Fuel rail assembly and method of fabrication

Claim 1

A fabricated fuel rail assembly for an engine, said assembly comprising an elongated sheet metal fuel rail body defining a fuel supply passage and having a plurality of axially spaced transversely extending fuel injector sockets, said passage intersecting said sockets for supplying fuel to said sockets, each of said sockets receiving a fuel injector adapted to deliver fuel from its socket to the engine, and a fuel pressure regulator for controlling the fuel pressure in said fuel supply passage, said pressure regulator including a diaphragm overlying a sheet metal base and defining a fuel chamber therebetween, said base including a fuel access region opening from said supply passage to said chamber and a fuel outlet opening from said chamber and a valve seat surrounding said outlet, said diaphragm carrying a valve member controlling fuel flow past said valve seat through said outlet, a coil spring engaging said diaphragm and biasing said diaphragm to urge said valve member toward said valve seat whereby fuel flow past said valve seat through said outlet is controlled to balance the fuel pressure on said diaphragm with the bias of said spring on said diaphragm, and wherein said fuel rail body is formed with a planar region and an aperture in said planar region, said pressure regulator base is formed with a planar region which overlies said fuel rail body planar region, said fuel access region is formed as a tubular fitting extruded from said base and extending directly into said aperture to provide a fuel flow connection from said fuel supply passage to said pressure regulator chamber, and said planar region of said pressure regulator base is brazed to said planar region of said fuel rail body to maintain said pressure regulator in a securely sealed assembly with said fuel rail body.

Claim 3

The method of fabricating a fuel rail assembly for an engine, said assembly comprising an elongated sheet metal fuel rail body defining a fuel supply passage and having a plurality of axially spaced transversely extending fuel injector sockets, said passage intersecting said sockets for supplying fuel to said sockets, each of said sockets receiving a fuel injector adapted to deliver fuel from its socket to the engine, and a fuel pressure regulator for controlling the fuel pressure in said fuel supply passage, said pressure regulator including a diaphragm overlying a sheet metal base and defining a fuel chamber therebetween, said base including a fuel access region opening from said supply passage to said chamber and a fuel outlet opening from said chamber and a valve seat surrounding said outlet, said diaphragm carrying a valve member controlling fuel flow past said valve seat through said outlet, a coil spring engaging said diaphragm and biasing said diaphragm to urge said valve member toward said valve seat whereby fuel flow past said valve seat through said outlet is controlled to balance the fuel pressure on said diaphragm with the bias of said spring on said diaphragm, said method comprising the steps of forming said fuel rail body with a planar region and an aperture in said planar region, forming said pressure regulator base with a planar region which overlies said fuel rail body planar region, forming said fuel access region by extruding a tubular fitting from said planar region of said pressure regulator base directly into said aperture to provide a fuel flow connection from said fuel supply passage to said pressure regulator chamber, and brazing said planar region of said pressure regulator base to said planar region of said fuel rail body about said fitting and said aperture to securely seal said pressure regulator to said fuel rail body.

Claim 4

The method of fabricating a fuel rail assembly for an engine, said assembly comprising an elongated sheet metal fuel rail body defining a fuel supply passage and having a plurality of axially spaced transversely extending fuel injector sockets, said passage intersecting said sockets for supplying fuel to said sockets, each of said sockets receiving a fuel injector adapted to deliver fuel from its socket to the engine, and a fuel pressure regulator for controlling the fuel pressure in said fuel supply passage, said pressure regulator including a diaphragm overlying a sheet metal base and defining a fuel chamber therebetween, said base including a fuel access region opening from said supply passage to said chamber and a fuel outlet opening from said chamber and a valve seat surrounding said outlet, said diaphragm carrying a valve member controlling fuel flow past said valve seat through said outlet, a coil spring engaging said diaphragm and biasing said diaphragm to urge said valve member toward said valve seat whereby fuel flow past said valve seat through said outlet is controlled to balance the fuel pressure on said diaphragm with the bias of said spring on said diaphragm, said method comprising the steps of forming said fuel rail body with a planar region and an aperture in said planar region, forming said pressure regulator base with a planar region which overlies said fuel rail body planar region, forming said fuel access region by extruding a tubular fitting from said planar region of said pressure regulator base directly into said aperture to provide a fuel flow connection from said fuel supply passage to said pressure regulator chamber, and brazing said planar region of said pressure regulator base to said planar region of said fuel rail body about said fitting and said aperture to securely seal said pressure regulator to said fuel rail body.