Fuel rail for a fuel system of an internal combustion engine

Abstract

A fuel rail for a fuel system includes a single unitary rail body extending from a first end to a second end opposite the inlet end. The first end is configured for engagement to a high pressure fuel line. A flow passage extends from the second end to an end wall within the fuel rail, and a first end passage extends from the first end through the end wall to the flow passage.

Description

Technical Field

[0001] This application relates to internal combustion engines, and more specifically to fuel rails for fuel systems of internal combustion engines. Background Technology

[0002] Fuel leaks can cause malfunctions in internal combustion engines. Identifying and repairing leaking components in the fuel system is often difficult, time-consuming, and costly. Therefore, robust fuel system components resistant to fuel leaks are needed. Consequently, significant unmet needs remain for the unique apparatus, methods, systems, and techniques disclosed herein.

[0003] Disclosure of Example Implementations To clearly, concisely, and accurately describe the exemplary embodiments of this disclosure, the ways and methods of making and using these exemplary embodiments, and to enable the practice, making, and using of these exemplary embodiments, reference will now be made to certain exemplary embodiments (including those illustrated in the accompanying drawings), and these exemplary embodiments will be described using specific language. However, it should be understood that this does not constitute a limitation on the scope of the invention, and that the invention includes and protects such changes, modifications, and further applications of the exemplary embodiments that will occur to those skilled in the art. Summary of the Invention

[0004] One embodiment is a unique fuel rail for a fuel system of an internal combustion engine. Another embodiment is a unique method for manufacturing a fuel rail for a fuel system of an internal combustion engine. Another embodiment is a unique fuel rail manufactured according to a unique method. Further embodiments, forms, objects, features, advantages, aspects, and benefits will become apparent from the following description and drawings. Attached Figure Description

[0005] Figure 1 This is a schematic diagram illustrating certain aspects of an example system comprising an internal combustion engine and a fuel system having a fuel rail, according to the present disclosure.

[0006] Figure 2 This is an example embodiment based on the present disclosure. Figure 1 A longitudinal sectional view of the fuel rails of the fuel system.

[0007] Figure 3 yes Figure 2 An enlarged view of the first end of the fuel rail.

[0008] Figure 4 It shows the formation of a second end of the fuel rail opposite to the first end toward the first end. Figure 2 A longitudinal cross-sectional view of a portion of the flow channel in the fuel guide rail.

[0009] Figure 5It shows the first end passing through the fuel rail to Figure 4 A perspective view of the first end channel formed by the flow channel formed in the middle. Detailed Implementation

[0010] refer to Figure 1 The illustration depicts a system 100, which includes an internal combustion engine 102 (also referred to herein as "engine 102") and a fuel system 120 operatively coupled to the engine 102. In the illustrated embodiment, the engine 102 is a direct-injection reciprocating piston internal combustion engine configured and operable to burn fuel injected directly into respective combustion cylinders of a plurality of combustion cylinders 104 by one or more fuel injectors 122 of the fuel system 120. It should be understood that the engine 102 can be configured and provided in various forms, including various numbers of combustion cylinders 104 and various numbers and / or types of fuel injectors 122, including port injectors.

[0011] In the illustrated embodiment, fuel system 120 is configured and provided as a high-pressure common rail (HPCR) fuel system. Fuel system 120 includes a fuel rail 150 that receives pressurized fuel from fuel pump 124 and distributes the pressurized fuel to fuel injectors 122. In the illustrated embodiment, fuel pump 124 is provided and configured as a high-pressure fuel pump and includes one or more pump elements (E1…En), such as in-cylinder piston pump elements configured to pressurize the fuel received by fuel pump 124. However, any type of fuel pump 124 is contemplated.

[0012] In one embodiment, a flow control valve 126 (such as an inlet metering valve, an active inlet metering valve, or other type of metering valve) is located at or upstream of the inlet of the fuel pump 124 and is operatively coupled to and controlled by, for example, an engine control unit (not shown), to meter or regulate the flow of fuel entering the fuel pump 106. The flow control valve 126 is configured and operable to receive fuel pumped from the fuel tank 128 by a pump 130, which may be configured and provided as a low-pressure fuel pump. The fuel pump 124 and the flow control valve 126 may be configured such that the fuel flow provided by the flow control valve 126 can maintain the required pressure in one or more components of the fuel system 120, such as the fuel injector 122 and / or the fuel rail 150.

