Actuator arrangement for an electromagnetically operated fuel injector and method for constructing

1. An actuator arrangement for an electromagnetically operated fuel injector, comprising:

a pole member having a first end face and defining an aperture extending from the first end face;

an actuator core received within the aperture, wherein the actuator core carries at least one contact member having a contact face that is exposed through the aperture,

wherein an encapsulating member is received within the aperture and surrounding the at least one contact member, and wherein the first end face of the pole member, the contact face and the encapsulating member are arranged to provide the actuator arrangement with a planar surface for mating with an adjacent component.

2. An actuator arrangement as claimed in claim 1 , wherein the aperture is offset from the longitudinal axis of the pole member so as to provide the pole member with a major wall portion and a minor wall portion and wherein the major wall portion defines an axial drilling.

3. An actuator arrangement as claimed in claim 2 , wherein the axial drilling is parallel to the longitudinal axis of the actuator.

4. An actuator arrangement as claimed in claim 1 , wherein

the at least one contact member comprises first and second contact members that are exposed through the aperture and the actuator core comprises a core member,

wherein the aperture of the pole member, and the core member, are shaped to permit the core member to be angularly orientated within the aperture relative to the pole member.

5. An actuator arrangement as claimed in claim 4 , wherein the aperture is circular and the core member is circular.

6. An actuator arrangement as claimed in claim 4 , wherein the first and second contact members are integrated within an insulator member that is carried on the core member.

7. An actuator arrangement as claimed in claim 6 , wherein an encapsulating layer is carried on the insulator member and envelops the first and second contact members such that contact faces defined by the contact members are flush with a first surface of the encapsulating layer.

8. An actuator arrangement as claimed in claim 6 , wherein the first and second contact faces defined by the first and second contact members are flush with a first surface of the pole member.

9. An actuator arrangement as claimed in claim 1 , wherein:

the actuator core comprises a solenoid having first and second terminal ends and a core member;

and the actuator arrangement further comprises

an insulator member carried on the core member; and

first and second contact members received within the insulating member, wherein the at least one contact member is the first contact member, wherein the first terminal end of the solenoid is secured to the first contact member and wherein the second terminal end of the solenoid is secured to the second contact member.

10. An actuator arrangement as claimed in claim 9 , wherein the first terminal end is wound around the first contact member for one or more turns and wherein the second terminal end is wound around the second contact member for one or more turns.

11. An actuator arrangement as claimed in claim 10 , wherein each of the first and second contact members is provided with edges that grip the respective terminal end.

12. An actuator arrangement as claimed in claim 9 , wherein each of the first and second contact members defines a respective contact face which engages respective power supply electrodes of opposite polarity, in use.

13. An actuator arrangement as claimed in claim 9 , wherein each of the first and second contact members is a polyhedron.

14. An actuator arrangement as claimed in claim 9 , wherein the first and second contact members are received in the insulating member by initially melting the insulating member in regions local to the first and second contact members and urging the first and second contact members into the melted regions of the insulating member.

15. An actuator arrangement as claimed claim 9 , wherein the solenoid is wound on a coil former carried by the core member and wherein the coil former and the insulating member are linked by a linking member that extends through a slot provided on the core member, such that the insulating member and the coil former are a unitary component.

16. A method of constructing an electromagnetic actuator for a fuel injector, comprising:

providing an actuator core member,

moulding an insulating member onto a first end face of the core member;

providing at least one contact member, and

integrating the at least one contact member with the insulating member by locally melting the insulating member in the region of the at least one contact member to soften said insulating member and urging said at least one contact member into the insulating member.

17. The method of claim 16 , including locally melting the insulating member by ultrasonic welding.

18. The method of claim 16 , further including moulding a coil former onto the core member and forming a solenoid onto the core member.

19. The method of claim 18 , wherein the insulating member and coil former are a unitary moulded component.

20. A method for constructing an electromagnetic actuator for a fuel injector, comprising:

providing a pole member having first and second faces and defining an aperture;

receiving an actuator core member within the aperture, the core member having at least one contact member associated therewith exposed through the aperture and coplanar with the first end face of the outer pole member;

machining the first end face of the pole member and the at least one contact member simultaneously.