are not excluded from the claim as a whole.

As used herein, the transitional phrases "consists essentially of and "consisting essentially of are used to define a nozzle, nozzle structure, fuel injector, fuel injector system, and/or method that includes materials, steps, features, components, or elements, in addition to those literally disclosed, provided that these additional materials, steps, features, components, or elements do not materially affect the basic and novel

characteristic(s) of the claimed invention. The term "consisting essentially of occupies a middle ground between "comprising" and "consisting of. Further, it should be understood that the herein-described nozzles, nozzle structures, fuel injectors, fuel injector systems, and/or methods may comprise, consist essentially of, or consist of any of the herein- described components and features, as shown in the figures with or without any additional feature(s) not shown in the figures. In other words, in some embodiments, the nozzles, nozzle structures, fuel injectors, fuel injector systems, and/or methods of the present invention may have any additional feature that is not specifically shown in the figures. In some embodiments, the nozzles, nozzle structures, fuel injectors, fuel injector systems, and/or methods of the present invention do not have any additional features other than those (i.e., some or all) shown in the figures, and such additional features, not shown in the figures, are specifically excluded from the nozzles, nozzle structures, fuel injectors, fuel injector systems, and/or methods.

The complete disclosure of the patents, patent documents, and publications identified herein are incorporated by reference in their entirety as if each were individually incorporated. To the extent there is a conflict or discrepancy between this document and the disclosure in any such incorporated document, this document will control.

From the above disclosure of the general principles of the present invention and the preceding detailed description, those skilled in this art will readily comprehend the various modifications, re-arrangements and substitutions to which the present invention is susceptible, as well as the various advantages and benefits the present invention may provide. Therefore, the scope of the invention should be limited only by the following claims and equivalents thereof. In addition, it is understood to be within the scope of the present invention that the disclosed and claimed nozzle structures may be useful in other applications (i.e., not as fuel injector nozzles). Therefore, the scope of the invention may be broadened to include the use of the claimed and disclosed structures for such other applications.