Provisional Application Serial No. 60/052,693, (Attorney Docket 97 P 7674 US), entitled"Methods For Mounting Fuel Pressure Regulators,"filed on 16 July 1997.

Both cited patent applications are expressly incorporated in its entirety by reference.

BACKGROUND OF THE INVENTION A current industry trend in the automotive industry is to mold various components of an engine from composite materials, such as plastic, instead of from metallic materials which was the standard practice. However, if not all of the components were manufactured from the composite material, a problem resulted when metallic components were to be connected to composite components at the mounting interface. Producing a mounting interface and retention mechanism for a pressure regulator on the fuel passage posed mold tooling challenges above those encountered for a separate fuel rail. Small complex details that may be achieved in a mold for a fuel rail are of a significantly greater concern on large molds that produce an intake manifold.

U. S. Patent 5,390,638, issued to Hornby, describes a fuel rail assembly in which metallic tubes are connected to main plastic fuel tubes.

The main fuel tubes 52,54 have been produced by injection molding from suitable material for handling pressurized liquid fuel, such as gasoline. Main fuel tube 54 includes an integral socket 60 into which a conventional fuel pressure regulator 62 is inserted and retained in a secure, sealed manner.

The retention means includes a retention clip 194 comprising a flat,

somewhat U-shaped fork 196 having tines 198. An aperture tongue 200 is spaced from, but generally parallel with the fork 196. Cup 60 contains a plurality of slits into which the tines are inserted. These tines along with the tongue 20 are employed to retain the fuel regulator in place.

U. S. Patent 5,577,478, issued to Tuckey, illustrates a fuel pressure rail assembly constructed from metallic material into which a fuel pressure regulator is secured. A spring clip 20 having a horseshoe shaped resilient band 130 is constructed and arranged to snap through the pressure regulator skirt 86 and flange 88 to secure the regulator in place.

U. S. Patent 5,094,211, issued to Mahnke et al, relates to a device for mounting a fuel regulator 32 within a cup section 52 of an automotive fuel rail. An upper mounting flange 86 is used to secure the fuel regulator within the cup 50.

U. S. Patent 5,070,844, issued to Daly, illustrates a fuel rail assembly 10 comprising a plurality of rigid composite injector-receiving socket members 12 connected together in a straight line by rigid straight metallic tubes 14. Hairpin clips 54 assist in the connection of the metallic tubes 14 to the socket members 12.

Although the patent to Hornby et al describes a device in which a fuel pressure regulator is secured into a plastic fuel rail by the utilization of a spring clip, it was believed necessary to develop additional devices and methods of securing the fuel pressure regulator to a molded plastic fuel rail as described in the present invention.

SUMMARY OF THE INVENTION Various deficiencies in the prior art are addressed by the present invention directed to various methods and devices for securing integral and stand alone configurations for return and returnless flow operation pressure regulators to fuel rails molded by composite metallic material. However, it is to be noted that the means and methods of attaching the fuel pressure regulator to the fuel rails can also be fabricated from

metallic material.. Although the appearance of these connections might change, the function would be retained.

When used with stand alone fuel pressure regulators, various devices can be used to secure the regulator to the end of the composite fuel rail. For example, various types of clips can be used to secure a bracket attached to the fuel pressure regulator to the end of the fuel rail. A barbed end clip that directly withstands the fuel pressure at loading can be used as well as a molded version having a strap spanning two barbs. A shear clip design engaging a slot molded into the fuel passage having flexible tabs at the ends thereof would provide a locking feature. Furthermore, a living hinge can be employed encircling both the fuel pressure regulator as well as the end of the fuel rail.

Additionally, the stand alone fuel pressure regulator can be secured to the end of the fuel rail using a locking pin to secure the fuel regulator within a slot molded into a retaining member provided at the end of the fuel rail. The fuel regulator is initially inserted into the retaining member by a twisting motion. Other securing mechanisms would include spring action devices molded within the manifold. It is noted that the retaining feature must limit rotation after the regulator has been installed.

When used with integral fuel pressure regulators, a cap can be attached to the fuel passage by engaging a series of slots with corresponding features on the fuel passage. This cap would include various engaging members, such as small lugs for engaging ribs directly molded onto the retaining member connected to the fuel rail. Similar to the stand alone fuel regulator, clips could also be used to hold the pressure regulator properly in place.

