Modular and scalable common rail fuel system architecture

Abstract

A connecting member for a fuel system includes a body having an inlet configured to receive fuel; a first outlet fluidly coupled to the inlet and configured to release fuel from the body; a second outlet fluidly coupled to the inlet and configured to fluidly couple to a fuel injector; and a fuel path fluidly coupling the inlet, the first outlet, and the second outlet, the fuel path including an accumulator volume.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Patent Application Serial No. 63 / 055,973, filed on July 24, 2020, and entitled “Modular and Scalable Common Rail Fuel System Architecture,” the entire disclosure of which is expressly incorporated herein by reference. Technical Field

[0003] The present disclosure generally relates to systems for injecting fuel into an internal combustion engine. Background of the Invention

[0005] In an internal combustion engine, fuel is supplied to the engine via a fuel injection system. The fuel injection system directs fuel contained in a fuel pump through injector lines connected to fuel injectors. The fuel injectors are directly or indirectly coupled to cylinders in the engine. The fuel mixes with air (either inside or outside the cylinder) and ignites within the cylinder to power the engine. Internal combustion engines are available in a variety of different sizes and can vary in cylinder arrangement (e.g., inline or V-arrangement) and the number of cylinders in the arrangement.

[0006] In certain fuel systems used with internal combustion engines, an accumulator volume for the fuel can be placed in the injector, so that the injector acts as a miniature accumulator, or the accumulator volume can be placed in the fuel rail. However, having the accumulator volume in the injector results in a unique injector that is taller and / or more expensive than a standard injector, while having the accumulator volume in the fuel rail requires additional space for packaging the fuel rail. Therefore, there is a need for a fuel system that places the accumulator volume outside of the injector, allowing for the use of conventional fuel injectors, and also outside of the fuel rail, eliminating the need for the system to include a fuel rail. Summary of the Invention

[0007] In one embodiment of the present disclosure, a connection member for a fuel system is provided. The connection member includes a body having an inlet configured to receive fuel, a first outlet fluidly coupled to the inlet and configured to release fuel from the body, a second outlet fluidly coupled to the inlet and configured to be fluidly coupled to a fuel injector, and a fuel path fluidly coupling the inlet, the first outlet, and the second outlet, the fuel path including an accumulator volume.

[0008] In another embodiment of the present disclosure, a fuel distribution system is provided. The fuel distribution system includes: at least one connecting member having an inlet, a first outlet, and a second outlet; a first external fuel line fluidly coupled to the inlet of the at least one connecting member; a second external fuel line fluidly coupled to the first outlet of the at least one connecting member; and an internal fuel line fluidly coupled to the second outlet of the connecting member. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Advantages and features of the embodiments of the present disclosure will become more apparent from the following detailed description of exemplary embodiments explained in conjunction with the accompanying drawings, in which:

[0010] Figure 1 shows a perspective view of an embodiment of a fuel distribution system of the present disclosure coupled to an engine, wherein the fuel distribution system includes a plurality of connecting members, a plurality of external fuel lines, and a plurality of internal fuel lines;

[0011] Figure 2 Shown Figure 1 a schematic diagram of an embodiment of a fuel distribution system coupled to an engine in an end-to-end series configuration, wherein the fuel distribution system further comprises a high-pressure fuel pump, a pressure-limiting valve, and a fuel tank, wherein the pressure-limiting valve is positioned at a rear end of the fuel distribution system;

[0012] Figure 3 Shown Figure 2 A schematic diagram of an embodiment of a fuel distribution system, wherein the pressure limiting valve is positioned at the front end of the fuel distribution system;

[0013] Figure 4 shows a schematic diagram of another embodiment of a fuel distribution system of the present disclosure connected to an engine in a center feed or split flow configuration, wherein the fuel distribution system includes a high pressure fuel pump, a plurality of connecting members, a plurality of external fuel lines, a plurality of internal fuel lines, a pressure limiting valve, a junction block, and a fuel tank;

[0014] Figure 5A Shown Figure 4 a schematic diagram of a first embodiment of a junction block;

[0015] Figure 5B Shown Figure 4 a schematic diagram of a second embodiment of a junction block;

[0016] Figure 6A Shown Figure 1 a right front perspective view of an embodiment of a connecting member of a fuel distribution system;

[0017] Figure 6B Shown Figure 6A a left front perspective view of a connecting member;

[0018] Figure 6C Shown Figure 6A a left side elevation view of a connecting member;

[0019] Figure 7 Shown Figure 6A a translucent left front perspective view of the connecting member;