[0013] Further reference Figures 2 to 5The fuel rail 150 includes a first end 152 that receives high-pressure fuel from the fuel pump 124. The fuel rail 150 includes a rail body 156 extending from the first end 152 to an opposing second end 154. The rail body 156 is a single, monolithic component from the first end 152 to the second end 154, eliminating the need for joints or other separate components that engage with the rail body forming the first end 152 of the fuel rail 150. Eliminating any such joints or separate components eliminates potential leakage points within the fuel system 120.

[0014] The guide rail body 156 includes an elongated longitudinal portion 158 extending along a central longitudinal axis L. The longitudinal portion 158 includes a first end channel 160 extending therefrom from a first end 152, and a flow channel 162 extending therefrom from a second end 154. In one embodiment, the central longitudinal axis L is centered along the flow channel 162. The first end channel 160 intersects the flow channel 162 at an end wall 164 located within the guide rail body 156, adjacent to and downstream of the first end 152.

[0015] The first end 152 may be an inlet end, an outlet end, a plug end, and / or a sensor end. In one embodiment, the first end 152 is configured to engage with a fuel system component, such as a high-pressure fuel line supplying or receiving fuel from the first end channel 160. The rail body 156 includes a configuration at the first end 152 that can engage with the fuel system component. For example, a fitting 132 may be provided to connect at least one high-pressure fuel line to the fuel rail 150. Other embodiments envision high-pressure fuel lines and / or other types of fuel system components, such as fittings, plugs, sensors, etc., connected at the first end 152 along and nominally parallel to the longitudinal axis L.

[0016] In the illustrated embodiment, the rail body 156 includes external threads 174 adjacent to a first end 152. These external threads 174 threadedly engage fuel system components (such as pipe nuts of pipe fittings 132) that can be positioned around a high-pressure fuel line 134, which will be connected in flow communication to a first end channel 160 of the fuel rail 150. The rail body 156 may also include an external tool engagement surface 176 (such as a hexagonal surface or other external shape) surrounding a longitudinal portion 158, which allows tools to engage and retain the fuel rail 150 during installation.

[0017] A flow channel 162 extends from a first end channel 160 through a second end 154. In another embodiment, the second end 154 includes a flow channel portion passing through the second end 154, the diameter of which is reduced relative to the flow channel 162, similar to the first end channel 160. In still other embodiments, the flow channel 162 includes the same or similar size as the first end channel 160. A longitudinal portion 158 of the guide body 156 includes an enlarged connecting portion 178 at the second end 154. The flow channel 162 includes a widened portion 180 in the connecting portion 178. The connecting portion 178 is configured, for example, to have internal threads, external threads, or other configurations to engage with a dump valve or pressure relief valve 136 operable to return excess fuel from the fuel rail 150 to the fuel system 120 when open. In other embodiments, the dump valve 136 is located away from the second end 154 and is connected to the second end 154 via a fuel line coupled to the connecting portion 178.

[0018] The flow channel 162 is in fluid communication with a plurality of injector ports 166 that project outward from the longitudinal portion 158 and define a flow path for fuel flow to the connected fuel injectors 122. While six injector ports 166 are shown in the illustrated embodiment, the fuel rail 150 may include any number of injector ports 166, depending on the number of fuel injectors 122 to be connected. At least one sensor port 168 (such as at a boss 196 in the longitudinal portion 158) may also be provided in fluid communication with the flow channel 162. The rail body 156 also includes mounting tabs 170 that project laterally outward from the longitudinal portion 158. Each mounting tab 170 includes a hole 172 configured to receive a fastener to secure the fuel rail 150 in place, such as to a cylinder head or other engine component.

[0019] Along the injector port 166, the flow channel 162 includes a first cross-sectional area or dimension D1 orthogonal to the central longitudinal axis L, while the first end channel 160 includes a second cross-sectional area or dimension D2 orthogonal to the central longitudinal axis L. The outer end of the first end channel 160 includes a flared end channel portion 182 that extends from the first end 152 along a portion of the length of the first end channel 160. In one embodiment, dimensions D1 and D2 are diameters, and the first end channel 160 and the flow channel 162 have circular cross-sections. However, other shapes are not excluded.