The foregoing features and other objects will become apparent from a reading of the following specification in connection with the drawings, wherein like parts have the same index numerals.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated herein and constitute part of this specification, include one or more presently preferred embodiments of the invention, and together with a general description given above and a detailed description given below, serve to disclose principes of the invention in accordance with a best mode contemplated for carrying out the invention.

FIG. 1 is a perspective view of an intake manifold with an integral fuel passage showing a typical pressure regulator in position; FIG. 2 is an exploded diagram of a stand alone fuel pressure regulator to be connected to a fuel rail; FIG. 3 is a perspective view of the pressure regulator of FIG. 2 connected to the fuel rail; FIG. 4 is a view showing two devices for fastening the regulator shown in FIG. 2 to the fuel rail; FIG. 5 is an exploded view of another embodiment of a device for connecting a stand alone pressure regulator to a fuel rail; FIG. 6 is a perspective view of the pressure regulator of FIG. 5 connected to the fuel rail; FIG. 7 is a view of one of the fastening elements shown in FIG.

5; FIG. 8 is an exploded view of another embodiment of the element fastening the stand alone fuel regulator to the fuel rail; FIG. 9 is a perspective view of the regulator-fuel rail assembly of FIG. 8; FIG. 10 is an exploded view of another embodiment showing a stand alone pressure regulator-fuel rail connection assembly; FIG. 11 is a perspective view showing the connection of the regulator of FIG. 10 to the fuel rail; FIG. 12 is an exploded view showing several fastening elements for connecting an integral pressure regulator to a fuel line;

FIG. 13 is a detailed view of one of the fastening elements of FIG. 12; FIG. 14 is a detailed view of the second fastening element of FIG. 12; FIG. 15 is a perspective view showing the integral pressure regulator connected to the fuel rail; FIG. 16 is an exploded view showing the integral pressure regulator connected to the fuel rail by another embodiment; FIG. 17 is a perspective view of the pressure regulator of FIG.

16 connected to the fuel rail; FIG. 18 is an exploded view of the integral pressure regulator connected to the fuel rail by another embodiment; FIG. 19 is a perspective view showing the integral pressure regulator of FIG. 18 connected to the fuel rail; FIG. 20 is a perspective view of a demand-type returnless integral pressure regulator connected to the fuel line; FIG. 21 is a sectional view taken through lines B-B of FIG. 20; FIG. 22 is a perspective view taken through lines A-A of FIG.

20; FIG. 23 is an exploded view showing a demand-type integral returnless pressure regulator connected to a fuel line by one of two fastening elements; FIG. 24 shows a perspective view of the connection illustrated in FIG. 23; FIG. 25 shows an exploded view of a demand-type integral returnless pressure regulator connected to a fuel line by another embodiment; FIG. 26 is a perspective view of the connection illustrated in FIG. 25; FIG. 27 is an exploded view showing a demand-type integral returnless regulator connected to a fuel rail by another embodiment;

FIG. 28 shows the connection illustrated in FIG. 27; FIG. 29 is an exploded view of the demand-type integral returnless fuel regulator connected to a fuel line by another embodiment; FIG. 30 is a perspective view shown in the combination illustrated in FIG. 29; FIG. 31 is a sectional view along lines C-C of FIG. 32; FIG. 32 is an exploded view showing the demand-type integral returniess pressure regulator connected to a fuel line by another embodiment; and FIG. 33 is a perspective view of the combination illustrated in FIG. 32.

DESCRIPTION OF THE PREFERRED EMBODIMENTS While the present invention will be described hereinafter in connection with preferred embodiments thereof, it will be understood that it is not intended to limit the invention to those embodiments. On the contrary, it is intended to cover all alternatives, modifications, and equivalents as may be included in the spirit and scope of the invention as defined by the appended claims.

