Accumulator fuel injection system

• US 5,241,935 A
• Filed: 01/28/1992
• Issued: 09/07/1993
• Est. Priority Date: 02/03/1988
• Status: Expired due to Term

• Current Assignee: Clean Air Power, Inc. (Clean Air Power Ltd.)
• Original Assignee: Servojet Electronic Systems, Ltd.
• Inventors: Roach, Alan R., Pena, James A., Beck, Niels J., Johnston, Bevan H.
• Primary Examiner(s): MILLER, CARL STUART
• Application Number:
  US07/830,981
• Time in Patent Office: 588 Days
• Field of Search: 123/299, 123/300, 123/447, 123/467, 123/458, 123/446, 239/88-96
• US Class Current: 123/300
• CPC Class Codes: F02B 1/04 with fuel-air mixture admission into cylinder
• CPC Class Codes: F02B 2075/125 Direct injection in the combustion chamber for spark ignition engines, i.e. not in pre-combustion chamber
• CPC Class Codes: F02M 2200/30 Fuel-injection apparatus having mechanical parts, the movement of which is damped
• CPC Class Codes: F02M 47/02 of accumulator-injector type, i.e. having fuel pressure of accumulator tending to open, and fuel pressure in other chamber tending to close, injection valves and having means for periodically releasing that closing pressure
• CPC Class Codes: F02M 57/02 Injectors structurally combined with fuel-injection pumps
• CPC Class Codes: F02M 57/025 hydraulic, e.g. with pressure amplification
• CPC Class Codes: F02M 57/026 Construction details of pressure amplifiers, e.g. fuel passages or check valves arranged in the intensifier piston or head, particular diameter relationships, stop members, arrangement of ports or conduits
• CPC Class Codes: F02M 59/105 hydraulic drive F02M59/32 takes precedence
• CPC Class Codes: F02M 61/06 the valves being furnished at seated ends with pintle or plug shaped extensions
• CPC Class Codes: F02M 61/20 Closing valves mechanically, e.g. arrangements of springs or weights or permanent magnets; Damping of valve lift
• CPC Class Codes: F02M 63/0205 for cutting-out pumps or injectors in case of abnormal operation of the engine or the injection apparatus, e.g. over-speed, break-down of fuel pumps or injectors safety devices acting on engine fuel system on lubricant pressure failure F01M1/24; for cutting-out pumps for stopping the engine
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

A series of method and apparatus advances in the accumulator-type fuel injector art, applicable to both intensified and unintensified accumulator injectors, which cooperate to provide major improvements in internal combustion engine fuel economy, reduction of noise, and reduction of undesirable exhaust emissions, including smoke, oxides of nitrogen and hydrocarbons. According to the invention, injector needle closure speed is increased for sharper fuel cutoff and better atomization proximate closure, and needle closure bounce is minimized to minimize fuel dribble proximate closure by reducing both mass and length of the needle, which can be accomplished by a longitudinally divided needle. Hydraulic damping also damps and cushions both needle closing and needle opening. The accumulator cavity and needle spring cavity are separated, enabling the accumulator cavity to be as small as desired for high accumulator closing pressure, while nevertheless enabling a strong, fast-acting spring to be used, both factors cumulatively contributing to good closure atomization. A two-stage needle lift is provided for first injecting a pilot fuel charge for preignition, and then injecting the main fuel charge, thereby eliminating the usual adverse premixed burning. The injection spray pattern is automatically varied for improved engine efficiency over the engine power spectrum by utilizing a pintle-type injector nozzle which is variably controlled according to the quantity of fuel delivered.

Claims

1. In an internal combustion engine accumulator-type fuel injector, a method of reducing undesirable premixed burning in the engine which comprises:

raising injector needle means off its valve seat a small constant low-lift increment for a sufficient interval of time to inject a small pilot fuel charge into the engine; and

then raising the needle means to a higher position to inject the main fuel charge into the engine.

2. A method according to claim 1, wherein said low-lift increment is in the range of from about 1% to about 20% of maximum needle lift.

3. A method according to claim 1, wherein said small pilot charge is in the range of from about 2% to about 20% of the total fuel charge.