[0020] Figure 8A Shown Figure 6A Along Figure 7 a cross-sectional view of the connecting member taken along line 8A-8A;

[0021] Figure 8B Shown Figure 6A Along Figure 7 a cross-sectional view of the connecting member taken along line 8B-8B;

[0022] Figure 9 shows a cross-sectional view of another embodiment of a connecting member of the present disclosure;

[0023] Figure 10 Shown is connected to Figure 1 a cross-sectional view of one of the connecting members and one of the internal fuel lines of one of the injectors of the engine; and

[0024] Figure 11 Shown Figure 10 A more detailed cross-sectional view of the internal fuel lines and injectors.

[0025] Throughout the several views, corresponding reference numerals indicate corresponding parts. Although the drawings represent embodiments of the present disclosure, they are not necessarily drawn to scale and certain features may be exaggerated to better illustrate and explain the present disclosure. The examples set forth herein illustrate embodiments of the present disclosure in one form, and such examples should not be construed as limiting the scope of the present disclosure in any way. DETAILED DESCRIPTION

[0026] See Figures 1 to 4 , shows a fuel distribution system 100 of the present disclosure coupled to an engine 20 having a plurality of cylinders (not shown) covered by a cylinder head 22 and a plurality of fuel injectors 24 providing fuel to the cylinders through the cylinder head 22. Figures 1 to 4In the exemplary embodiment shown in FIG, engine 20 includes six cylinders. However, in various embodiments, the number of cylinders in engine 20 may include four, six, twelve, eighteen, or any other number of cylinders. Furthermore, in various embodiments, each cylinder may be covered by a separate cylinder head, while in other various embodiments, two or more cylinders may be covered by a single cylinder head that spans the two or more cylinders.

[0027] The fuel delivery system 100 generally includes: a high pressure ("HP") fuel pump 110; a pressure limiting valve ("PLV") 112; a fuel source or fuel tank 114; a plurality of connecting members 102, each of which is coupled to the rocker housing 26 ( Figure 1 ), the rocker housing being coupled to the cylinder head 22 of the engine 20; a plurality of external fuel lines 104 fluidly coupling the connecting member 102 to each other and / or to a high pressure (“HP”) fuel pump 110 and / or a fuel source 114 ( Figure 2 ); and a plurality of internal fuel lines 106 that fluidly couple the connection member 102 to the fuel injectors 24 of the engine 20. In various embodiments, the internal fuel lines 106 may be coupled to the fuel injectors 24 ( Figure 10 and Figure 11 The injector connector 107 may include a single or multiple O-rings 105 for sealing purposes ( Figure 11 The inner fuel line 106 and / or the outer fuel line 104 may be a double-wall fuel line including a main passage 108 and a fuel leakage channel 109 surrounding the main passage 108 ( Figure 11 ).

[0028] refer to Figure 2 and Figure 3 In various embodiments, the connection members 102 are coupled in series or end-to-end such that the HP fuel pump 110 is coupled to a first one of the connection members 102 at one end or the other of the fuel distribution system 100, which is then coupled in series to the other connection members 102. When the connection members 102 are coupled in series, the PLV 112 may be coupled at either end of the fuel distribution system 100 and fluidly coupled to the fuel source 114 and / or the fuel pump 110. For example, Figure 2 As shown in , the PLV 112 may be coupled to the last connecting member 102 in the chain of connecting members 102, between the last connecting member 102 and a fuel source 114. When the PLV 112 is coupled downstream of the last connecting member 102, the fuel source 114 may be positioned between the PLV 112 and the fuel pump 110. Alternatively, as shown in Figure 3As shown in , the PLV 112 may be coupled upstream of a first connection member 102 in the chain of connection members 102, between the fuel pump 110 and the first connection member 102. When the PLV 112 is coupled upstream of the first connection member 102, the PLV 112 may be directly coupled to both the fuel pump 110 and the fuel source 114.

[0029] See now Figure 4 In various other embodiments, connecting member 102 is coupled to HP fuel pump 110 in a center-feed or split-flow configuration, such that HP fuel pump 110 is fluidly coupled between two of the intermediate connecting members 102 and then coupled to connecting members 102 in series, one side of each of the intermediate connecting members 102. When connecting member 102 is coupled to HP fuel pump 110 in a center-feed or split-flow configuration, the pressure drop between injectors 24 is lower than when connecting member 102 is coupled to HP fuel pump 110 in series or end-to-end. PLV 112 is typically coupled to connecting member 102 and fuel pump 110 via junction block 111. PLV 112 may alternatively be placed in various other locations relative to fuel distribution system 100 and engine 20. For example, PLV 112 may be positioned between two rocker housings 26, cylinder head 22, and / or connecting member 102.

