Integrated Common Rail Output Connectors for Engine Head Sealing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High-pressure fuel injection systems require numerous fittings and seals to maintain pressure integrity, leading to high costs and complex assembly, as existing fittings can only be used once and must be replaced when disconnecting injectors.
Innovation Solution
The output connectors of the common rail pass through the cylinder head wall as both through-holes and caps, using radial or flat annular gaskets for sealing, allowing for integrated production with the rail and reducing the number of components needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional separate fittings and seals are used for each high-pressure pipe connection, then sealing integrity is maintained, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the fitting and seal into a single integrated component. The output connector of the common rail incorporates sealing elements (O-rings, gaskets, or elastomeric seals) directly into its structure, eliminating the need for separate fittings and seals at each connection point. This integration reduces the total number of components while maintaining sealing integrity through the built-in sealing features.
Solution Approach 2:
The output connectors of the common rail are designed to perform multiple functions: they serve as both the structural connection point for high-pressure pipes and as the sealing element itself. The connectors incorporate sealing surfaces and sealing elements that create pressure-tight seals without requiring additional dedicated sealing components, thus achieving multi-functionality.
2Reliability
If numerous separate fittings are used for each injector connection, then sealing is guaranteed, but assembly complexity and time increase
Solution Approach 1:
By combining the fitting and seal into one integrated output connector component, the assembly process is simplified. Instead of installing separate fittings and seals for each connection, the integrated connector is installed as a single unit, reducing the number of assembly steps and improving productivity while maintaining reliable sealing.
3Reliability
If traditional fittings are used that can only be used once, then sealing integrity is maintained, but cost increases due to replacement requirements
Solution Approach 1:
The output connectors are designed with reusable sealing capabilities. The integrated sealing elements (such as elastomeric seals or metal-to-metal sealing surfaces) are built into the connector structure, allowing the same connector to be repeatedly installed and removed multiple times while maintaining sealing integrity, eliminating the need to replace fittings after each use.
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
This solution simplifies assembly, reduces costs, and allows for interchangeable high-pressure pipes, while maintaining the necessary sealing integrity and precision in engine assembly, regardless of rail production methods.
Implementation Method 1
Means for fastening the rail to the head of the internal combustion engine keep the rail pressed against said head, to guarantee the necessary uniform compression of the annular gaskets.
Data Source
Figure 1
Figure 2~2A
Figure 3
AI summary
A sealing system of a head (H) of an internal combustion engine (E) with common rail (CR) external to the head, the common rail having a longitudinal tubular shape with two or more output connectors (SN), in one piece with said common rail and distributed along said common rail (CR) and aligned with one another so as to lie on a same common plane (PL), and wherein the head (H) of the internal combustion engine (E) comprises a wall (HW) provided with through holes (TH) in the same number as said two or more output connectors (SN), the sealing system being defined by said two or more output connectors (SN), said through holes (TH), distributed so as to be simultaneously engaged by said two or more output connectors (SN) and sealing means (G, Gl) interposed between said wall (HW) and said two or more output connectors (SN).