4. A method according to claim 1, which comprises varying said interval of time to vary the quantity of said pilot charge.

5. A method according to claim 1, which comprises controlling needle lift by controlled venting of pressurized liquid from a pressurized zone located above said needle means.

6. A method according to claim 1, which comprises varying said interval of time by varying the rate of said venting.

7. A method according to claim 6, which comprises lengthening said interval of time by reducing the rate of said venting, and shortening said interval of time by increasing the rate of said venting.

8. A method according to claim 6, wherein the rate of said venting is varied by variably orificing vent passage means leading from said pressurized zone.

9. A method according to claim 6, wherein the rate of said venting is varied by varying the vent pressure.

10. A method according to claim 8, wherein the rate of said venting is also varied by varying the vent pressure.

11. A method according to claim 5, wherein said injector is an intensified-type accumulator injector having a longitudinally divided needle comprising a lower tip section and an upper plunger section, and the top of said upper plunger section is exposed to said pressurized zone.

12. A method according to claim 5, wherein said injector is an unintensified-type accumulator injector having a longitudinally unitary needle, and the top of said unitary needle is exposed to said pressurized zone.

13. A method according to claim 5, wherein said injector is an intensified-type accumulator injector having a low pressure cylinder with communicating inlet/vent passage means, and a high pressure intensifying cylinder which is in liquid communication with said pressurized zone;

and

which comprises controlling needle lift by venting pressurized liquid from said low pressure cylinder through said inlet/vent passage means, which in turn causes venting of intensified pressure from said high pressure cylinder, and hence from the communicating said pressurized zone.

14. A method according to claim 5, wherein said injector is an unintensified-type accumulator injector with communicating inlet/vent passage means which is in liquid communication with said pressurized zone;

and

which comprises controlling needle lift by venting pressurized liquid from said pressurized zone through said inlet/vent passage means.

15. In an internal combustion engine accumulator-type fuel injector, a method of reducing undesirable premixed burning in the engine which comprises:

raising injector needle means off its valve seat a small low-lift increment for a sufficient interval of time to inject a small pilot fuel charge into the engine; and

then raising the needle means to a higher lift position to inject the main fuel charge into the engine;

controlling needle lift by controlling venting of pressurized liquid from a pressurized zone located above said needle means;

providing said pressurized zone in the form of cavity means above the upper end of said needle means;

providing stop plate means in said cavity means normally disposed at a lower position in which there is an axial clearance space between said needle means upper end and a bottom surface of said plate means which defines said low-lift increment;

establishing downward force-transmitting means generally axially directed through said plate means to said needle means upper end;

sealing said plate means relative to wall means of said cavity means in said lower position of the plate means such that downward force on said needle means upper end from liquid pressure in said cavity means above said plate means is restricted to said force-transmitting means;

establishing sufficient liquid pressure in said cavity means prior to initiation of an injection event for said force-transmitting means to, with the aid of needle closure spring force, hold said needle means down against its seat against upward force of accumulator pressure on said needle means;

venting liquid pressure from said cavity means sufficiently for upward force of accumulator pressure on said needle means to overcome the combined downward forces of said force-transmitting means and the needle spring, but insufficient to overcome the downward force of liquid pressure in said cavity means against said plate means, causing said needle means to lift into engagement with said plate means bottom surface in said low-lift increment of needle movement; and

further venting liquid pressure from said cavity means sufficiently for upward force of accumulator pressure on said needle means to overcome the combined downward forces of said force-transmitting means, the needle spring, and the force of liquid pressure in said cavity means on said plate means, causing said needle means to lift, together with said plate means, to its full lift position.

16. A method according to claim 15, wherein said force-transmitting means comprises passage means through said plate means for direct transmission of liquid pressure from said cavity means to said needle means upper end.

17. A method according to claim 15 wherein said force-transmitting means comprises pin means generally axially slideable through said plate means, said pin means having an upper end exposed to liquid pressure in said cavity means and a lower end engageable with said needle means upper end.

18. A method according to claim 15, wherein said sealing of said plate means is provided between a flat upwardly facing bottom surface of said cavity means and a flat downwardly facing bottom surface of said plate means.

