Embodiments include a fuel rail and method for making the fuel rail. Embodiments of the fuel rail include an elongate tubular body with a wall defining a lumen, the elongate tubular body formed with a thermoset composite material, and a pressure port having a lumen in fluid communication with the lumen of the elongate tubular body.
1. A fuel rail, comprising:
an elongate tubular body having a wall defining a lumen, the elongate tubular body formed with a thermoset composite material; and
a pressure port having a lumen in fluid communication with the lumen of the elongate tubular body, where the pressure port includes a collar extending at least partially around the elongate tubular body; and
an overmold layer around the collar and the elongate tubular body to secure the collar of the pressure port to the elongate tubular body.
2. The fuel rail of claim 1 , wherein the thermoset composite material is formed from a liquid resin thermoset precursor that is selected from an unsaturated polyester, a polyurethane, an epoxy, a phenolic, a silicone, an alkyd, an allylic, a vinyl ester, a furan, a polyimide, a cyanate ester, a bismaleimide, a polybutadiene, and a polyetheramide.
3. The fuel rail of claim 1 , wherein the elongate tubular body includes reinforcement member impregnated with the thermoset composite material.
4. The fuel rail of claim 3 , wherein the collar of the pressure port extends at least partially between the reinforcement member of the elongate tubular body.
5. The fuel rail of claim 1 , wherein the elongate tubular body includes reinforcement member impregnated with the thermoset composite material.
6. The fuel rail of claim 5 , wherein the pressure port includes reinforcement member impregnated with the thermoset composite material.
7. The fuel rail of claim 5 , wherein the elongate tubular body has a burst strength of not less than 160,000 pounds per square inch (PSI).
8. The fuel rail of claim 1 , wherein the pressure port includes a collar having a surface defining at least part the lumen of the elongate tubular body.
9. The fuel rail of claim 8 , wherein the elongate tubular body includes reinforcement member wound over at least a portion of the collar, the reinforcement member impregnated with the thermoset composite material.
10. A fuel rail, comprising:
an elongate tubular body having a wall defining a lumen, the elongate tubular body formed with reinforcement member impregnated with a thermoset composite material;
a pressure port having a lumen and a collar, the collar extending at least partially around the elongate tubular body and the lumen in fluid communication with the lumen of the elongate tubular body; and
an overmold layer around the collar and the elongate tubular body.
11. The fuel rail of claim 10 , wherein the overmold layer is a thermoset composite material that secures the collar of the pressure port to the elongate tubular body.
12. The fuel rail of claim 10 , wherein the collar of the pressure port extends at least partially between the reinforcement member of the elongate tubular body.
13. The fuel rail of claim 10 , wherein the collar of the pressure port includes a surface defining at least part the lumen of the elongate tubular body.
14. The fuel rail of claim 13 , wherein the reinforcement member is wound over at least a portion of the collar.
15. The fuel rail of claim 10 , wherein the thermoset composite material is formed from a liquid resin thermoset precursor having a viscosity of 1,000 to 500,000 centipoises.
16. A method for forming a fuel rail, comprising:
forming an elongate tubular body having a wall defining a lumen with a thermoset composite material;
coupling a pressure port to the elongate tubular body;
providing the pressure port over the elongate tubular body;
coupling the pressure port to the elongate tubular body with a thermoset composite material overmold; and
providing for fluid communication between the lumen of the elongate tubular body and a lumen of the pressure port.
17. The method of claim 16 , wherein coupling the pressure port includes integrally forming the pressure port and the elongate tubular body from the thermoset composite material.
18. The method of claim 17 , including providing a reinforcement member within the wall of the elongate tubular body and a wall of the pressure port.
19. The method of claim 16 , including:
providing a reinforcement member within the wall of the elongate tubular body;
positioning a collar of the pressure port over the elongate tubular body; and
coupling the collar of the pressure port to the elongate tubular body with a thermoset composite material overmold.
20. The method of claim 16 , wherein forming an elongate tubular body includes:
winding reinforcement members over at least a portion of a collar of the pressure port; and
curing the thermoset composite material to form the elongate tubular body.
21. The method of claim 16 , wherein providing for fluid communication include drilling an opening through the wall of the elongate tubular body to provide fluid communication between the lumen of the elongate tubular body and the lumen of the pressure port.
22. The method of claim 16 , wherein forming the elongate tubular body includes forming the elongate tubular body with a resin transfer molding process.
23. The method of claim 16 , including over molding the elongate tubular body and at least a portion of the pressure port with a liquid resin thermoset; and
curing the liquid resin thermoset.
24. The fuel rail of claim 1 , wherein the collar completely encircles the elongate tubular body.
25. The fuel rail of claim 1 , wherein the overmold layer is formed of the thermoset composite material.
26. The fuel rail of claim 1 , wherein the overmold layer is formed of a second thermoset composite material.
27. The fuel rail of claim 1 , wherein the overmold layer includes a mounting structure for attaching the fuel rail to an engine.
28. The fuel rail of claim 1 , wherein the wall defining the lumen of the elongate body includes a smooth surface as compared to an outer surface of the elongate tubular body.