Fuel Injection Valve Magnetic Alignment and Latching Mechanism
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Solution Overview
Problem
Current fuel injection valves for gasoline direct injection engines face challenges in achieving precise alignment and reduced torsion angles due to manufacturing tolerances and flexible injection-molded plastic lugs, leading to increased soot particle emissions and non-uniform fuel distribution in combustion chambers.
Innovation Solution
A valve design featuring a spring-loaded latching mechanism and a locking element that engages with a groove in the cylinder head, allowing for axial insertion and rotation, which reduces the tolerance chain and eliminates the need for additional alignment bores, while providing a large detent force against twisting and facilitating easy assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If flexible injection-molded plastic lugs are used for torsional fixation, then ease of manufacture is improved, but manufacturing precision deteriorates due to large play in grooves leading to large torsion angles
Solution Approach 1:
The patent replaces the mechanical groove-lug fixation system with a magnetic field-based alignment system. The valve body is equipped with a first magnet and the injection mold with a second magnet, creating magnetic attraction that ensures precise alignment during injection without requiring mechanical grooves and lugs. This eliminates the play and torsion angle issues while maintaining ease of manufacture through simplified mechanical structures.
2Manufacturing precision
If additional alignment bores are added to improve alignment accuracy, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent eliminates the need for additional alignment bores by substituting mechanical alignment features with magnetic alignment. The magnets embedded in the valve body and injection mold create automatic magnetic alignment during the injection process, achieving high alignment accuracy without adding complex mechanical alignment bores or features to the valve structure.
3Manufacturing precision
If the valve is firmly fixed to reduce torsion, then manufacturing precision is improved, but ease of operation deteriorates due to difficulty in assembly and disassembly
Solution Approach 1:
The patent employs a dynamic locking mechanism using a latch member that can transition between locked and unlocked states. During assembly, the latch member is pushed to engage with the locking protrusion, firmly fixing the valve body to the injection mold. During disassembly, the latch member is released to allow easy removal, thus achieving both firm fixation for precision and ease of operation.
4Ease of manufacture
If a simple locking mechanism is used, then ease of manufacture is improved, but reliability deteriorates due to insufficient detent force against twisting
Solution Approach 1:
The patent employs a spherical locking ball that engages with a corresponding spherical recess in the locking mechanism. The spherical geometry provides large contact area and detent force against twisting forces while maintaining simplicity in manufacture. The ball-and-socket type locking provides reliable anti-twist capability without complex mechanical structures.
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 enhances the accuracy of fuel injection patterns, reduces soot formation, and improves exhaust gas composition by ensuring precise alignment and stable fuel distribution within the combustion chamber, aligning with stringent emissions regulations.
Implementation Method 1
A spring element 25 is arranged in the recess 20 and acts upon the locking element 26 in a radial direction 27
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A valve (2) serves to meter a fluid, which may in particular be configured as a fuel injection valve for internal combustion engines. A valve housing (5) is provided, wherein an outer surface (18) is formed on a joining section (55) of the valve housing (5). A locking means (26) is arranged at a location (19) within or at the edge of the outer surface (18) of the joining section (55), which permanently or at least in a locking state projects radially beyond the outer surface (18). Furthermore, an arrangement (1) with such a valve (2) is specified.