Fuel Injection Pressure Regulator Discharge Chamber Dead Volume
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Solution Overview
Problem
Existing pressure regulators for high-pressure fuel injection systems in internal combustion engines fail to optimize the flow/pressure curve due to sudden increases in pressure caused by static pressure in the discharge chamber, leading to inefficient regulation and liquid return.
Innovation Solution
The pressure regulator incorporates an annular widening of the discharge chamber above the valve seat, creating a dead volume that absorbs kinetic and static pressure, with an annular support and crimped valve body design to simplify manufacturing and enhance efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the discharge chamber is designed with a compact structure, then the device complexity is reduced, but the static pressure in the upper part of the discharge chamber increases causing sudden gradient increase in the flow/pressure curve
Solution Approach 1:
The patent introduces a dead volume region in the lower part of the discharge chamber, extending axially below the outlet openings. This adds a dimensional element (axial extension) to the discharge chamber structure, creating a separate functional zone that absorbs kinetic energy and reduces static pressure without complicating the overall compact design.
Solution Approach 2:
The dead volume acts as an intermediary region between the high-pressure inlet and the liquid return circuit. It serves as a buffer zone that mediates the pressure transition, absorbing kinetic energy from the liquid flow and reducing static pressure before the liquid returns to the circuit, thereby optimizing the flow/pressure curve.
2Length of moving object
If the outlet openings are positioned close to the valve seat, then the device length is reduced, but the kinetic energy of the liquid cannot be effectively absorbed leading to increased static pressure
Solution Approach 1:
The patent extends the discharge chamber axially below the outlet openings to create a dead volume region. This axial extension provides the necessary space for kinetic energy absorption without increasing the overall height of the device beyond acceptable limits, as the dead volume is positioned in the lower part where it can function efficiently within the compact structure.
Solution Approach 2:
The patent converts the harmful effect of liquid kinetic energy (which causes pressure fluctuations and inefficiency) into a beneficial effect by designing the dead volume to absorb this kinetic energy. The liquid's own motion and pressure are utilized to fill and pressurize the dead volume, thereby dampening pressure fluctuations and smoothing the flow/pressure curve.
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 design reduces pressure in the discharge chamber to match the liquid return circuit pressure, optimizing the flow/pressure curve and improving the efficiency of liquid return and regulation operations.
Implementation Method 1
the dead volume developed in the part of the discharge chamber around the valve seat is located directly at the outlet of the liquid and therefore allows the kinetic energy of the liquid to be absorbed
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
The invention relates to a pressure regulator for a high-pressure ramp of a system for injecting fuel into an internal combustion engine, comprising a solenoid valve element (10) which receives an electromagnet (40). The electromagnet controls a needle (20) that closes a valve seat (30) which is connected to a high-pressure inlet and opens into a discharge chamber (13), said discharge chamber communicating with a liquid recirculation system (5) by means of outlet openings (14). The rear face (12) of the solenoid valve element (10) receives a coil (40) which controls the opening process of an armature (41) that is rigidly connected to the needle (20) and is subject to a closing return spring (25). The discharge chamber (13) is located on the front face (11) of the solenoid valve element (10) on the axis (XX) of the needle (20), and the discharge chamber surrounds the needle. A cavity (15) passes through the discharge chamber, said cavity receiving an inlet valve element (50), and a bore (51) which opens into the valve seat (30) passes axially through the inlet valve element. The discharge chamber (13) through which the needle (20) passes axially and the outlet openings (14) which are connected to the liquid recirculation system open transversally into a wall (131) in the discharge chamber (13) below the upper part (132) of the chamber. The regulator is characterized in that the regulator comprises an annular expansion (70) of the discharge chamber (13) below the outlet openings (14) along the extension of a conical surface (31), which forms the valve seat (30) and an annular dead volume (70), above the surface (54) of the valve element (50), which forms the base of the discharge chamber (13) and has the valve seat (30) in the center of the valve element.