Fuel Injector Electrical Module with Compressible Elastic Element
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Solution Overview
Problem
Conventional fuel injectors face issues with back leak fuel flow, leading to wear, deposit formation, and increased production costs due to the need for custom-built components for each injector size, as well as inefficiencies in managing high-pressure back leak fuel.
Innovation Solution
An electrical module with a compressible elastic element, such as a coil spring, is integrated into the fuel injector, allowing for variable length and simplifying manufacturing by eliminating the need for a separate back leak conduit, and mixing back leak fuel with an external fuel flow to create a cooling mixture that reduces component damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate back leak conduit is drilled through the fuel injector body, then the back leak fuel can be evacuated and returned to the fuel management system, but the machining complexity and production cost increase significantly
Solution Approach 1:
The patent combines the back leak fuel evacuation function with the electrical module housing structure. The electrical module body itself serves as the conduit housing, eliminating the need for a separate drilled conduit through the injector body. This merging of functions reduces machining complexity while maintaining back leak fuel management capability.
Solution Approach 2:
The electrical module is designed to serve multiple functions: it houses the electrical components (actuator, contacts, conductors) and simultaneously provides the structural housing for back leak fuel evacuation. This multi-functionality eliminates the need for separate dedicated back leak conduits, simplifying manufacturing.
2Productivity
If the back leak fuel flow channel is made with narrow diameter to manage fuel flow, then the fuel return is efficient, but the alignment precision required during machining increases
Solution Approach 1:
The electrical module housing integrates the fuel flow channel structure, so the channel is formed as part of the housing cavity rather than requiring separate precision drilling and alignment through multiple injector components. This eliminates the need for high-precision alignment of narrow diameter channels.
3Reliability
If custom-built components are manufactured for each injector size, then the injector performance is optimized, but the production cost and device complexity increase
Solution Approach 1:
The electrical module is designed as a universal component that can be adapted to different injector sizes. The same basic module design with integrated housing and back leak channel structure can serve multiple injector variants, reducing the need for custom-built components for each size while maintaining performance.
Solution Approach 2:
The electrical module design allows for adaptive configuration to different injector sizes through flexible positioning and sizing of the actuator and electrical contacts within the standardized housing structure, enabling one module design to serve multiple applications.
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 solution reduces wear and damage from high-pressure back leak fuel, simplifies manufacturing by allowing a single module to fit various injector lengths, and improves operational efficiency by using a cooling mixture that extends the lifespan of components.
Implementation Method 1
the body of the module is comprised of a compressible elastic element, such as a coil spring, such that the length of the module is variable by compressing the elastic element
Implementation Method 2
mixing back leak fuel with an external fuel flow to create a cooling mixture that reduces component damage
Data Source
AI summary
An electrical module for use within a fuel injector for delivering fuel to an internal combustion engine is described. The electrical module has a variable length. The electrical module comprises electrical contacts for operatively connecting the electrical module to a power plug of a fuel injector. The electrical module also comprises an actuator for operatively controlling a control valve disposed within the fuel injector. The electrical module also comprises electrical conductors arranged within a protective housing. These electrical conductors provide an electrical connection between the electrical contacts and the actuator in order to provide electrical power to the actuator when the electrical contacts are operatively connected to the power plug of the fuel injector. The body of the electrical module is comprised of a compressible elastic element, such that the length of the module is variable by compressing the elastic element. Injectors including such electrical modules are also described.