Fuel Distributor Baffle for Uniform Port Fuel Distribution

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Solution Overview

Problem

Existing port-injected engines face challenges in uniformly distributing fuel among intake valve openings due to the influence of incoming intake air, leading to suboptimal fuel and air mixing, particularly with fuels like methanol that are difficult to vaporize.

Innovation Solution

A fuel distributor with a baffle wall extending into the intake port, forming a fuel channel and having varied porosity or cross-sectional area, shields the fuel spray from incoming intake air, ensuring more uniform distribution of fuel to multiple intake valve openings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If fuel is injected into the intake port without shielding, then the fuel injection system is simple, but the fuel distribution among intake valve openings is biased and non-uniform

Engineering Contradiction:

Improvefuel distribution uniformityVSAvoidfuel distributor structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The fuel distributor divides the fuel spray into multiple streams using a baffle wall with varying porosity, creating distinct fuel channels that direct fuel to different intake valve openings. This segmentation ensures uniform fuel distribution among multiple valves by physically separating and directing fuel flow to each valve opening independently.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The baffle wall incorporates locally varied porosity, with different sections having different open areas to control fuel flow distribution. This local quality variation allows precise control over fuel distribution patterns, directing appropriate fuel amounts to each intake valve opening based on its specific position and requirements.

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If fuel is injected closer to intake valve openings, then fuel distribution may be more direct, but incoming intake air creates bias and disrupts uniform fuel-air mixing

Engineering Contradiction:

Improvefuel-air mixing uniformityVSAvoidintake air flow bias

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The baffle wall acts as an intermediary structure between the fuel injector and intake valve openings. It mediates the interaction between fuel spray and incoming intake air by controlling their relative positions and mixing patterns, preventing the harmful bias that would otherwise occur due to direct exposure to high-velocity intake air streams.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The fuel distributor structure preliminarily counteracts the harmful effects of intake air flow by positioning and shaping fuel spray before it encounters the full force of incoming air. The baffle wall pre-conditions the fuel-air interaction to prevent excessive bias and ensure more uniform mixing downstream.

Inventive Principle:

Principle #9Preliminary anti-action

3Manufacturing precision

If alcohol fuel is injected without proper vaporization control, then injection timing is simple, but vaporization is insufficient causing fuel dripping and poor distribution

Engineering Contradiction:

Improvefuel vaporization extentVSAvoidvaporization control mechanism

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The fuel distributor extends in the radial direction from the injector bore, creating a three-dimensional fuel distribution pattern. This dimensional extension provides additional space and time for fuel vaporization by distributing fuel across a larger volume and exposing it to greater surface area for heat transfer, thereby improving vaporization without requiring complex heating mechanisms.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 distributor enhances uniform fuel delivery and improves fuel vaporization by limiting bias in distribution, allowing for better fuel-air mixing and combustion efficiency.

Implementation Method 1

shielding fuel spray of the injected fuel from incoming intake air via a baffle wall of a fuel distributor

Methodology Applied

Scientific EffectShielding:

Implementation Method 2

The baffle wall forms a fuel channel and has at least one of a circumferentially varied porosity or an axially varied cross-sectional area

Methodology Applied

Scientific EffectFluid flow through porous structure: Porosity

Data Source

PatentUS12553407B2Port-injected engine having fuel distributor for reduced bias in fuel distribution

Publication Date: 2026.02.17 CATERPILLAR INC

AI summary

An engine system includes an engine housing including a plurality of intake valve openings, an intake port extending to the plurality of intake valve openings and an injector bore extending to the intake port. The engine system also includes a fuel system having a port fuel injector, and a fuel distributor having a baffle wall. The baffle wall extends into the intake port and extends at least partially around a fuel spray axis, forming a fuel channel and having at least one of a circumferentially varied porosity or an axially varied cross sectional area. The baffle wall shields fuel spray of an injected fuel such as methanol to limit a bias in distribution of fuel among the plurality of intake valve openings.