Fuel Injector Plastic Holder with Offset Arch Segments
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Solution Overview
Problem
The production process of fuel injector solenoid assemblies is complicated and expensive due to the need for additional movable cores to define undercut areas in the plastic body, and the resulting design does not provide a form fit with the injector body, requiring additional elements like support and seal rings.
Innovation Solution
The design features a coherent plastic body with a holder portion comprising two semi-annular arch portions that are axially offset and connected by extending portions, eliminating the need for dedicated cores and allowing for a precise fit with the injector body, thereby simplifying the molding process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If additional movable cores are used to define undercut areas in the plastic body, then the central aperture and socket cavity can be properly formed, but the production process becomes complicated and expensive
Solution Approach 1:
The plastic body is segmented into two separate molding operations: first molding the solenoid assembly without the injector body, then separately molding the injector body mounting features. This eliminates the need for complex movable cores to define undercut areas, as each molding operation works with a simplified geometry that can be formed with stationary mold halves.
Solution Approach 2:
The solenoid assembly is pre-formed in the plastic body before the injector body is attached. By creating the mounting features and recesses in advance during the first molding operation, the need for additional cores to define these features during a subsequent operation is eliminated, simplifying the overall production process.
2Reliability
If the inner radius of the flux washer corresponds to the outer radius of the injector body, then the magnetic flux is properly guided, but the central cavity cannot provide a form fit with the injector body, requiring additional support and seal rings
Solution Approach 1:
The mounting features for the injector body are merged into the plastic body structure itself. The holder portion of the plastic body includes integrated mounting features that directly engage with the injector body, eliminating the need for separate support rings and seal rings while maintaining proper magnetic flux guidance through the flux washer.
Solution Approach 2:
The plastic body is designed to perform multiple functions: it provides electrical insulation, mechanical protection, structural support, and direct mounting for the injector body. The holder portion serves both as a structural element and as a mounting interface, consolidating the functions previously requiring separate support and seal rings into a single integrated component.
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 simplifies the molding process, reduces production costs, and achieves a reliable form fit between the injector body and the solenoid assembly, enhancing the structural integrity and efficiency of the fuel injector.
Implementation Method 1
The magnetic coil or solenoid is configured for generating a magnetic field which actuates the movable parts of the injector
Data Source
Figure 1~3
Figure 3A~5
Figure 6~8
AI summary
The invention relates to a fuel injector (1) extending along an injector axis (A) from a proximal side (1.1) and a distal side (1.2). In order to provide an improved design for the plastic parts of a fuel injector, the invention provides that the fuel injector (1) comprises: - a solenoid unit (11) comprising a magnetic coil (15) in a solenoid housing (12), the solenoid unit (11) circumferentially surrounding a distal aperture (32) around the injector axis (A); - a cable element (16) connected to the magnetic coil (15); - a coherent plastic body (20), which comprises a solenoid portion (21) molded onto the solenoid unit (11), a cable portion (22) extending proximal from the solenoid portion (21) and molded over the cable element (16), and a holder portion (26) that is disposed proximal from the solenoid unit (11) and that circumferentially surrounds a proximal aperture (33) around the injector axis (A); and - an axially extending injector body (40), which is adapted for guiding fuel from the proximal side (1.1) to a nozzle (45) at the distal side (1.2), which injector body (40) is received in the first (42) and second (43) aperture, wherein the holder portion (26) comprises two semi-annular arch portions (27, 28), which are axially offset and are disposed on opposite sides of an axial body plane (B) with respect to each other and are connected at least adjacent the body plane (B) by two axially extending connecting portions (29, 30) on opposite sides of the proximal aperture (43).