FIG. 1 illustrates a typical intake manifold 14 and was included to show the positioning of a pressure fuel regulator 16 with respect to a fuel rail 10. Although the fuel rail 10 is constructed from a composite material such as plastic, this need not be the case and the teaching of the present invention can be extended to manifold castings or separate fuel lines of various construction methods. A plurality of connectors 12 are included through which metering valves or injectors deliver on a suitable electric command, the quantity of fuel necessary to form the correct pressurized mixture to supply to an internal combustion engine. The fuel pressure regulator 16 sits within a cup 18 directly molded or connected to the fuel rail 10. The types of fasteners used to retain the pressure regulator 16 firmly within the cup 18 will be explained with respect to the remaining figures of the present invention. The fuel rail or line 10 is connected to a fuel pump through

a line 22 by a standard quick connection 24, as well as other conventional connection methods. The regulator 16 may communicate with the intake manifold vacuum via a conduit (not shown) coupled to a nipple 20 associated with the regulator's upper housing. Although FIG. 1 illustrates the positioning of an integral fuel pressure regulator, it is noted that any type of fuel regulator such as a stand alone fuel regulator or a demand-type integral returnless regulator could also be utilized.

The present invention will be described with respect to both integral and stand alone fuel pressure regulators. A stand alone configuration has a pair of ports for fuel inlet and return on a body that contains the fuel. A significant portion of the body holds pressurized fuel in the interior while the exterior is exposed to the atmosphere. Generally, the stand alone configuration has a bracket attached to the housing that serves as the interface to mounting surfaces on other components. It can be mounted anywhere, including remotely from the fuel rail or engine. This is contrasted with an integral configuration. The integral configuration also has inlet and return ports. However, these ports are submerged in the cavity of a mating part that has corresponding passages. The body structure containing the pressurized fuel is almost entirely submerged inside the mating part cavity. It is not able to be located remotely from the fuel rail unless it has an additional piece that covers the passages. A separate retaining mechanism, usually a clip, is necessary to hold the regulator in a cavity.

Both the stand alone configuration as well as the integral configuration could operate as either a return system or a returnless system.

The return system continually recirculates the fuel. More fuel than is necessary for engine consumption circulates through the fuel rail, with the excess being returned to the tank for continued usage. A returnless system requires that all fuel entering the fuel rail be consumed. This system can have a pressure regulator that still returns excess fuel to the fuel tank. In this situation, the fuel is routed to the rail before the regulator as a spur off the main fuel line. Any pressurized fuel on that spur must enter the engine through the fuel rail. All bypass fuel exiting the regulator returns to the fuel

tank. A special version of this is the demand-type returnless configuration.

This configuration requires that all fuel leaving the regulator be consumed by the engine. It works by providing just enough fuel into the rail to ensure that it is full and at pressure. Any time fuel is consumed, the regulator opens to allow more fuel to enter.

FIGS. 2,3 and 4 illustrate a first embodiment of the present invention in which a stand alone pressure regulator 16 is attached to the rail 10 utilizing either a conventional threaded screw 40 or a thread forming or self-tapping screw 36. The pressure regulator 16 includes an upper housing 26 as well as a lower housing 28. A bracket 32 is affixed to the lower housing 28 of the pressure regulator 16. This bracket is provided with two holes 34.

The regulator 16 is secured to the fuel rail 10 utilizing the bracket 32 cooperating with two holes 48,50 provided on a retaining member 44 directly molded onto the fuel rail 10. A fuel communications bore 54 is directly in communication with an inlet attached to the lower housing 28. It is noted that the bracket 32 can surround this fuel outlet or two separate brackets can be utilized. A fuel inlet 30 connecting the pressure regulator to the fuel tank is also connected to the lower housing 28 of the fuel regulator 16.

If a conventional screw 40 provided with a threaded shank 42 is used to affix the bracket 32 to the fuel rail retaining member 44, the corresponding hole 46 of the retaining member 44 would have a bore having corresponding threads therein. Additionally, a rigid plastic surface 48 is also directly molded to the retaining member 44. Conversely, if a thread forming screw 36 having a shank 38 is employed, the threads provided within the hole 50 would be formed when the screw 36 is screwed through the bracket 34 into hole 50. In this instance, obviously the material of the shank 38 must be stronger than that of the hole 50.

FIG. 3 illustrates the stand alone pressure regulator 16 directly connected to the fuel line 10 using either the conventional screw 40 or the thread forming screw 36, or a combination of the two screws shown in FIG. 4.

