Fuel Injector Alignment Tab with Flexible Prongs
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Solution Overview
Problem
Current fuel injector and fuel rail assemblies face issues with secure alignment and easy disconnection, as the compressed O-ring's integrity is compromised during shipment and assembly, leading to potential misalignment and sticking due to soot or carbon build-up, necessitating a solution for quick and secure connection and easy separation.
Innovation Solution
The integration of a fuel injector alignment tab with flexible prongs that secure the fuel injector to the injector cup, which is brazed or welded to the fuel rail, allowing for alignment and secure connection while enabling quick disconnection, with the tab's dual-angle prongs facilitating easy insertion and increased force for removal, ensuring proper alignment and secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If only a compressed O-ring is used to secure the fuel injector to the injector cup, then the device complexity is reduced, but the reliability of the connection is compromised resulting in potential parting or misalignment during shipment and assembly
Solution Approach 1:
The patent combines the alignment and retention functions into a single integrated tab structure that is molded as one piece with the fuel injector body. The tab includes both positioning features for alignment and engagement features for secure retention, eliminating the need for separate alignment and retention components while maintaining connection integrity throughout operation.
Solution Approach 2:
The tab is constructed from a flexible material that exhibits different mechanical properties than the rigid fuel injector body. This flexible material allows the tab to elastically deform during installation to pass through the injector cup opening, then maintains secure engagement through its elastic recovery, providing both ease of installation and reliable retention.
2Reliability
If a secure and aligned assembly of the fuel injector to the fuel rail is implemented, then the reliability of the connection is improved, but the ease of separation during servicing is reduced
Solution Approach 1:
The tab incorporates flexible prongs that can dynamically change their engagement state. During normal operation, the prongs maintain a engaged state for secure retention. During servicing, when force is applied to the fuel injector, the prongs can elastically deform and disengage from the injector cup, enabling easy removal without damaging components.
Solution Approach 2:
The tab is segmented into multiple functional zones: a rigid portion attached to the fuel injector body, flexible prongs for engagement, and specific geometric features for alignment. This segmentation allows each zone to perform its specific function optimally while working together to provide both secure operation and easy serviceability.
3Reliability
If the fuel injector is securely retained during operation, then the reliability is improved, but the force required for removal increases making servicing difficult
Solution Approach 1:
The tab's flexible material properties allow it to exhibit different force characteristics under different conditions. During normal operation, the material maintains high retention force through elastic deformation. During removal, the same material properties allow the tab to yield and disengage with relatively low force, changing the force parameter based on the operational state.
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 solution provides a secure and aligned connection of the fuel injector to the fuel rail, preventing misalignment and easy separation during servicing, with the dual-angle prongs ensuring a strong attachment that resists dislodgment during operation and reduces the force required for installation while allowing easier removal.
Implementation Method 1
The tab may employ a flexible first prong and a flexible second prong such that the first prong and the second prong protrude through the notch to secure the tab to the flange
Implementation Method 2
The first entry contact surface and the first prong interior straight wall surface form a first angle that is less than a second angle formed by the first exit contact surface (extended) and the first sidewall surface of the first outside wall
Data Source
AI summary
Attaching a fuel injector to a common rail may utilize a fuel injector and an integral tab that has a solid head portion from which a first flexible prong and a second flexible prong protrude and define a gap therebetween. A fuel injector cup may define a notch through which the first prong and the second prong reside to secure the fuel injector to the fuel injector cup, which is attached to the rail. A first prong interior straight wall surface and a second prong interior straight wall surface may face the gap and be parallel. The prongs may define entry contact surfaces and exit contact surfaces that meet at prescribed angles to aid in insertion and hinder retraction of the injector tab from the injector cup. The tab defines a solid head portion below the gap that resides in the notch.