19. A method according to claim 15, wherein said sealing of said plate means is provided between an outer cylindrical surface of said plate means and a cylindrical surface of said cavity means, and between an inner cylindrical surface of said plate means and an outer cylindrical surface of said needle means upper end.

20. A method according to claim 15, which comprises defining a position of maximum needle lift by having said plate means engage downwardly facing stop shoulder means of said cavity means.

21. A method according to claim 15, which comprises defining said axial clearance space below a substantially flat downwardly facing of said plate means.

22. A method according to claim 15, which comprises locating said upper end of said needle means proximate the level of the bottom of said plate means in the closed position of said needle means, and defining said axial clearance space by substantially the axial depth of a downwardly facing axial recess in the bottom of said plate means.

23. A method according to claim 15, which comprises locating said upper end of said needle means within an axial recess in the bottom of said plate means in the closed position of said needle means, and defining said axial clearance space between said upper end of said needle means and the top of said axial recess.

24. A method according to claim 15, wherein said injector is an intensified-type accumulator injector.

25. A method according to claim 15, wherein said injector is an unintensified-type accumulator injector.

26. In an internal combustion engine accumulator-type fuel injector, a method of reducing undesirable premixed burning in the engine which comprises:

raising injector needle means off its valve seat a small low-lift increment for a sufficient interval of time to inject small pilot fuel charge into the engine; and

then raising the needle means to a higher lift position to inject the main fuel charge into the engine;

controlling needle lift by controlling venting of pressurized liquid from a pressurized zone located above said needle means, said controlled venting comprising

first relatively slowly venting pressurized liquid from said pressurized zone to produce said low-lift increment of lift of said needle means; and

then relatively rapidly venting pressurized liquid from said pressurized zone to produce said raising of said needle means to its full lift position.

27. A method according to claim 26, which comprises producing said relatively slow venting by venting pressurized liquid through bleed orifice means.

28. A method according to claim 27, which comprises adjusting the rate of said relatively slow venting by adjusting the size of said bleed orifice means.

29. A method according to claim 27, which comprises producing said relatively rapid venting by venting pressurized liquid through primary vent conduit means.

30. A method according to claim 26, which comprises producing said relatively slow venting by venting pressurized liquid from behind piston means the front of which is in liquid communication with said pressurized zone.

31. A method according to claim 30, which comprises venting the pressurized liquid from behind said piston means through bleed orifice means.

32. A method according to claim 31, which comprises adjusting the rate of venting of the liquid from behind said piston means by adjusting the size of said bleed orifice means.

33. A method according to claim 30, which comprises producing said relatively rapid venting by utilizing movement of said piston means caused by said venting of liquid from behind it to open vent conduit means into liquid communication with said pressurized zone for venting of pressurized liquid from said pressurized zone.

34. A method according to claim 33, wherein said injector is an intensified-type accumulator injector.

35. A method according to claim 33, wherein said injector is an unintensified-type accumulator injector.

36. A method according to claim 26, which comprises:

placing positive stop means at a first stop position in which it is spaced said low-lift increment above the upper end of said needle means during said relatively slow venting so as to positively stop said needle means at its said low-lift increment of lift; and

releasing said stop means from its said low-lift position during said relatively rapid venting so as to enable said needle means to lift to its said higher lift position.

37. A method according to claim 36, wherein said releasing of said stop means enables said stop means to be raised to a second stop position in which it is spaced a maximum lift amount above the upper end of said needle means during said relatively rapid venting so as to positively stop said needle means at its said full lift position.

38. A method according to claim 36, which comprises:

holding said stop means in its said first stop position by fluid pressure means during said relatively slow venting; and

venting pressure from said fluid pressure means so as to perform said releasing of said stop means.

39. A method according to claim 38, which comprises employing stop piston means as said stop means.

40. A method according to claim 38, wherein said venting of fluid pressure from said fluid pressure means is performed substantially simultaneously as said relatively rapid venting from said pressurized zone.

41. A method according to claim 40, which comprises employing the same venting means to perform said relatively rapid venting from said pressurized zone and to perform said venting from said fluid pressure means.

