Fuel Injection Device Integrated Sealing Structure
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Solution Overview
Problem
Existing fuel injection devices for internal combustion engines are complex and costly to produce, particularly due to the integration of electrical and return connections which require separate handling and sealing.
Innovation Solution
The fuel injection device simplifies construction by partially encapsulating the return and electrical connections with plastic material, integrating the magnet group and return channels within an all-plastic overmolding process, and utilizing a support plate with guide pins and spring devices for efficient leakage and cooling medium discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate handling and sealing of electrical and return connections is used, then connection reliability is improved, but device complexity and production cost increase
Solution Approach 1:
The patent combines the return connection and electrical connection into a single integrated sealing structure. The plastic material simultaneously seals both the return connection (for coolant drainage) and the electrical connection (for magnet coil signaling), eliminating the need for separate sealing mechanisms and reducing overall construction complexity while maintaining connection reliability.
Solution Approach 2:
The plastic sealing material serves multiple functions: it seals the return connection for coolant leakage, seals the electrical connection for the magnet coil, and provides structural support for both connections. This multi-functionality reduces the number of separate components needed and simplifies the overall device construction.
2Reliability
If separate handling and sealing of electrical and return connections is used, then connection reliability is improved, but production cost increases
Solution Approach 1:
By merging the sealing of return connections and electrical connections into a single plastic overmolding process, the patent eliminates multiple separate sealing operations and assembly steps. This integration reduces manufacturing time, labor costs, and material costs while maintaining the reliability of both connection types.
Solution Approach 2:
The plastic material is applied in advance to simultaneously seal both connections during the overmolding process, rather than applying separate seals sequentially. This preliminary action consolidates multiple sealing operations into one manufacturing step, reducing production complexity and cost.
3Device complexity
If magnet group is integrated with connections, then device complexity is reduced, but sealing reliability may worsen
Solution Approach 1:
The patent uses plastic material that is applied over the magnet group, return connection, and electrical connection to create a composite sealed structure. This plastic encapsulation provides uniform sealing across all integrated components, maintaining sealing reliability while achieving construction simplicity through integration.
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 approach results in a cost-effective and simplified fuel injection device design that effectively manages leakage and cooling media discharge, enhancing the reliability and efficiency of the fuel injection process while reducing production costs.
Implementation Method 1
a magnet actuator (25) which interacts in a known manner with a magnet coil (26) to which the electrical connection (33) is assigned
Implementation Method 2
the return connection (8) and the electrical connection (33) are partially encapsulated with plastic material (62)
Implementation Method 3
The spring device can also include a disc spring, which acts on a magnetic actuator with a prestressing force
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a fuel injection device for injecting fuel into a combustion chamber of an internal combustion engine, comprising an end (6) that is located at a distance from the combustion chamber and has at least one electric connection (33) and at least one return flow connection (40). In order to create a fuel injection device (1) that has a simple design and can be produced cost-effectively, the return flow connection (40) and the electric connection (33) are integrated in a common connecting member.