[0030] refer to Figure 5A and Figure 5B The junction block 111 generally includes an inlet 120 fluidly coupled to the fuel pump 110, a first outlet 122 fluidly coupled to the PLV 112, and a second outlet 124 and a third outlet 126, each fluidly coupled to the connection member 102. In various embodiments, the junction block 111 may include an inlet passage 130 that splits into two outlet passages 132 and 134 extending to the second outlet 124 and the third outlet 126, wherein the first outlet passage 136 tees into the inlet passage 130 and extends to the first outlet 122 before the inlet passage 130 splits into the outlet passages 132 and 134. In various other embodiments, the junction block 111′ may include an inlet passage 130′ that tees into a longitudinal passage 138 that extends from a first side 140 of the junction block 111′ to a second side 142 of the junction block 111′, and two outlet passages 132′ and 134′ that extend from the longitudinal passage 138 to a second outlet 124′ and a third outlet 126′. A first end 150 of the longitudinal passage 138 includes a plug 152, while a second end 154 of the longitudinal passage 138 extends to the first outlet 122′.

[0031] See now Figures 6A to 6C 、 Figure 7、 Figures 8A to 8B as well as Figure 9 , the connecting member 102, 102* will be described in more detail. The connecting member 102, 102* includes a body 200, 200* having an inlet 202, 202* configured to fluidly couple with an external fuel line 104 from an upstream connecting member 102, 102* or HP fuel pump 110 or PLV 112; a first outlet 204, 204* configured to fluidly couple with an external fuel line 104 coupled to a downstream connecting member 102, 102* or PLV 112; and a second outlet 206, 206* configured to fluidly couple to an internal fuel line 106 that fluidly couples the connecting member 102, 102* to the fuel injector 24 ( Figure 10 In various embodiments, the inlet 202 is positioned between the first outlet 204 and the second outlet 206 (FIGS. 6-8), while in other various embodiments, the first outlet 204* is positioned between the inlet 202* and the second outlet 206* ( Figure 9 ).

[0032] The connecting member 102 may also include a first groove 208 and a second groove 210 that are configured to receive a sealing member to seal the connection between the connecting member 102 and the rocker housing 26 / cylinder head 22, and / or include a clamping plate 212 that is configured to help retain the connecting member 102 within the rocker housing 26 / cylinder head 22. In various embodiments, the clamping plate 212 is positioned between the inlet 202 and the second outlet 206, and the first groove 208 and the second groove 210 are positioned between the clamping plate 212 and the second outlet 206. The connecting member 102 may also or alternatively include a retaining slot 214 (not shown) that is configured to retain a wiring harness clamp (not shown). Figure 6B In various embodiments, the retaining groove 214 is positioned adjacent to the second outlet 206 .

[0033] refer to Figures 7 to 9The connecting member 102, 102* further includes a fuel path / accumulator volume 216, 216* that fluidly couples the inlet 202, 202*, the first outlet 204, 204*, and the second outlet 206, 206*; and a fuel leakage path 240 that fluidly couples the inlet 202, 202*, the first outlet 204, 204*, and / or the second outlet 206, 206*. The fuel path / accumulator volume 216, 216* includes a first portion 218, 218* having a first diameter d1, d1* and a second portion 220, 220* having a second diameter d2, d2*. In various embodiments, such as those shown in Figures 6-8, the first portion 218 extends from the first outlet 204, adjacent the exterior end 222 of the body 200, through both the inlet 202 and the second outlet 206, and the second portion 220 extends between the second outlet 206 and the interior end 224 of the body 200. In other various embodiments, such as Figure 9 , a first portion 218* can extend from the inlet 202* adjacent the outer end 222 of the connecting member 102*, just past the first outlet 204*, while a second portion 220* extends downwardly from adjacent the first outlet 204*, past the second outlet 206* adjacent the inner end 224 of the connecting member 102*. In various embodiments, the fuel paths / volumes 216, 216* include a first plug 226, 226* in the outlet 228, 228* of the fuel paths / volumes 216, 216* positioned at the inner end 224, and / or a second plug 230 in the outlet 232 of the fuel paths / volumes 216* positioned at the outer end 222. The fuel path / volume 216* may further include a control orifice 234 between the first portion 218* and the second portion 220*, wherein the control orifice 234 is positioned downstream of the inlet 202* and the first outlet 204* and closer to the inner end 224 than the inlet 202* and the first outlet 204*.

