Fuel Injection Nozzle Perforation Using Vibrating Zirconia Filler
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Solution Overview
Problem
Existing methods for forming through-holes in hollow members using laser irradiation often damage the opposite wall due to uncontrolled laser reflection or scattering, making it difficult to reliably prevent damage to the opposite wall during the perforation process.
Innovation Solution
A perforation method and apparatus that involves inserting a filler material, such as a zirconia ball or powder, which is not melted by the laser, and vibrating it to prevent continuous laser exposure to the same position, thereby blocking the laser light from reaching the opposite wall. The filler is rotated and moved vertically to constantly change the laser application point, ensuring the opposite wall is not damaged.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser light is used to form through-holes in hollow members, then hole formation efficiency is improved, but the opposite wall is damaged due to uncontrolled laser reflection or scattering
Solution Approach 1:
A filler material (such as zirconia powder or balls) is introduced as an intermediary substance into the hollow member to intercept and block the laser light before it reaches the opposite wall. The filler absorbs or scatters the laser energy, preventing direct transmission while allowing the laser to effectively melt and form holes in the wall material.
Solution Approach 2:
The filler material is subjected to mechanical vibration during the laser irradiation process. This vibration causes the filler particles to move and redistribute, preventing them from settling in positions where they could be continuously exposed to laser light and potentially transmit it to the opposite wall, thereby enhancing the blocking effect.
2Object-affected harmful factors
If a mirror reflector is used to reflect laser light to a light absorber, then the opposite wall can be protected, but the laser light may be reflected to the inner wall if angles are not strictly controlled
Solution Approach 1:
Instead of using a precision mirror reflector system that requires strict angular control, the invention employs a filler material that can be easily introduced and removed. The filler serves as a simple, non-precise blocking medium that does not require complex alignment or control mechanisms, significantly reducing device complexity while maintaining protection of the opposite wall.
3Object-affected harmful factors
If fluid is introduced to cause cavitation to scatter laser light, then the opposite wall can be protected, but part of the scattered laser light may still reach the inner wall
Solution Approach 1:
The invention changes the physical state and properties of the filler material through vibration. By applying mechanical vibration, the filler particles maintain a dynamic, dispersed state that enhances their ability to block laser light. This parameter change (from static to dynamic) improves the reliability of laser light blocking compared to static fluid or powder systems.
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
Effectively prevents damage to the opposite wall by ensuring the laser light is blocked by the filler, allowing for precise formation of through-holes without complex control of laser irradiation conditions, and reduces the amount of fine powder generated, minimizing interference with the perforation process.
Implementation Method 1
The end portion is irradiated with the laser light L from the outside. Therefore, the wall of the end portion is melted by the laser light L from the outside to the inside.
Implementation Method 2
Since the filler is not melted, the laser light is blocked by the filler and thereby is prevented from reaching the opposite wall.
Implementation Method 3
a fluid (particularly a liquid) to the end portion of the fuel injection nozzle is introduced for causing cavitation to scatter the laser light
Implementation Method 4
irradiating the wall with the laser light while vibrating the filler
Data Source
AI summary
A perforation method and an perforation apparatus in which a hollow member of a fuel injection nozzle is filled with a filler such as a zirconia ball, and a laser light is applied to the hollow member to form an injection hole while vibrating the zirconia ball using an ultrasonic vibrator. After the injection hole is formed, the laser light is introduced through the injection hole to the inside of the fuel injection nozzle, and thereby is applied to the vibrated zirconia ball.