42. A method according to claim 41, which comprises:

producing said relatively slow venting by venting pressurized liquid from behind control piston means the front of which is in liquid communication with said pressurized zone; and

producing both said relatively rapid venting and said venting from said fluid pressure means by utilizing movement of said piston means caused by said venting of liquid from behind it to open vent conduit means into fluid communication with both said pressurized zone and said fluid pressure means.

43. A method according to claim 42, which comprises employing stop piston means as said stop means.

44. A method according to claim 38, which comprises utilizing a common source of pressurized liquid to produce pressurization in said pressurized zone and in said fluid pressure means.

45. A method according to claim 44, wherein said injector is an intensified-type accumulator injector.

46. In an internal combustion engine accumulator-type fuel injector, apparatus for injecting a small pilot charge for reducing undesirable premixed burning of the main charge, which comprises:

elongated valve element needle means longitudinally slideable in the body means of the injector having a lower tip adapted to close against the valve seat of the injector and having an upper end;

cavity means defined within said body means above said needle means upper end;

liquid inlet/vent conduit means communicating with said cavity means for sequentially introducing pressurized liquid into said cavity means and venting pressurized liquid from said cavity means;

stop plate means in said cavity means normally disposed at a lower, seated position in which there is an axial clearance space between said needle means upper end and a downwardly facing surface of said plate means which defines a low-lift increment of movement of said needle means, said stop plate means having downward force-transmitting means generally axially directed therethrough to said needle means upper end;

said plate means being sealed relative to wall means of said cavity means in said lower position of said plate means such that downward force on said needle means upper end from fluid pressure in said cavity means above said plate means is restricted to said force-transmitting means;

fluid pressure introduced into said cavity means through said conduit means prior to an injection event being sufficient for said force-transmitting means, with the aid of the force of the needle closure spring, to hold said needle means down against its seat against upward force of accumulator pressure on said needle means;

fluid pressure remaining in said cavity means after partial venting of fluid pressure from said cavity means through said conduit means being sufficiently reduced for upward force of accumulator pressure on said needle means to overcome the combined downward forces of said force-transmitting means and the needle spring, but still being sufficient for its downward force against said plate means to hold said plate means in its seated position, whereby said needle means will lift into engagement with said plate means downwardly facing surface in said low-lift increment of movement to inject said pilot charge; and

further venting of fluid pressure from said cavity means enabling upward force of accumulator pressure on said needle means to overcome the combined downward forces of said force-transmitting means, the needle spring, and the force of fluid pressure in said cavity means on said plate means, whereby said needle means will lift, together with said plate means, to a higher lift position.

47. Apparatus according to claim 46, wherein said force-transmitting means comprises fluid passage means through said plate means for direct transmission of fluid pressure from said cavity means to said needle means upper end.

48. Apparatus according to claim 46, wherein said plate seal is between a flat upwardly facing bottom surface of said cavity means and a flat downwardly facing bottom surface of said plate means.

49. Apparatus according to claim 46, which comprises downwardly facing stop shoulder means of said cavity means;

engagement of said stop plate means against said shoulder means defining a maximum lift position of said needle means.

50. Apparatus according to claim 46, wherein said plate means has a substantially flat downwardly facing surface below which said axial clearance space is defined.

51. Apparatus according to claim 46, wherein said injector is an intensified-type accumulator injector.

52. Apparatus according to claim 46, wherein said injector is an unintensified-type accumulator injector.

53. In an internal combustion engine accumulator-type fuel injector, apparatus for injecting a small pilot charge for reducing undesirable premixed burning of the main charge, which comprises:

elongated valve element needle means longitudinally slideable in the body means of the injector adapted to close against the valve seat of the injector and having an upper end;

a liquid pressure zone defined in said body means above said needle means upper end for applying downward force on said needle means upper end which increases with increased liquid pressure in said zone and decreases with decreased liquid pressure in said zone; and

hydraulic circuit means in liquid communication with said zone through inlet/vent conduit means for first applying sufficient hydraulic pressure to said zone to hold said needle means down on its seat prior to initiation of an injection event, next partially venting liquid pressure from said zone sufficiently for said needle means to rise off of said seat a small constant low-lift increment for injection of a small pilot fuel charge into the engine, and then further venting liquid pressure from said zone sufficiently for said needle means to rise to a higher lift position for injection of the main fuel charge into the engine.

