Fuel Injection Valve Covering Portion for Leakage Prevention

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Solution Overview

Problem

Existing fuel injection valves face issues with fuel leakage due to high pressure causing separation between components, leading to inappropriate fuel injection, and spatter particles from welding can contaminate the flow passage during manufacturing.

Innovation Solution

A fuel injection valve design that includes a covering portion to cover the stationary boundary between the passage forming portion and the stationary core from the flow passage side, preventing fuel leakage and spatter particles from entering the flow passage during welding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If high pressure is applied to ensure proper fuel injection, then fuel injection performance is improved, but component separation and fuel leakage occur

Engineering Contradiction:

Improvefuel injection performanceVSAvoidcomponent separation

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The fuel injection valve is divided into distinct components (valve body, valve element, seal, support tubular body) that can be assembled and sealed together. The segmentation allows each component to be optimized for its specific function while maintaining overall system reliability under high pressure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A seal member is pre-installed between the valve element and support tubular body before assembly. This preliminary sealing action prevents fuel leakage from the outset, allowing high pressure to be applied without causing component separation or leakage.

Inventive Principle:

Principle #10Preliminary action

2Strength

If welding is performed to join components, then structural strength is improved, but spatter particles contaminate the flow passage

Engineering Contradiction:

Improvejoint strengthVSAvoidspatter particles contamination

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The harmful spatter particles are extracted or removed from the flow passage through a cleaning process after welding. The flow passage is cleaned to eliminate contamination from welding spatter, allowing the joint to maintain its strength while preventing particle contamination.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The welding process, which generates harmful spatter particles, is performed in a controlled manner where the heat and fusion create a strong joint. The potential harm of spatter is mitigated by subsequent cleaning, transforming the welding process into a beneficial joining method while eliminating the contamination issue.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Ease of manufacture

If components are joined without covering portions, then manufacturing simplicity is maintained, but fuel leakage occurs at boundaries

Engineering Contradiction:

Improveassembly simplicityVSAvoidfuel leakage

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The seal member is merged with the support tubular body through integration or secure attachment. This combining of the sealing function with the structural component ensures that the boundary between components is sealed, preventing fuel leakage while maintaining manufacturing simplicity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The seal member acts as an intermediary element between the valve element and support tubular body. This intermediate component fills the gap and creates a sealed boundary, preventing fuel leakage at the joint interface without complicating the overall assembly structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 design effectively limits fuel leakage and ensures proper fuel injection by preventing separation between components and contamination from spatter particles, maintaining the integrity of the valve's operation.

Implementation Method 1

a coil, which generates a magnetic flux when the coil is energized

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

a movable core, which is attracted toward the stationary core when the movable core becomes a passage of the magnetic flux

Methodology Applied

Scientific EffectMagnetic force: Magnetism

Data Source

PatentUS11162465B2Fuel injection valve

Publication Date: 2021.11.02 DENSO CORP

AI summary

A fuel injection valve configured to inject fuel from an injection hole includes: a coil that is configured to generate a magnetic flux when the coil is energized; a stationary core that forms a portion of a flow passage, which is configured to conduct the fuel to the injection hole, wherein the stationary core is configured to become a passage of the magnetic flux; a movable core that is configured to be attracted toward the stationary core when the movable core becomes a passage of the magnetic flux; a passage forming portion that is placed on a downstream side of the stationary core and forms a portion of the flow passage; and a covering portion that covers a stationary boundary, which is a boundary between the passage forming portion and the stationary core, from a flow passage side of the stationary boundary where the flow passage is located.