Fuel Injector Nozzles with High Coefficient of Discharge

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Solution Overview

Problem

Current fuel injector nozzles for internal combustion engines face challenges in maximizing fuel efficiency and reducing energy requirements while minimizing emissions, particularly in maintaining a consistent mass flow rate under reduced pressure conditions.

Innovation Solution

The development of fuel injector nozzles with optimized nozzle through-holes, featuring a coefficient of discharge greater than 0.50, designed to enhance fluid flow efficiency through specific inlet and outlet dimensions and configurations, including multiphoton processes for fabrication, which allow for variable and directional fluid flow, reducing pressure requirements and improving overall system performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If traditional nozzle designs are used, then manufacturing is simpler, but fuel efficiency and energy reduction are limited

Engineering Contradiction:

Improvefuel efficiencyVSAvoidmanufacturing complexity

Core Design Contradiction:

Use of energy by moving objectVSEase of manufacture

Solution Approach 1:

The nozzle is divided into multiple through-holes (e.g., 2-650 through-holes) with specific diameter ranges (5-500 μm), allowing optimized fuel distribution across multiple channels. This segmentation enables improved fuel efficiency while maintaining manufacturability through standardized hole patterns and geometries.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention specifies precise parameter ranges including through-hole diameter (5-500 μm), coefficient of discharge (>0.50), and inlet/outlet area ratios (0.1-10.0). These parameter optimizations improve fuel flow characteristics and energy efficiency while remaining within manufacturable limits using conventional precision machining and drilling techniques.

Inventive Principle:

Principle #35Parameter changes

2Use of energy by stationary object

If pressure is reduced to lower energy requirements, then energy consumption decreases, but maintaining consistent mass flow rate becomes difficult

Engineering Contradiction:

Improveenergy consumptionVSAvoidmass flow rate consistency

Core Design Contradiction:

Use of energy by stationary objectVSReliability

Solution Approach 1:

By optimizing the coefficient of discharge to greater than 0.50 and controlling the ratio of inlet to outlet areas (0.1-10.0), the nozzle maintains reliable mass flow rate consistency even at reduced operating pressures. The specific through-hole diameter range (5-500 μm) further ensures stable flow characteristics across varying pressure conditions.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The use of multiple small through-holes (5-500 μm diameter) creates redundant flow paths that maintain consistent total mass flow rate even if individual holes experience minor variations or clogging. This multi-channel approach provides reliability at lower energy consumption levels.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Productivity

If nozzle through-holes are optimized for higher coefficient of discharge, then fuel efficiency improves, but manufacturing precision requirements increase

Engineering Contradiction:

Improvefuel flow efficiencyVSAvoidnozzle hole precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The invention defines practical parameter ranges (through-hole diameter 5-500 μm, coefficient of discharge >0.50) that achieve high fuel flow efficiency while remaining manufacturable with conventional precision techniques. These parameters balance performance optimization with manufacturing capability.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Dividing the fuel flow into multiple through-holes (2-650 holes) allows the system to achieve high overall efficiency through cumulative effect of many smaller, easier-to-manufacture holes. Each individual hole can be made with standard precision, but the collective array achieves the desired >0.50 coefficient of discharge.

Inventive Principle:

Principle #1Segmentation

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 optimized nozzle design enhances fuel efficiency, reduces energy consumption, and maintains a consistent mass flow rate even at reduced pressures, thereby improving the performance and efficiency of internal combustion engines.

Implementation Method 1

at least one nozzle through-hole exhibiting a coefficient of discharge, CD, of greater than about 0.50 as calculated by the formula: CD=Qoutlet/(Ainlet×(2×(P1-P2)/ρ)0.5)

Methodology Applied

Scientific EffectCoefficient of discharge:

Implementation Method 2

each of the one or more nozzle through-holes comprises an inlet opening on the inlet face connected to an outlet opening on the outlet face by a cavity defined by an interior surface

Methodology Applied

Scientific EffectFluid flow through orifices:

Data Source

PatentUS10590899B2Fuel injectors with improved coefficient of fuel discharge

Publication Date: 2020.03.17 3M INNOVATIVE PROPERTIES CO

AI summary

Nozzles and method of making the same are disclosed. The disclosed nozzles have at least one nozzle through-hole therein, wherein the at least one nozzle through-hole exhibits a coefficient of discharge, CD, of greater than about 0.50. Fuel injectors containing the nozzle are also disclosed. Methods of making and using nozzles and fuel injectors are further disclosed.