[0020] The first end channel 160 extends through the end wall 164 and leads to the flow channel 162. In one embodiment, the first end channel 160 is eccentric relative to the flow channel 162. For example, the flow channel 162 may be centered along a central longitudinal axis L, while the first end channel 160 is offset from the central longitudinal axis L. In another embodiment, the first end channel 160 is concentric with the flow channel 162, and both are centered about or offset from the central longitudinal axis L.

[0021] In one embodiment, the flow channel 162 is formed by gun drilling through the longitudinal portion 158 of a guide body 156, which is provided as a solid metal monolithic piece. During manufacturing, the flow channel 162 is drilled into the longitudinal portion 158 to form a blind end wall 164' at that point. A first end channel 160 is then formed through the first end 152 to pierce the blind end wall 164' to fluidly connect the first end 152 to the flow channel 162, thereby transforming the blind end wall 164' into an end wall 164.

[0022] In one embodiment, the flow channel 162 is formed with a fillet 184 located between a longitudinal wall 186 extending along and defining the flow channel 162 and a blind end wall 164'. The fillet 184 provides a curved transition between the blind end wall 164' and the longitudinal wall 186. In one specific embodiment, the fillet 184 is approximately 50 micrometers. Other embodiments envision other sizes for the fillet 184 and / or non-curved fillets.

[0023] In one embodiment, the flow channel 162 is formed such that the blind end wall 164' has a concave shape with a vertex 190 offset from the central longitudinal axis L. In one embodiment, the blind end wall 164' has a first angular orientation A1 and a second angular orientation A2, the first angular orientation A1 being located between the longitudinal wall 186 along a first side of the flow channel 162 and the blind end wall 164', and the second angular orientation A2 being located between the longitudinal wall 186 along a second side of the flow channel 162 opposite to the first side and the blind end wall 164'. Since the first end channel 160 is smaller than the flow channel 162, after the first end channel 160 is formed, a rounded corner 184 and angular orientations A1 and A2 also exist between the end wall 164 and the longitudinal wall 186. However, when the first end channel 160 pierces the blind end wall 164', the vertex 190 may be removed, or it may not be removed.

[0024] In one embodiment, a method of manufacturing the fuel rail 150 includes forming a flow channel 162 through a solid fuel rail body 156 to form a blind end wall 164' located within the fuel rail 150. The flow channel 162 is formed through a second end 154 of the fuel rail 150 toward the blind end wall 164' of the opposite first end 152 of the fuel rail 150. The method further includes forming a first end channel 160 through the opposite first end 152 and through the blind end wall 164' to the flow channel 162.

[0025] In one embodiment, the first end channel 160 is formed eccentrically with the flow channel 162. In one embodiment, the first end channel 160 has a flared inlet channel portion 182 that extends from the first end 152 along a portion of the length of the first end channel 160. In one embodiment, the flow channel 162 has a first cross-sectional area or size D1, and the first end channel 160 has a second cross-sectional area or size D2 that is smaller than the first cross-sectional area or size D1.

[0026] In one embodiment, the flow channel 162 is formed along a central longitudinal axis L such that the blind end wall 164' is formed to include a recessed shape having a vertex 190 offset from the central longitudinal axis L. In another embodiment, the flow channel 162 is formed to include a fillet 184 located between the longitudinal wall 186 of the flow channel 162 and the blind end wall 164'.

[0027] In one embodiment, the blind end wall 164' is formed to have a recessed shape, the blind end wall 164' having a first angular orientation A1 and a second angular orientation A2, the first angular orientation A1 being located between the longitudinal wall 186 along the first side of the flow channel 162 and the blind end wall 164', and the second angular orientation A2 being located between the longitudinal wall 186 along the second side of the flow channel 162 opposite to the first side and the blind end wall 164'.

[0028] In one embodiment, the fuel rail 150 is entirely manufactured from a solid forged fuel rail body 156, which is a single, integral body of metallic material. In one embodiment, the fuel rail 150 is a single, integral rail body 156 extending from a first end 152 to a second end 154 opposite to the first end 152. In other embodiments, the rail body 156 is a single, integral rail body 156 formed from a material blank and / or by drawing on a mandrel tube, wherein operation stops at a blind end.

[0029] The first end 152 is configured for direct engagement with a pipe nut of a high-pressure fuel line, plug, sensor, and / or fitting 132 without the need for an intermediate fitting, and the fuel rail 150 is manufactured such that a blind end wall 164' is formed within the fuel rail 150 through the second end 154 of the solid fuel rail body 156 to form a flow channel 162, and then an end wall 164 is formed through the first end 152 and through the blind end wall 164' to the flow channel 162 to form a first end channel 160.

