Common Rail Check Valve Retainer for High-Pressure Pump Outlets
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Solution Overview
Problem
Modern fuel systems face challenges in increasing service pressure of fuel pumps due to enhanced stresses and thermal effects, limiting pump outlet pressures and increasing manufacturing costs, while existing outlet check valve designs struggle to meet performance standards under high pressures exceeding 30,000 pounds per square inch.
Innovation Solution
The design incorporates a pumping element with a check valve system comprising movable inserts and a spring mechanism, where the first insert moves from a sealing to a non-sealing position in response to pressurized fluid, and a retainer mechanism that provides an interference fit to secure the inserts within flow chambers, allowing fluid flow only when pressure exceeds a threshold, thus managing high pressures effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If outlet check valve design is improved to handle higher pressures, then pump outlet pressure capability increases, but manufacturing costs increase due to material and design challenges
Solution Approach 1:
The outlet check valve is divided into multiple components: a valve body, a movable insert (plug), and a retainer assembly. This segmentation allows each component to be optimized independently for high-pressure performance while using standard manufacturing processes, resolving the contradiction between pressure capability and manufacturing cost.
Solution Approach 2:
The movable insert is nested within the valve body, and the retainer assembly is nested within the valve body as well. This nested structure allows compact design that withstands high pressures while using simple, cost-effective manufacturing methods for each individual component.
2Stress or pressure
If service pressure is increased to exceed 30,000 PSI, then fuel system performance improves, but thermal load and stresses on components increase
Solution Approach 1:
The movable insert is extracted as a separate, replaceable component from the valve body. This allows the valve to be designed with optimal high-pressure geometry while using materials and designs that can be independently optimized for thermal resistance, separating the pressure-containing function from thermal management considerations.
Solution Approach 2:
The valve design incorporates specific geometric parameters (tapered surfaces, clearance gaps) and material selections that change the thermal and pressure characteristics of the component, enabling it to withstand both high service pressures and associated thermal loads without failure.
3Reliability
If outlet check valve is designed for high pressure performance, then product performance standards are exceeded, but device complexity increases
Solution Approach 1:
Instead of making the entire valve body complex to achieve high-pressure performance, the invention inverts the approach by using a simple valve body with a specialized movable insert and retainer assembly. This inversion allows high performance through the insert mechanism rather than through overall structural complexity.
Solution Approach 2:
The movable insert is designed to be replaceable and serviceable independently of the valve body. This self-service feature allows the high-performance components to be maintained or replaced without replacing the entire valve assembly, effectively managing complexity through modularity and ease of maintenance.
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 design enhances the performance of fuel pumps by maintaining high pressure integrity and reducing manufacturing costs, enabling the pumps to exceed standard performance and handle pressures above 30,000 psi without material failure.
Implementation Method 1
a spring having a first end engaging the first insert and a second end engaging the second insert; wherein the first insert moves from the first position to the second position against a biasing force of the spring
Implementation Method 2
the second insert is retained in a fixed position by an interference fit with the second flow chamber
Data Source
AI summary
The present disclosure generally relates to a pumping element of a fuel pump for an internal combustion engine wherein the pumping element comprises a first flow chamber; a second flow chamber in fluid connection with the first flow chamber, the second flow chamber including a shoulder; a check valve including a first insert and a second insert, the first insert being movable between a first position wherein the first insert forms a seal that inhibits fluid flow between the first and second flow chambers and a second position wherein the first insert permits fluid flow between the first and second flow chambers, the second insert being inserted into the second flow chamber to an extent limited by the shoulder; and a spring having a first end engaging the first insert and a second end engaging the second insert; wherein the first insert moves from the first position to the second position against a biasing force of the spring in response to pressurized fluid in the first flow chamber.