Injector for reductant delivery unit having fluid volume reduction assembly

1. A reductant delivery unit, comprising:

a fluid injector having a fluid inlet disposed at a first end of the fluid injector for receiving a reductant, and a fluid outlet disposed at a second end of the fluid injector for discharging the reductant, the fluid injector defining a fluid path for the reductant from the fluid inlet to the fluid outlet, the fluid injector comprising:

a tube member having an end disposed at or near the fluid inlet of the fluid injector, the tube member configured to pass reductant along the fluid path;

a calibration tube disposed in the tube member and including a bore defined in an axial direction through the calibration tube, the bore defining at least a portion of the fluid path through the fluid injector;

an actuator unit disposed within the fluid injector downstream of the calibration tube;

a valve assembly operatively coupled to the actuator unit, wherein a position of the calibration tube within the tube member at least partly sets an opposing opening force for the valve assembly;

wherein the actuator unit comprises a pole piece disposed in a fixed position within the fluid injector and including a bore defined axially through the pole piece, an armature movably positioned within the fluid injector, a coil disposed in proximity to the pole piece and the armature, and a spring disposed between an end of the calibration tube and the armature, wherein the spring biases the armature away from the pole piece in an absence of current passing through the coil so that the valve assembly is placed in a closed position to prevent reductant from passing through the fluid outlet; and

wherein the valve assembly comprises a valve body portion and a pin member at least partly disposed therein, the valve body portion including a shoulder portion disposed orthogonal to a longitudinal axis of the fluid injector; and

a spacer member disposed downstream, relative to a direction of reductant flow through the fluid injector, of a downstream end portion of the armature, and disposed upstream of the shoulder portion of the valve body portion.

2. The reductant delivery unit of claim 1 , wherein the spacer member is formed from compressible, resilient material.

3. The reductant delivery unit of claim 2 , wherein the compressible, resilient material comprises one of a rubber composition and closed cell foam.

4. The reductant delivery unit of claim 2 , wherein the spacer member is ring shaped.

5. The reductant delivery unit of claim 1 , wherein the spacer member has a polygonal cross-section.

6. The reductant delivery unit of claim 1 , wherein the spacer member has a circular or oval shaped cross-section.

7. The reductant delivery unit of claim 1 , wherein the spacer member is compressed by freezing reductant in the fluid injector, and expands when frozen reductant melts.

8. The reductant delivery unit of claim 1 , wherein the spacer member occupies a space in the fluid path of the fluid injector.

9. The reductant delivery unit of claim 1 , wherein an inner surface of the valve body portion protrudes radially inwardly and widens downstream of the radial protrusion to at least partly define a space in which the spacer member is disposed.

10. A fluid injector, comprising:

a fluid inlet disposed at a first end and configured to receive a fluid, and a fluid outlet disposed at a second end of the fluid injector for discharging the fluid, the fluid injector defining a fluid path for the fluid from the fluid inlet to the fluid outlet;

a tube member having an end disposed at or near the fluid inlet of the fluid injector, the tube member configured to pass fluid along the fluid path;

a calibration tube disposed in the tube member, and includes a bore defined in an axial direction through the calibration tube, the bore defining at least a portion of the fluid path through the fluid injector;

an actuator unit disposed within the fluid injector downstream of a calibration filter tube, relative to a direction of flow of fluid along the fluid path from the fluid inlet to the fluid outlet of the fluid injector, the actuator unit engaging an end of the calibration tube;

a valve assembly operatively coupled to the actuator unit, wherein a position of the calibration tube within the tube member sets an opposing opening force of the valve assembly; and

a spacer member disposed between a downstream end portion of the actuator unit and a portion of the valve assembly, the spacer member constructed from a compressible, resilient material so as to compress due to expansion forces from fluid in the fluid injector freezing, and to expand when frozen fluid in the fluid injector melts, the spacer member occupying a space in the fluid path of the fluid injector.

11. The fluid injector of claim 10 , wherein the actuator unit comprises a pole piece disposed in a fixed position within the fluid injector and including a bore defined axially through the pole piece, an armature movably positioned within the fluid injector, a coil disposed in proximity to the pole piece and the armature, and a spring disposed between the armature and the calibration tube and disposed in the bore of the pole piece such that the end of the calibration tube contacts the spring, and the spring biases the armature away from the pole piece in an absence of current passing through the coil so that the valve assembly is placed in a closed position to prevent a reductant from passing through the fluid outlet; and

wherein the valve assembly comprises a valve body portion and a pin member at least partly disposed therein, the valve body portion including a shoulder portion disposed orthogonal to a longitudinal axis of the fluid injector; and

wherein the spacer member is disposed downstream of a downstream end portion of the armature and disposed upstream of the shoulder portion of the valve body portion.

12. The fluid injector of claim 10 ,

wherein the actuator unit comprises a pole piece disposed in a fixed position within the fluid injector and including a bore defined axially through the pole piece, an armature movably positioned within the fluid injector, and a coil disposed in proximity to the pole piece and the armature,

wherein the valve assembly comprises a valve body portion and a pin member at least partly disposed therein, the valve body portion including a shoulder disposed orthogonal to a longitudinal axis of the fluid injector; and

wherein the spacer member is disposed downstream of a downstream end portion of the armature and disposed upstream of the shoulder of the valve body portion.

13. The fluid injector of claim 10 , wherein the spacer member is formed from compressible, resilient material.

14. The fluid injector of claim 13 , wherein the compressible, resilient material comprises one of a rubber composition and closed cell foam.

15. The fluid injector of claim 10 , wherein the spacer member is ring shaped.

16. The fluid injector of claim 10 , wherein the spacer member has a polygonal cross-section.

17. The fluid injector of claim 10 , wherein the spacer member has a circular or oval shaped cross-section.

18. The fluid injector of claim 10 , wherein the spacer member is formed from compressible, resilient material, the spacer member being compressed by freezing reductant in the fluid injector and expands when frozen reductant melts.

19. The fluid injector of claim 10 , wherein the spacer member occupies a space in the fluid path of the fluid injector.

20. The fluid injector of claim 11 , wherein an inner surface of the valve body portion protrudes radially inwardly and then widens downstream of the radial protrusion to at least partly define a space in which the spacer member is disposed, a diameter of the inner surface of the valve body portion defining the space being greater than a diameter of the inner surface of the valve body portion elsewhere.