Integrated Fuel Heater for Flex Vehicle Cold Start
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Solution Overview
Problem
Conventional auxiliary tank systems and heating systems for flex fuel vehicles, such as those using ethanol, face challenges in improving cold start performance due to high ignition points and low steam pressure, leading to start issues in low temperatures, and existing heater solutions have inefficiencies and safety concerns.
Innovation Solution
A fuel heating device with a heater, solenoid valve, temperature sensor, and controller that preheats fuel stored in a housing with PTC elements, ensuring rapid temperature increase of the fuel to a preset temperature for efficient cold start, eliminating the need for a separate fuel tank and minimizing heat loss during supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an auxiliary tank system is used to store separate cold-start fuel, then cold start performance is improved, but device complexity and cost increase due to additional parts
Solution Approach 1:
The patent combines the fuel storage and heating functions into a single integrated fuel heating device. The heater unit is installed within the existing fuel tank structure, eliminating the need for separate auxiliary tanks and their associated mounting brackets, fuel lines, and control systems. This merging approach maintains cold start capability while reducing overall system complexity.
Solution Approach 2:
The fuel heating device serves multiple functions: it acts as both a fuel storage container and a heating system. The device can selectively supply heated fuel during cold starts and unheated fuel during normal operation, making it a multi-functional component that replaces what would traditionally require separate dedicated systems.
2Temperature
If a heater is installed in the fuel supply system, then fuel temperature is increased for cold start, but energy consumption increases
Solution Approach 1:
The heater is activated in advance during the ignition-on state to preheat fuel before cold start conditions occur. By performing the heating action preliminarily, the system ensures fuel is ready for cold start without requiring continuous heating operation, thereby reducing overall energy consumption while maintaining effective cold start capability.
Solution Approach 2:
The heating operation is performed periodically or intermittently based on detected fuel temperature and engine operating conditions, rather than continuously. The controller activates the heater only when fuel temperature falls below a predetermined threshold, reducing energy consumption while ensuring fuel is heated when needed for cold start performance.
3Productivity
If fuel is heated rapidly to preset temperature, then cold start performance improves, but heat loss during supply increases
Solution Approach 1:
The heated fuel is supplied through a dedicated cold start line that acts as an intermediary pathway, isolated from the main fuel line. This separate supply path minimizes heat loss to the surrounding environment during fuel delivery, allowing rapid heating without proportionally increasing energy loss during the supply process.
Solution Approach 2:
The fuel heating device utilizes insulating structures and minimized exposure surfaces to reduce heat loss during fuel supply. By controlling the thermal environment of the fuel passage and using appropriate insulation, the system maintains heated fuel temperature during delivery, reducing energy loss despite rapid heating.
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 fuel heating device rapidly increases fuel temperature to a preset level within a short time, improving cold start performance without additional fuel storage, reducing current consumption, and ensuring safety by maintaining fuel temperature during supply.
Implementation Method 1
a fuel heating device with a heater, solenoid valve, temperature sensor, and controller that preheats fuel stored in a housing with PTC elements
Data Source
AI summary
A fuel heating device may improve cold start performance and solve a number of problems of conventional auxiliary tank and heating systems of a flex fuel vehicle (FFV). The fuel heating device may include a heater having embedded therein a heat emission object for heating fuel, a solenoid valve connected the heater such that a flow path to a first outlet is opened or closed to selectively supply fuel, a temperature sensor installed in the heater, and a controller for turning on and off the heater and opening and closing the solenoid valve according to a temperature of the fuel, in which the outlet of the heater is connected with a cold start injector through a cold start line and an inlet of the solenoid valve is connected with a fuel line connected from the fuel tank.