54. Apparatus according to claim 53, which comprises variable orifice means associated with said conduit means for varying the rate of said partial venting so as to vary the length of time of said low-lift increment and thereby vary the amount of said pilot charge.

55. Apparatus according to claim 53, which comprises means associated with said conduit means for varying the vent pressure applied to said conduit means for varying the rate of said partial venting so as to vary the length of time of said low-lift increment and thereby vary the amount of said pilot charge.

56. Apparatus according to claim 53, wherein said hydraulic circuit means is adapted to relatively slowly vent pressurized liquid from said zone to produce said low-lift increment of lift of said needle means, and then to relatively rapidly vent pressurized liquid from said zone to produce said raising of said needle means to its said higher lift position.

57. Apparatus according to claim 56, which comprises bleed orifice means in said hydraulic circuit means through which pressurized liquid is bled to produce said relatively slow venting.

58. Apparatus according to claim 57, wherein said bleed orifice means is variable in size for adjustment of the rate of said relatively slow venting.

66. Apparatus according to claim 53, which comprises positive stop means in said body means in communication with said hydraulic circuit means and spaced above said upper end of said needle means;

said stop means being held by said hydraulic circuit means at a first stop position in which it is spaced said low-lift increment above said upper end of said needle means during said partial venting so as to positively stop said needle means at its said low-lift increment of lift; and

said stop means being released by said hydraulic circuit means from its said low-lift position during said further venting so as to enable said needle means to lift to its said full lift position.

67. Apparatus according to claim 66, wherein said stop means has a second stop position in which it is spaced the full lift amount above said upper end of said needle means;

said release of said stop means by said hydraulic circuit means enabling said needle means to move said stop means upwardly to its said second stop position at which said stop means positively stops said needle means at its said full lift position.

68. Apparatus according to claim 66, wherein said hydraulic circuit means comprises liquid pressure means in communication with said stop means which holds said stop means at its said first stop position;

and

vent means in communication with said liquid pressure means for venting liquid pressure from said liquid pressure means so as to cause said releasing of said stop means.

69. Apparatus according to claim 68, wherein said stop means comprises stop piston means.

70. Apparatus according to claim 68, wherein said hydraulic circuit means is arranged to vent liquid pressure from said liquid pressure means through said vent means substantially simultaneously with said further venting of liquid pressure from said zone.

71. Apparatus according to claim 70, wherein the same vent means is employed in said hydraulic circuit means to perform said further venting from said zone and said venting from said liquid pressure means.

72. Apparatus according to claim 71, wherein said same vent means comprises hydraulic cylinder means, and piston means having a front end and a rear slideable in said cylinder means;

said cylinder means in front of said piston means being liquid-filled and in liquid communication with said inlet/vent conduit means;

primary vent conduit means in communication with said cylinder means; and

further vent conduit means from said liquid pressure means in communication with said cylinder means;

said primary and further vent conduit means being closed by said piston means prior to initiation of an injection event and during said partial venting from said zone, and being opened by rearward sliding movement of said piston means in said cylinder means upon said further venting from said zone.

73. Apparatus according to claim 72, wherein said stop means comprises stop piston means.

74. Apparatus according to claim 68, which comprises a common source of pressurized liquid for producing pressurization in said pressurized zone and in said liquid pressure means.

75. Apparatus according to claim 74, wherein said injector is an intensified-type accumulator injector.

59. In an internal combustion engine accumulator-type fuel injector, apparatus for injecting a small pilot charge for reducing undesirable premixed burning of the main charge, which comprises:

elongated valve element needle means longitudinally slideable in the body means of the injector adapted to close against the valve seat of the injector and having an upper end;

a liquid pressure zone defined in said body means above said needle means upper end for applying downward force on said needle means upper end which increases with increased liquid pressure in said zone and decreases with decreased liquid pressure in said zone;

hydraulic circuit means in liquid communication with said zone through inlet/vent conduit means for first applying sufficient hydraulic pressure to said zone to hold said needle means down on its seat prior to initiation of an injection event, next partially venting liquid pressure from said zone sufficiently for said needle means to rise off of said seat a small low-lift increment for injection of a small pilot fuel charge into the engine, and then further venting liquid pressure from said zone sufficiently for said needle means to rise to a full lift position for injection of the main fuel charge into the engine;