FIGS. 5,6 and 7 illustrate a second embodiment of the present invention in which a barbed fastening member 56 is used to secure the stand alone pressure fuel regulator 16 to a retaining member 44 molded to the fuel line 10. The fastener 56 includes a plastic band 58 having ends 60,62 offset from the band 58. Attached to each of the ends 60,62 would be a single flexible barb 64,66 respectively.

Each of these barbs is provided with flexible tabs 68,70 as shown in FIG. 7. The barbs including the flexible tabs 68,70 are pressed through the holes 34 in the bracket 32 and are then inserted into the holes 46,50 of the retaining member 44. The tabs 68,70 collapse during insulation and spread out once they enter the holes 46,50 to secure the pressure regulator in place. It is noted that a metallic version of the clip could be constructed using a band and two separate rivet clips. Both the plastic and metallic configuration are particularly efficient since the pressure regulator can be installed without the use of any tools. Alternatively, two separate clips could be used without employing the band 58. This embodiment would be constructed to directly withstand the fuel pressure loading of the regulator.

FIG. 6 illustrates the pressure regulator 16 as it is installed into the molded retaining member 44 of the fuel rail 10.

FIGS. 8 and 9 illustrate yet another embodiment of the present invention for securing a stand alone fuel pressure regulator 16 to a fuel line 10. In this instance, a plastic retaining member 72 is molded to the end of the fuel line 10. This member 72 is provided with a recessed interior area 74 into which the bracket 32 connected to the lower housing 28 of the regulator 16 would be inserted. Two pairs of slots 71,73,75 and 77 are provided in the retaining members 72. A forked shear clip 76 includes two parallel leg portions 80,82 connected by a band portion 78 through angled portions 94, 96. Flexible tabs 84,86 are provided within a slot in each of the legs 80,82 close to the ends 88,90 thereof. These tabs provided the locking feature for the fuel regulator 16. Once the bracket 32 is inserted within the recessed interior 74 of the retaining member 72, the shear clip 76 is slid through the

slots 71,73,75 and 77 of the retaining member 72 and the bracket 32 thereby retaining the fuel pressure regulator 16 in place as is shown in FIG.

9.

It is noted that the stand alone configuration includes a lip 92 extending around the bottom periphery of the top housing 26 of the regulator.

Due to this configuration, angled portions 94 and 96 offset the plane of the legs 80,82 from the plane of the band 78. Once the flexible tabs 80,82 are slid past the bottom surface of the retaining member 72, these tabs would move in the direction shown by the arrows in FIG. 8 which would be normal to the plane of the clip and thereby retain the regulator 16 in the retaining member 72. It is also noted that a similar function could be achieved by a motion in the plane of the shear clip 76.

FIGS. 10 and 11 illustrate yet another embodiment in which a stand alone pressure regulator 16 is connected to a plastic fuel line or rail 10.

In this embodiment, a plastic retaining member 100 is molded to the end of the fuel line 10. Slots 102 and 104 are provided within the retaining member 100. Slot 102 is provided with a bottom support member 108 and slot 104 includes a top support member 106. These slots are adapted to receive each end of the bracket 32. A locking pin 110 having flexible barbs 112 on its end are used to secure the pressure regulator 16 to the retaining member 100 after the bracket 32 is properly inserted within the slots 102 and 104. The barbs 112 would be used to positively secure the bracket in place. Although it is noted that other types of retaining members can be employed for this purpose. To properly receive the fuel pressure regulator 16 in place, the regulator 16 is rotated on its fuel passage axis as shown by arrows 114,116 and 118. At this point, the fuel pressure regulator 16 is pushed into the fuel communication bore so that one end of the bracket 32 is provided above the slot 102 and the second end is provided under the slot 104. The fuel pressure regulator 16 is then rotated in the opposite direction on its axis to engage the bottom support member 108 as well as the top support member 106 of the slots 102 and 104. At this point, the barbed locking pin 110 is

inserted into one or more of the bracket holes to secure the fuel pressure regulator 16 against rotation as shown in FIG. 11.