[0034] See Figure 7 and Figure 8B, the connecting member 102 also includes a fuel leak path 240 that is fluidly coupled to the inlet 202, the first outlet 204, and / or the second outlet 206. The fuel leak path 240 generally includes a main fuel leak path 242 that extends from the second outlet 206 to the exterior end 222; and a second outlet path 244 that fluidly couples the second outlet 206 to the main fuel leak path 242. The main fuel leak path 242 generally includes a first outlet 246 in the exterior end 222 of the body 200; and a second outlet 248 located along the bottom surface of the body 200. The first outlet 246 generally includes a plug (not shown) to allow fuel leakage to exit the main fuel leak path 242 through the second outlet 248. In various embodiments, the fuel leak path 240 also includes an inlet leak path 250 and a first outlet leak path 252. The inlet leakage passage 250 and the first outlet leakage passage 252 may each independently fluidly couple the connection inlet 202 and / or the first outlet 204 to the main fuel leakage passage 242 , or include separate outlets (not shown) along an exterior surface of the body 200 .

[0035] Now refer to Figure 10 and Figure 11 , the flow of fuel will be described. Fuel is supplied from the HP fuel pump 110 to the first connecting member 102 via the external fuel line 104. As the fuel enters the connecting member 102 via the inlet 202, the fuel fills the fuel path / accumulator volume 216. Excess fuel supplied to the connecting member 102 is transferred to the first outlet 204 and is transferred to the subsequent downstream connecting member 102 via a separate external fuel line 104'. When fuel is required in the fuel injector 24, the fuel within the accumulator volume 216 is transferred via the second outlet 206 to the main passage 108 of the internal fuel line 106 to the fuel injector 24. Any fuel leakage between the fuel injector 24 and / or the internal fuel line 106 is discharged through the passage 109 ( Figure 11 ) passes back to the second outlet 206 and enters the fuel leakage path 240 ( Figure 7 and Figure 8B ), thereby being collected or discharged in a controlled manner. In addition, any fuel leakage around the inlet 202 and the first outlet 204 is transmitted through the inlet leakage path 250 and the first outlet leakage path 252, thereby being collected or discharged in a controlled manner.

[0036] Various embodiments of the system described herein offer benefits applicable to both in-line and V-type internal combustion engines. The modular system allows the fuel system to be integrated into existing engines. When the connection is on the hot side of the engine, the multi-wall design reduces the risk of fuel being ejected from the injector connection. Leaking fuel at the cold-side connection routes fuel away from hot components and reduces the risk of leaking fuel contacting hot areas. Leaked fuel can be discharged or collected in a controlled manner. Various embodiments of the system can reduce total cost of ownership and engine maintenance time.

[0037] Although various embodiments of the present disclosure have been shown and described, it should be understood that these embodiments are not limited thereto. Those skilled in the art may change, modify, and further apply the embodiments. Therefore, these embodiments are not limited to the details previously shown and described, but include all such variations and modifications.

[0038] In addition, the connecting lines shown in the various figures included herein are intended to represent exemplary functional relationships and / or physical connections between various elements. It should be noted that many alternative or additional functional relationships or physical connections may exist in actual systems. However, the benefits, advantages, problem solutions, and any elements that may cause any benefit, advantage, or solution to appear or become more significant should not be interpreted as key, essential, or necessary features or elements. Therefore, the scope is limited only by the appended claims, in which references to singular elements are not intended to mean "one and only one", but "one or more", unless explicitly stated so. In addition, when a phrase similar to "at least one of A, B, or C" is used in a claim, it is intended that the phrase be interpreted to mean that A may exist alone in an embodiment, B may exist alone in an embodiment, C may exist alone in an embodiment, or any combination of elements A, B, or C may exist in a single embodiment; for example, A and B, A and C, B and C, or A and B and C.

[0039] In the detailed description herein, references to "one embodiment," "an embodiment," "an example embodiment," etc. indicate that the described embodiment may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases do not necessarily refer to the same embodiment. Furthermore, when a particular feature, structure, or characteristic is described in conjunction with one embodiment, it should be understood that it is within the knowledge of one skilled in the art having the benefit of this disclosure to enable such feature, structure, or characteristic to function in conjunction with other embodiments, whether or not explicitly described. After reading the description, it will be clear to one skilled in the relevant art how to implement the disclosure in alternative embodiments.