[0030] This document contemplates various aspects and embodiments of this application. For example, one aspect relates to a method of manufacturing a fuel rail. The method includes: forming a flow channel through a solid, one-piece fuel rail body to a blind end wall located within the fuel rail, the flow channel being formed through one end (or second end 154) of the fuel rail toward the opposite end (or first end 152) of the fuel rail to the blind end wall; and forming an end channel through the opposite end and through the blind end wall to the flow channel.

[0031] In embodiments of the method, forming the end channel includes forming the end channel eccentrically with respect to the flow channel.

[0032] In an embodiment of the method, forming an end channel includes forming an end channel having a flared end channel portion that extends from the other end along a portion of the length of the end channel.

[0033] In an embodiment of the method, forming a flow channel includes forming a flow channel having a first cross-sectional area; and forming an end channel includes forming an end channel having a second cross-sectional area smaller than the first cross-sectional area.

[0034] In an embodiment of the method, forming a flow channel includes forming a flow channel along a central longitudinal axis; and forming a flow channel includes forming a blind end wall that includes a concave shape having a vertex offset from the central longitudinal axis.

[0035] In an embodiment of the method, forming a flow channel includes forming a blind end wall with rounded corners located between the longitudinal wall of the flow channel and the blind end wall.

[0036] In an embodiment of the method, forming a flow channel includes forming a blind end wall with a concave shape, the blind end wall having a first angular orientation and a second angular orientation, the first angular orientation being located between a longitudinal wall along a first side of the flow channel and the blind end wall, and the second angular orientation being located between a longitudinal wall along a second side of the flow channel opposite to the first side and the blind end wall.

[0037] In one embodiment, the method includes forming a thread around a fuel rail at the other end for connection to a tube nut of a high-pressure fuel line.

[0038] In an embodiment of the method, the fuel rail body is a solid forged rail body, which is an integral piece of metal material.

[0039] According to another aspect of this disclosure, a fuel rail for a fuel system is provided. The fuel rail includes a one-piece integral rail body extending from a first end to a second end opposite the first end. The first end is configured for engagement with a fuel system component. The fuel rail is manufactured by: forming a flow channel through the one-piece fuel rail body to a blind end wall located within the fuel rail, the flow channel being formed through the second end of the fuel rail toward the opposite first end of the fuel rail to the blind end wall; and forming an end channel through the first end and through the blind end wall to the flow channel.

[0040] Another aspect of this disclosure relates to a fuel rail for a fuel system. The fuel rail includes a single integral rail body extending from a first end to an opposing second end. The rail body includes a flow channel extending through the second end to an end wall located within the rail body. The rail body also includes a first end channel extending through the first end and through the end wall.

[0041] In one embodiment of the fuel rail, the rail body includes external threads at a first end. These external threads are configured to engage with a pipe nut on a high-pressure fuel line.

[0042] In an embodiment of the fuel rail, the second end is configured to engage with a dump valve.

[0043] In an embodiment of the fuel rail, the first end channel is eccentric relative to the flow channel.

[0044] In an embodiment of the fuel rail, the end wall has a recessed shape and a first angular orientation and a second angular orientation. The first angular orientation is located between the longitudinal wall of the first side along the flow channel and the end wall, and the second angular orientation is located between the longitudinal wall of the second side along the flow channel opposite to the first side and the end wall.

[0045] In an embodiment of the fuel guide, the fillet extends between the longitudinal wall and the end wall of the flow channel.

[0046] In an embodiment of the fuel rail, the flow channel has a first cross-sectional area, the first end channel includes a second cross-sectional area, and the second cross-sectional area is smaller than the first cross-sectional area.

[0047] In one embodiment, the fuel rail includes a plurality of fuel injector ports that extend through the rail body into the flow channel in an orientation transverse to the flow channel.

[0048] In one embodiment, the fuel rail includes a plurality of mounting tabs extending outward from a longitudinal portion of the rail body. Each of these mounting tabs includes a hole for a fastener.