FIGS. 12,13,14 and 15 illustrate two clips for retaining an integral pressure regulator 120 within a plastic retaining cup 122 molded to and attached to a fuel rail 10 by a plastic support 124. Fastening members 130,132 represent various push on forked shear clips used to retain the pressure regulator 120 within the retaining cup 122. Clip 130 is provided with two flexible legs 134,136 connected together by a head portion 137. The end portion of each of the legs 134,136 includes locking members 140,138 respectively. These locking members are shown in more detail in FIG. 13 and move in the plane of the clip as shown by arrows 133,135, allowing locking members 138 to deflect in the plane of the clip. Retaining cup 122 is provided with two slots 126,128 through which the legs 134,136 as well as the retaining members 138,140 would pass. Therefore, when the integral pressure regulator 120 is inserted within the retaining cup 122 and the legs 134,136 of the retaining member 130 pass through slots 126 and 124, the inner surfaces 127,129 would be maintained against the outer surface of the integral pressure regulator 120 as illustrated in FIG. 15.

The second plastic retaining member 132 includes flexible legs 142,144 connected by a band 146. As shown in FIG. 14, each of the legs includes an undercut portion 148 adapted to cooperate with retaining cup, 122 to retain the integral pressure regulator 120 within the cup 122 after the retaining member 132 is inserted through the slots 126,128. Once the undercut portions 148 clear their respective slots 126,128, they would also move in the plane of the clip as shown by arrows 150,152 and would abut the end surface of the retaining cup 122 to properly maintain the integral pressure regulator 120 therein.

FIGS. 16 and 17 illustrate a means for fastening the integral fuel pressure regulator 120 to a fuel rail 10 employing a fastening clip 168 and a retaining cup 154 attached to the fuel rail 10 via a mounting device 156. The retaining cup 154 is provided with a first pair of slots 160,162 as well as a

second pair of slots 164,166 all provided on an upper housing portion 158 of the cup 154. The clip 168 includes two flexible legs 170,172 connected by a band portion 174. Similar to the other fastening devices used according to the present invention, the clip 168 can be manufactured from a plastic composite material or a metallic material. Each of the legs 170,172 is provided with a flexible end portion 176,178 respectively. These end portions deflect transverse to the plane of the clip as indicated by arrows 180, 182. Each of the end portions 176,178 is provided with an undercut portion 184,186 respectively. Therefore, once the integral pressure regulator 120 is inserted within the retaining cup 154, the legs 170,172 of the clip 168 would be inserted through slots 160,162 as well as 164,166 respectively. Once the undercut portions 184,186 extend through slots 162,166, the legs would deflect upward thereby allowing the undercut portions 184,186 to contact the outer surface of the top portion 158 of cup 154, thereby holding the regulator 120 firmly in place as illustrated in FIG. 17.

FIGS. 18-22 illustrate an integral fuel pressure regulator 20 attached to the fuel rail 10 utilizing a twist cap 194 lock. It is noted that the demand-type fuel regulators could also be employed. FIGS. 18-20 illustrate the embodiment in conjunction with fuel pressure regulator 120 and FIGS. 21- 22 employ fuel pressure regulator 202. Retaining member 20 is molded directly to the end of the fuel rail 10 and includes a plurality of ribs 192 evenly spaced on its periphery. The cap 194 as shown in both FIGS. 18 and 20 includes one or more gripping surfaces 196 for twisting the cap onto the retaining cup 190 as well as a plurality of dimples 200 provided on the inner surface of the cap 194, each of the dimples corresponding to one of the ribs 192. As shown in more detail in the section views shown in FIGS. 21 and 22, the ribs 192 in combination with its respective dimple 200 would lock the fuel pressure regulator 202 in place after it has been twisted into the closed position as shown in FIGS. 19 and 20. In this position, the cap 194 will remain firmly in place and would not move from this closed position to an

open position. Similar to all of the fastening devices described in this invention, this cap can be installed without the use of any tools.

FIGS. 23 and 24 illustrate a demand-type integrat returnless fuel pressure regulator 202 mounted at the end of a molded plastic fuel rail 10. Reference numeral 204 refers to a fuel inlet connected to the fuel tank.