[0040] In addition, no element, component, or method step in this disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein shall be interpreted under the terms of 35 U.S.C. § 112(f) unless the phrase "means for..." is used to expressly recite the element. As used herein, the term "comprise" or any other variation thereof is intended to cover non-exclusive inclusions, such that a process, method, article, or apparatus that includes a list of elements may include not only those elements, but may also include other elements not expressly listed or inherent to such process, method, article, or apparatus.

Claims

1. A connecting member for a fuel system including a fuel injector, comprising: A main body, the main body having: an inlet configured to receive fuel; a first outlet fluidly coupled to the inlet and configured to release excess fuel from the body; a second outlet fluidly coupled to the inlet and configured to be fluidly coupled to the fuel injector; as well as A fuel path fluidly couples the inlet, the first outlet, and the second outlet, the fuel path including an accumulator volume. 2 . The connection member of claim 1 , wherein the inlet is positioned between the first outlet and the second outlet. 3 . The connection member of claim 1 , wherein the first outlet is positioned between the inlet and the second outlet.

4. The connecting member according to claim 1, further comprising: A fuel leak path has at least one fuel leak path fluidly coupled to at least one of the inlet, the first outlet, and the second outlet.

5. The connecting member of claim 4 , wherein the at least one fuel leak passage of the fuel leak path includes a main leak passage, an inlet leak passage, a first outlet leak passage, and a second outlet leak passage, at least one of the inlet leak passage, the first outlet leak passage, and the second outlet leak passage being fluidly coupled to the main leak passage. 6 . The connection member of claim 5 , wherein each of the inlet leak path, the first outlet leak path, and the second outlet leak path is fluidly coupled to the main leak path. 7 . The connection member of claim 1 , wherein the fuel path includes a first portion having a first diameter and a second portion having a second diameter, the second diameter being larger than the first diameter.

8. The connecting member of claim 7, wherein the first portion extends from adjacent the first end of the connecting member through the second outlet.

9. The connecting member of claim 7, wherein the first portion extends through the inlet and the first outlet and ends before reaching the second outlet.

10. The connecting member of claim 1, further comprising a clamping plate positioned between the inlet and the second outlet, and at least one passage positioned between the clamping plate and the second outlet.

11. The connecting member of claim 1, further comprising a groove adjacent the second outlet, the groove being configured to retain a wiring harness clip.

12. A fuel dispensing system comprising: at least one connecting member according to any one of claims 1 to 11; a first external fuel line fluidly coupled to the inlet of the at least one connecting member; a second external fuel line fluidly coupled to the first outlet of the at least one connecting member; as well as An internal fuel line is fluidly coupled to the second outlet of the connecting member.

13. The fuel distribution system of claim 12, wherein at least one of the first external fuel line, the second external fuel line, and the internal fuel line includes a first wall defining a main passageway of the line and a second wall defining a channel extending between the first and second walls.

14. The fuel delivery system of claim 12, wherein the inlet and the first outlet are configured to be positioned externally of a cylinder of an engine.

15. The fuel dispensing system of claim 12, further comprising: a high-pressure fuel pump fluidly coupled to the at least one connecting member; and a pressure limiting valve fluidly coupled to the at least one connecting member. 16 . The fuel delivery system of claim 15 , wherein the high pressure fuel pump is coupled to the first external fuel line and the pressure limiting valve is coupled to the second external fuel line.

17. The fuel distribution system of claim 15, wherein the at least one connecting member includes a first connecting member and a second connecting member, the second external fuel line is fluidly coupled to an inlet of the second connecting member, a third external fuel line is fluidly coupled to a first outlet of the second connecting member, the high-pressure fuel pump is coupled to the first connecting member via the first external fuel line, and the first outlet of the second connecting member is coupled to the pressure limiting valve via the third external fuel line.

18. The fuel delivery system of claim 15, wherein the at least one connecting member includes a first connecting member and a second connecting member, the high-pressure fuel pump is fluidly coupled to the first connecting member via the first external fuel line, and the high-pressure fuel pump is fluidly coupled to an inlet of the second connecting member via a third external fuel line.

19. The fuel delivery system of claim 18, wherein the pressure limiting valve is coupled to the first and second connecting members through the high-pressure fuel pump.

20. The fuel distribution system of claim 15, wherein the at least one connecting member includes a first connecting member and a second connecting member, and the pressure limiting valve is positioned between the first connecting member and the second connecting member.

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