[0049] While exemplary embodiments of this disclosure have been detailed and described in the accompanying drawings and foregoing description, their nature should be considered illustrative rather than restrictive. It should be understood that only certain exemplary embodiments have been shown and described, and protection is intended for all changes and modifications falling within the spirit of the claimed invention. It should be understood that while the use of terms such as desirable, preferred, preferred, or more preferred in the foregoing description indicates that the features so described may be more desirable, this may not be necessary, and embodiments lacking these may be contemplated as being within the scope of the invention, defined by the appended claims. When reading the claims, the use of terms such as “a,” “an,” “at least one,” or “at least a portion” is not intended to limit the claims to only one object unless expressly stated otherwise in the claims. When the language “at least a portion” and / or “a portion” is used, the object may include a portion and / or the entire object unless expressly stated otherwise.

Claims

1. A method for manufacturing a fuel rail, the method comprising: A flow channel is formed by passing through the single-piece fuel rail body to a blind end wall located within the fuel rail, the flow channel being formed by passing through one end of the fuel rail toward the opposite end of the fuel rail to the blind end wall; and The flow channel is formed by passing through the opposite end and through the blind end wall to the flow channel.

2. The method of claim 1, wherein forming the end channel comprises forming the end channel eccentrically with respect to the flow channel.

3. The method of claim 1 or claim 2, wherein forming the end channel comprises forming the end channel having a flared end channel portion extending from the other end along a portion of the length of the end channel.

4. The method according to any of the preceding claims, wherein: Forming the flow channel includes forming the flow channel having a first cross-sectional area; and Forming the end channel includes forming the end channel having a second cross-sectional area smaller than the first cross-sectional area.

5. The method according to any of the preceding claims, wherein: Forming the flow channel includes forming the flow channel along a central longitudinal axis; and Forming the flow channel includes forming the blind end wall into a concave shape having a vertex offset from the central longitudinal axis.

6. The method according to any preceding claim, wherein forming the flow channel includes forming the blind end wall having a rounded corner located between the longitudinal wall of the flow channel and the blind end wall.

7. The method of claim 6, wherein forming the flow channel comprises forming the blind end wall having a recessed shape, the blind end wall having a first angular orientation and a second angular orientation, the first angular orientation being located between the longitudinal wall along a first side of the flow channel and the blind end wall, and the second angular orientation being located between the longitudinal wall along a second side of the flow channel opposite to the first side and the blind end wall.

8. The method according to any of the preceding claims, comprising forming a thread around the fuel rail at the other end for connection with a tube nut of a high-pressure fuel line.

9. The method according to any of the preceding claims, wherein the single-piece fuel rail body is a solid forged rail body, and the solid forged rail body is an integral piece of metal material.

10. A fuel rail for a fuel system, the fuel rail comprising a single integral rail body extending from a first end to a second end opposite an inlet end, the first end being configured to engage with a high-pressure fuel line, wherein the fuel rail is manufactured according to the method of claim 1.

11. A fuel rail for a fuel system, the fuel rail comprising: A single integral guide body extending from a first end to an opposite second end, the guide body including a flow channel extending through the second end to an end wall located within the guide body, the guide body also including a first end channel extending through the first end and through the end wall.

12. The fuel rail of claim 11, wherein the rail body includes an external thread at the first end, the external thread being configured to engage with a fuel system component.

13. The fuel rail of claim 11 or claim 12, wherein the second end is configured to engage with a dump valve.

14. The fuel rail according to any of the preceding claims, wherein the first end channel is eccentric relative to the flow channel.

15. The fuel rail according to any of the preceding claims, wherein the end wall has a recessed shape, the end wall has a first angular orientation and a second angular orientation, the first angular orientation being located between the longitudinal wall and the end wall along a first side of the flow channel, and the second angular orientation being located between the longitudinal wall and the end wall along a second side of the flow channel opposite to the first side.

16. The fuel guide according to any of the preceding claims, including a fillet located between the longitudinal wall and the end wall of the flow channel.

17. The fuel guide according to any of the preceding claims, wherein the flow channel has a first cross-sectional area, the first end channel includes a second cross-sectional area, and the second cross-sectional area is smaller than the first cross-sectional area.

18. The fuel rail according to any of the preceding claims, comprising a plurality of fuel injector ports extending through the rail body to the flow channel in an orientation transverse to the flow channel.

19. The fuel rail according to any of the preceding claims, comprising a plurality of mounting tabs extending outwardly from a longitudinal portion of the rail body, each of the mounting tabs including a hole for a fastener.

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