said hydraulic circuit means being adapted to relatively slowly vent pressurized liquid from said zone to produce said low-lift increment of lift of said needle means, and them to relatively rapidly vent pressurized liquid from said zone to produce said raising of said needle means to its said full lift position;

bleed orifice means in said hydraulic circuit means through which pressurized liquid is bled to produce said relatively slow venting;

said hydraulic circuit means comprising primary vent conduit means; and

control valve means in said hydraulic circuit means for isolating said primary vent conduit means from said zone prior to initiation of an injection event and during said relatively slow venting, and for placing said vent conduit means in communication with said primary vent conduit means to produce said relatively rapid venting.

60. Apparatus according to claim 59, wherein said control valve means comprises:

hydraulic cylinder means;

piston means slideable in said cylinder means and having a front and a rear;

said cylinder means in front of said piston means being liquid-filled and in liquid communication with said inlet/vent conduit means; and

slow vent means which communicates with said cylinder means behind said piston means for producing said relatively slow venting;

venting of liquid from behind said piston means through said slow vent means allowing said piston means to slide rearwardly in said cylinder means, which results in said partial venting of liquid pressure from said zone.

61. Apparatus according to claim 60, wherein said slow vent means comprises bleed orifice means.

62. Apparatus according to claim 61, wherein said bleed orifice means is variable in size for adjustment of the rate of said relatively slow venting.

63. Apparatus according to claim 60, which comprises primary vent conduit means in communication with said cylinder means;

said primary vent conduit means being closed by said piston means prior to initiation of an injection event, and being opened by said rearward sliding of said piston to provide said further venting of liquid pressure from said zone.

64. Apparatus according to claim 63, wherein said injector is an intensified-type accumulator injector.

65. Apparatus according to claim 63, wherein said injector is an unintensified-type accumulator injector.

76. In an internal combustion engine accumulator-type fuel injector, a method of reducing undesirable premixed burning in the engine which comprises:

raising injector needle means off its valve seat a small low-lift increment for a sufficient interval of time to inject a small pilot fuel charge into the engine; and

then raising the needle means to a higher lift position to inject the main fuel charge into the engine;

controlling needle life by controlled venting of pressurized liquid from pressurized zone means located above upwardly facing surface means of said needle means;

providing said pressurized zone means in the form of cavity means above said upwardly facing surface means of said needle means;

providing stop plate means in said cavity means normally disposed at a lower position in which there is an axial clearance space between said upwardly facing surface means of said needle means and a downwardly facing surface of said plate means which defines said low-lift increment;

establishing downward force-transmitting means generally axially directed through said plate means to said upwardly facing surface means of said needle means;

sealing said plate means relative to wall means of said cavity means in said lower position of said plate means such that downward force on said upwardly facing surface means of said needle means for liquid pressure in said cavity means above said plate means is restricted to said force-transmitting means;

establishing sufficient liquid pressure in said cavity means prior to initiation of an injection event for said force-transmitting means to, with the aid of needle closure spring force, hold said needle means down against its seat against upward force of accumulator pressure on said needle means;

venting liquid pressure from said cavity means sufficiently for upward force of accumulator pressure on said needle means to overcome the combined downward forces of said force-transmitting means and the needle spring, but insufficient to overcome the downward force of liquid pressure in said cavity means against said plate means, causing said needle means to lift into engagement with said plate means bottom surface in said low-life increment of needle movement; and

further venting liquid pressure from said cavity means sufficiently for upward force of accumulator pressure on said needle means to overcome the combined downward forces of said force-transmitting means, the needle spring, and the force of liquid pressure in said cavity means on said plate means, causing said needle means to lift, together with said plate means, to its said higher lift position.

77. A method according to claim 76, wherein said force-transmitting means comprises passage means through said plate means for direct transmission of liquid pressure from said cavity means to said needle means.

78. A method according to claim 76, wherein said force-transmitting means comprises pin means generally axially slideable through said plate means, said pin means having an upper end exposed to liquid pressure in said cavity means and a lower end engageable with said needle means.