A retaining cup 206 is molded to the end of the fuel rail 10 and includes two slots 208,210 on its periphery. In one embodiment, a fastening clip 212 having flexible legs 214 and 216 is used to secure the fuel pressure regulator 202 within the mounting cup 206. Flexible tabs 218 and 220 are provided on each end of the fastening clip 212 and deflect in the plane of the clip as shown by arrows 222 and 224. In this manner, once the fuel pressure regulator 202 is inserted within the retaining cup 206, the legs 214,216 of clip 212 are inserted through their respective slots 208,210. Once tabs 218, 220 pass out of the retaining cup 206, they will move in the direction shown by arrows 222,224 to secure the regulator 202 in place. A second option utilizes a flexible plastic or metallic clip 226 having legs 228,230 connected by a band member 232. Similar to the clip 212, the legs 228,230 of flexible clip 226 pass through the slots 208,210 of the retaining cup 206 to secure the regulator 202 in place as shown in FIG. 24. A slot 236 is provided at the bottom of the retaining cup 206 to allow the line 204 to be properly inserted when the regulator 202 is secured in place.

FIGS. 25 and 26 illustrate a device for securing a demand-type integral returnless pressure fuel regulator 202 to a plastic fuel rail with a plastic retaining cup 238 molded to one end of the line 10. A flexible clip 248 similar in many respects to the clip illustrated in FIG. 16 is used to secure the pressure regulator 202 in the retaining cup 238. In this instance, the retaining cup is provided with slots 240,242,246 and 248 through which legs 250,252 of the clip 248 would pass. Each of the legs is provided with flexible end portions 254,256 which deflect transverse to the plane of the clip as shown by arrows 258,260. A slot 262 is provided to accommodate line 204.

In this matter, the regulator 202 is secured in place as illustrated in FIG. 26.

FIGS. 27 and 28 are directed to another means for fastening the demand-type integral returnless regulator 202 to a plastic fuel line 10 having a plastic retaining cup molded to the end of the line 10. The retaining cup includes slots 264,266,268 and 270 provided around the periphery of the retaining cup 262. A tab 272 is also provided around the periphery of the cup 262. The plastic fastening device 274 includes a pair of legs 276,277 as well as a flexible arch portion 278 connected to the top of the clip 274. The arch portion includes a deflectable member 280 which deflects transverse to the plane of the clip as shown by arrows 282. Once the regulator 202 is inserted into the retention cup 262, the legs 276,277 would be inserted through the four slots 264,266,268 and 270. At this point, the portion 280 would deflect in a plane transverse to the plane of the clip as shown by arrow 282 and would be locked against the tab 272 thereby securing the regulator 202 in place as shown in FIG. 28.

FIGS. 29,30 and 31 show the use of an axial snap clip for securing a demand-type integral returless fuel pressure regulator 202 in place within a plastic retaining cup 286 molded to the end of the fuel rail 10, the plastic retaining cup including a slot 288 provided for the reception of the input line 204. The retaining cup 286 is provided with a raised surface 287 extending around the periphery of the retaining cup 286. A plastic or metallic snap cap 290 is used to straddle the pressure regulator 202, in a manner in which an increased bearing area limits the contact stress on the plastic retaining cup 286, thereby reducing the tendency to creep. The cap 290 is provided with a plurality of support tabs 294, each of the bearing members 292 are provided with scalloped recesses 296. The regulator 202 is inserted within the retaining cup 286 and the cap 290 is then snapped over the exterior surface of the retaining cup with the tabs 294 bearing against the raised periphery 287 as shown in FIG. 30 as well as FIG. 31.

FIGS. 32 and 33 illustrate another method and device for securing a demand-type integral returnless fuel pressure regulator 202 to a plastic fuel line 10 having a plastic retaining cup 300 molded to its end. The

retaining cup 300 is provided with a rim 302 extending around its entire periphery with the exception of slot 322 used to accommodate the line 204 of the regulator 202. The fastening device 303 contains split body portions 304 and 305 connected together by a living hinge 306. A slot 307 is provided is section 305 and a second slot 309 is provided within section 304. An end 310 of section 305 is provided with a flexible tab 312. End 308 of side 304 is provided with a recess 314. It is noted that this fastening device 303 can be constructed from a plastic type material. The pressure regulator 202 is inserted into the retaining cup 300. At this point, the fastening device 303 is closed around the rim 302 as shown by the arrows 316,318 and 320 so that portions of the rim 302 sit within the slots 307,309. Additionally, locking tab 312 would be inserted into the recess 314 to secure the regulator 202 in place. This is a particularly good design for high pressure environments.

Many modifications and variations are apparent from the foregoing description of the invention and all such modifications and variations are intended to be within the scope of the present invention.