Dual-Fuel Injector Layout With Integrated Solenoid Valve Control

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing fuel injectors for large internal combustion engines, particularly those used in ships, are inefficient in managing the injection of two different fuels, namely a relatively ignitable fuel like diesel and a less-ignitable fuel like methanol or ammonia, due to space constraints and lack of integration of solenoid valves for precise control.

Innovation Solution

A fuel injector design with integrated solenoid valves for each fuel type, arranged in a compact configuration between nozzle needles and fuel storage spaces, minimizing distance and optimizing alignment for efficient control of fuel flow through separate injection orifices.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If separate fuel injectors are used for each fuel type, then control precision is improved, but installation space increases

Engineering Contradiction:

Improvefuel flow control precisionVSAvoidinstallation space

Core Design Contradiction:

Measurement precisionVSArea of stationary object

Solution Approach 1:

The patent combines two separate fuel injector units into a single integrated injector head. Each fuel type (diesel and gas oil) has its own nozzle needle and solenoid valve, but both are housed within the same injector body, sharing common components like the injector housing and mounting interface. This merging approach maintains precise individual control of each fuel type while significantly reducing the number of separate injector units needed for installation.

Inventive Principle:

Principle #5Merging (Combining)

2Ease of operation

If solenoid valves are positioned far from nozzle needles, then valve control is simplified, but response time increases

Engineering Contradiction:

Improvevalve control simplicityVSAvoidfuel injection response time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The solenoid valves are positioned laterally adjacent to the nozzle needles in the radial direction, rather than being arranged linearly along the axial direction. This lateral positioning in a different spatial dimension allows the solenoid valves to be closely coupled with their respective nozzle needles, minimizing the axial distance between valve and needle while maintaining simple valve control mechanisms.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Length of moving object

If solenoid valves are arranged radially overlapping, then axial length is reduced, but transverse space increases

Engineering Contradiction:

Improveinjector axial lengthVSAvoidtransverse footprint

Core Design Contradiction:

Length of moving objectVSArea of moving object

Solution Approach 1:

The two solenoid valves are arranged radially adjacent to each other with their control pins extending parallel to the injector axis. The valves are positioned side-by-side in the radial direction, nesting their functional volumes within the cylindrical injector housing. This arrangement minimizes the axial length by stacking valve functions radially rather than axially, while the transverse footprint is contained within the circular cross-section of the injector body.

Inventive Principle:

Principle #7Nested doll (Nesting)

4Ease of manufacture

If control pins are offset from nozzle needle axes, then valve alignment is simplified, but injection precision decreases

Engineering Contradiction:

Improvevalve alignment simplicityVSAvoidfuel injection precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

Each solenoid valve's control pin is positioned with its axis parallel to and offset from the injector's longitudinal center axis, but each control pin is precisely aligned with its corresponding nozzle needle's axis. This local alignment ensures that the control pin acts directly on the spherical tip of its specific nozzle needle, maintaining precise fuel injection control. The offset from the center axis simplifies the overall valve arrangement and control mechanism design.

Inventive Principle:

Principle #3Local quality

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 design allows for a compact, efficient, and space-saving solution for dual-fuel engines, enabling precise control of both fuels, thereby optimizing engine performance and reducing installation space requirements.

Implementation Method 1

a first solenoid valve integrated in the fuel injector, for controlling the first nozzle needle and a second solenoid valve integrated in the fuel injector for controlling the second nozzle needle

Methodology Applied

Scientific EffectSolenoid: Solenoid

Data Source

PatentUS20250389244A1Fuel injector of an internal combustion engine and internal combustion engine

Publication Date: 2025.12.25 EVERLLENCE SE

AI summary

A fuel injector of an internal combustion engine, having a first nozzle needle guided in a first needle guide, which interacts with first fuel injection orifices such that the first nozzle needle either opens or blocks flow of a first fuel through the first fuel injection orifices, a second nozzle needle guided in a second needle guide, which interacts with second fuel injection orifices such that the second nozzle needle either opens or blocks flow of a second fuel through the second fuel injection orifices, a first solenoid valve controls the first nozzle needle, a second solenoid valve controls the second nozzle needle. The first and second solenoid valve are integrated in the fuel injector such that the first and second solenoid valves are each arranged in the longitudinal or axial direction of the fuel injector between the nozzle needles and a fuel storage space of the fuel injector.