Coaxial Needle Fuel Injectors for Reliable Dual-Fuel Combustion

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Solution Overview

Problem

Existing dual fuel injectors face challenges in manufacturing complexity, durability, fuel leakage, and synchronization issues, particularly for gas fuel injections, due to density differences and sealing complexities, leading to reliability and durability concerns.

Innovation Solution

A coaxial needle valve design allows for independent and collective injection of two fuels, with liquid fuels used for actuation, sealing, and cooling, enabling on-demand dual fuel injections tailored to engine conditions, and a novel combustion method to mitigate gas fuel fugitiveness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional dual fuel injector designs are used, then dual fuel injection capability is achieved, but manufacturing complexity and device complexity increase significantly

Engineering Contradiction:

Improvedual fuel injection capabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The single nozzle design integrates multiple fuel injection functions into one component, eliminating the need for separate nozzles for different fuel types. The nozzle body with its internal passage structure can handle both gaseous and liquid fuels through the same opening, reducing the number of parts and manufacturing complexity while maintaining dual fuel capability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent combines previously separate gas and liquid fuel injection systems into a unified single nozzle structure. By merging the fuel delivery paths and using a common nozzle body with appropriate passage configurations, the system reduces component count and simplifies manufacturing while preserving the ability to inject different fuel types.

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If complex fuel passages are arranged in compact nozzles, then dual fuel injection is enabled, but manufacturing difficulty and device complexity increase

Engineering Contradiction:

Improvedual fuel injectionVSAvoidfuel passage arrangement

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The nozzle body is designed with segmented internal passages that are clearly defined and separated within the compact structure. The fuel passages are arranged in distinct zones within the nozzle body, making them easier to manufacture and assemble while maintaining the compact dual-fuel injection capability.

Inventive Principle:

Principle #1Segmentation

3Adaptability or versatility

If gas fuel injection is implemented, then renewable fuel usage increases, but sealing and durability issues arise due to density differences

Engineering Contradiction:

Improverenewable fuel usageVSAvoidsealing and durability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The invention addresses sealing issues by adjusting design parameters such as orifice sizing, passage dimensions, and needle valve geometry to account for the lower density of gaseous fuels compared to liquid fuels. These parameter changes ensure proper sealing performance and durable operation when injecting gaseous renewable fuels.

Inventive Principle:

Principle #35Parameter changes

4Adaptability or versatility

If dual needle operations are used for dual fuel injections, then fuel injection flexibility is improved, but control complexity increases significantly

Engineering Contradiction:

Improvefuel injection flexibilityVSAvoidcontrol complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent extracts the complexity of dual needle synchronization control by using a single needle valve mechanism instead of two independently controlled needles. This simplifies the control system while maintaining the ability to inject different fuel types through the same nozzle opening.

Inventive Principle:

Principle #2Taking out (Extraction)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution enhances the reliability and durability of dual fuel injections, optimizing combustion by allowing flexible fuel injection based on engine conditions and reducing emissions through efficient fuel mixing.

Implementation Method 1

liquid fuels used for actuating, sealing and cooling of gas injection valves

Methodology Applied

Scientific EffectCooling: Cooling

Implementation Method 2

liquid fuels used for actuating, sealing and cooling of gas injection valves

Methodology Applied

Scientific EffectSealing: Lubrication

Implementation Method 3

liquid fuels used for actuating, sealing and cooling of gas injection valves

Methodology Applied

Scientific EffectLubrication: Lubrication

Data Source

PatentUS20250290455A1Injectors, methods, and systems for dual fuel combustion

Publication Date: 2025.09.18 QUANTLOGIC CORP

AI summary

A fuel injector for adaptive dual fuel injections has means to directly inject two types of fuels, which can be gas and liquid, or liquid and liquid, independently and collaboratively through a single nozzle. A fuel injection method and systems, along with a combustion method using the same, are also disclosed. The disclosed injectors, methods, and systems are applicable for conventional gas and liquid fuels, such as diesel, gasoline, natural gas, propane, as well as renewable liquid and gas fuels in general, including e-fuels, such as biodiesel, methanol, ethanol, hydrogen, biomethane, etc.