Compact Side Feed Inlet Port for DEF Injector
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Solution Overview
Problem
Existing reductant delivery systems face packaging constraints and inefficiencies in handling diesel exhaust fluid (DEF) due to the need for precise metering and handling of ammonia in lean-burn engine exhaust systems, particularly in compact vehicle designs.
Innovation Solution
A compact side feed inlet port for the injector is designed using stamped metal parts, featuring an inner and outer sleeve with a sealing mechanism that reduces overall height and fluid volume, allowing for flexible mounting and reduced DEF volume, which minimizes freezing strain and purge requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a traditional injector housing design is used, then the injector provides sufficient structural strength and sealing capability, but the overall height and packaging volume are excessive
Solution Approach 1:
The inner sleeve is nested within the outer sleeve, with the inner sleeve containing the sealing components and the outer sleeve providing structural support and mounting functions. This nested configuration reduces the overall volume while maintaining the required strength through the combined structure of both sleeves.
Solution Approach 2:
The inlet port is divided into two separate stamped metal sleeves instead of using a single monolithic housing. The inner sleeve handles sealing functions while the outer sleeve provides structural support, allowing each component to be optimized independently for its specific function while reducing overall complexity and volume.
2Length of moving object
If the inlet port height is reduced to meet packaging constraints, then packaging efficiency improves, but sealing reliability may be compromised
Solution Approach 1:
The inner sleeve is nested within the outer sleeve, allowing the sealing components to be positioned within the inner sleeve while the outer sleeve provides external support. This nested arrangement enables reduced overall height while maintaining sealing reliability through the concentric configuration of both sleeves.
Solution Approach 2:
The inner sleeve is provided with specific sealing features such as O-ring grooves and sealing surfaces at critical locations, while the outer sleeve focuses on providing structural support and mounting capabilities. This localized optimization of different regions allows compact dimensions while maintaining sealing reliability where it is most needed.
3Ease of manufacture
If stamped metal parts are used instead of traditional manufacturing methods, then manufacturing cost and complexity are reduced, but manufacturing precision may be affected
Solution Approach 1:
The inlet port components are manufactured as stamped metal parts rather than through expensive precision machining processes. The stamped sleeves are designed to achieve functional precision through the stamping process itself, with features such as O-ring grooves and sealing surfaces formed directly during stamping, reducing manufacturing cost while maintaining adequate precision for the application.
Solution Approach 2:
The manufacturing approach changes from traditional precision machining to stamping processes, with design parameters optimized for the stamping method. The stamped sleeves incorporate features such as formed sealing surfaces and mounting holes that are inherently suited to stamping, achieving the required precision through process-appropriate design rather than post-processing machining.
4Quantity of substance
If the DEF fluid volume in the inlet port is reduced, then freezing strain and purge requirements are minimized, but fluid delivery efficiency may be compromised
Solution Approach 1:
The fluid passage is segmented into distinct regions within the inner and outer sleeves, with the inner sleeve containing the DEF fluid and the outer sleeve providing a protective annular space. This segmentation allows reduction of the total fluid volume while maintaining adequate flow paths through the segmented configuration, reducing freezing strain while preserving delivery efficiency.
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 provides a cost-effective, compact, and efficient DEF delivery system with reduced fluid volume, enabling shorter purge times and less strain on components, while allowing for flexible packaging and reduced DEF needed for priming.
Implementation Method 1
sealing of the injector is accomplished using the interior sleeve, creating a sealing point
Implementation Method 2
fluid flows through the inlet conduit and into the cavity, and from the cavity into the inlet tube
Implementation Method 3
Assembly is accomplished by brazing or welding the components together, providing a strong, compact, and low-cost inlet port
Implementation Method 4
Assembly is accomplished by brazing or welding the components together, providing a strong, compact, and low-cost inlet port
Implementation Method 5
Being a stamped part, the outer sleeve may have various shapes... The outer sleeve, the inner sleeve, and the inlet tube are all formed using a stamping process
Implementation Method 6
having less volume of liquid in the inlet port equates to shorter purge times... the outer sleeve may have various shapes, such as different volume reduction features, to reduce the interior volume even further
Data Source
AI summary
A side feed inlet port for an injector, which makes use of stamped parts to form a compact, high strength three-piece inlet port at a significantly reduced cost. By using an inner sleeve and an outer sleeve, injector sealing is accomplished using the interior sleeve, creating a sealing point, while allowing for inlet conduit attachment to the outer sleeve at, above, or below the sealing point of the DEF injector. The construction of the inlet port is such that there is proper sealing between the inner sleeve and one or more seals, while allowing for the connection between the inlet conduit and the outer sleeve to reduce the overall height of the inlet port, and therefore, the injector. The position of the inlet conduit may be altered without affecting the sealing connection between the inner sleeve and the seal(s), such that the desirable overall height may be achieved.