79. A method according to claim 76, wherein said sealing of said plate means is provided between a flat upwardly facing bottom surface of said cavity means and a flat downwardly facing bottom surface of said plate means.

80. A method according to claim 76, wherein said sealing of said plate means is provided between an outer cylindrical surface of said plate means and a cylindrical surface of said cavity means, and between an inner cylindrical surface of said plate means and an outer cylindrical surface of said needle means.

81. A method according to claim 76, which comprises defining a position of maximum needle life by having said plate means engage downwardly facing stop shoulder means of said cavity means.

82. A method according to claim 76, which comprises defining said axial clearance space below a substantially flat bottom of said plate means.

83. A method according to claim 76, which comprises locating said upwardly facing surface means of said needle means proximate the level of the bottom of said plate means in the closed position of said needle means, and defining said axial clearance space by substantially the axial depth of a downwardly facing axial recess in the bottom of said plate means.

84. A method according to claim 76, which comprises locating said upwardly facing surface means of said needle means within an axial recess in the bottom of said plate means in the closed position of said needle means, and defining said axial clearance space between said upwardly facing surface means and the top of said axial recess.

85. A method according to claim 76, wherein said injector is an intensified-type accumulator injector.

86. A method according to claim 76, wherein said injector is an unintensified-type accumulator injector.

87. In an internal combustion engine accumulator-type fuel injector, apparatus for injecting a small pilot charge for reducing undesirable premixed burning of the main charge, which comprises:

elongated valve element needle means longitudinally slideable in the body means of the injector having a lower tip adapted to close against the valve seat of the injector and having an upper end, said needle means having upwardly facing surface means;

cavity means defined within said body means above said surface means of said needle means;

liquid inlet/vent conduit means communicating with said cavity means for sequentially introducing pressurized liquid into said cavity means and venting pressurized liquid from said cavity means;

stop plate means in said cavity means normally disposed at a lower, seated position in which there is an axial clearance space between said surface means of said needle means and a downwardly facing surface of said plate means which defines a low-lift increment of movement of said needle means, said stop plate means having downward force-transmitting means generally axially directed therethrough to said surface means of said needle means;

said plate means being sealed relative to wall means of said cavity means in said lower position of said plate means such that downward force on said surface means of said needle means from fluid pressure in said cavity means above said plate means is restricted to said force-transmitting means;

fluid pressure introduced into said cavity means through said conduit means prior to an injection event being sufficient for said force-transmitting means, with the aid of the force of the needle closure spring, to hold said needle means down against its seat against upward force of accumulator pressure on said needle means;

fluid pressure remaining in said cavity means after partial venting of fluid pressure from said cavity means through said conduit means being sufficiently reduced for upward force of accumulator pressure on said needle means to overcome the combined downward forces of said force-transmitting means and the needle spring, but still being sufficient for its downward force against said plate means to hold said plate means in its seated position, whereby said needle means will lift into engagement with said plate means downwardly facing surface in said low-lift increment of movement to inject said pilot charge; and

further venting of fluid pressure from said cavity means enabling upward force of accumulator pressure on said needle means to overcome the combined downward forces of said force-transmitting means, the needle spring, and the force of fluid pressure in said cavity means on said plate means, whereby said needle means will lift, together with said plate means, to a higher lift position.

88. Apparatus according to claim 87, wherein said force-transmitting means comprises fluid passage means through said plate means for direct transmission of fluid pressure from said cavity means to said needle means upper end.

89. Apparatus according to claim 87, wherein said stop plate seal is between a flat upwardly facing bottom surface of said cavity means and a flat downwardly facing bottom surface of said plate means.

90. Apparatus according to claim 87, which comprises downwardly facing stop shoulder means of said cavity means;

engagement of said stop plate means against said shoulder means defining a maximum lift position of said needle means.

91. Apparatus according to claim 87, wherein said plate means has a substantially flat downwardly facing surface below which said axial clearance space is defined.

92. Apparatus according to claim 87, wherein said injector is an intensified-type accumulator injector.

93. Apparatus according to claim 87, wherein said injector is an unintensified-type accumulator injector.