Fuel Injector Perforation Array for Particulate Filtration

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Solution Overview

Problem

Fuel injectors face contamination and performance issues due to high operating temperatures and particulate matter, which existing filtration strategies struggle to address effectively, especially in integrated systems where space and structural integrity are concerns.

Innovation Solution

A fuel injector case with a particulate-blocking perforation array, featuring a circumferential and axial distribution of perforations, integrated within the elongate body to form a fluid flow path, providing a filtered cooling fluid supply to the valve assembly and nozzle piece, thereby preventing particulate entry and maintaining performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a cooling fluid is delivered to the fuel injector to transfer heat energy, then the operating temperature is reduced, but the fuel becomes contaminated with particulates

Engineering Contradiction:

Improveoperating temperatureVSAvoidparticulate contamination

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The fuel injector case incorporates a porous filtration segment with a particulate-blocking perforation array that allows cooling fluid to pass through while trapping particulates. The porous structure enables simultaneous cooling and filtration functions within the same component.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The filtration segment acts as an intermediary between the cooling fluid and the fuel injector internal passages. It mediates by allowing heat transfer while blocking particulates, preventing contamination of the fuel injector components.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If a secondary filter assembly is added to protect fuel injector components, then particulate contamination is reduced, but the device complexity increases

Engineering Contradiction:

Improveparticulate contaminationVSAvoidfilter assembly complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The filtration function is merged with the fuel injector case structure itself. The filtration segment is formed as an integrated portion of the elongate body, combining the injector housing and filter into a single component rather than separate assemblies.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The fuel injector case serves multiple functions: it houses the valve assembly, provides structural support, and incorporates the filtration function through the particulate-blocking perforation array. This multi-functionality eliminates the need for separate filter assemblies.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If tight tolerances are machined for fuel injector components to operate at high temperatures, then the injector performance is optimized, but the manufacturing precision requirements increase

Engineering Contradiction:

Improveinjector performanceVSAvoiddimensional tolerance

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The invention changes the temperature parameter by introducing active cooling through the perforation array. By maintaining lower operating temperatures, the system can use slightly relaxed tolerances while maintaining reliability, as thermal expansion and dimensional instability are reduced.

Inventive Principle:

Principle #35Parameter changes

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 integrated filtration system effectively blocks particulates, reducing contamination and maintaining injector performance by providing a filtered cooling fluid without compromising the structural integrity of the fuel injector case, thus extending service life and reducing maintenance costs.

Implementation Method 1

The filtration segment has a particulate-blocking perforation array with a circumferential distribution of perforations and an axial distribution of perforations in the elongate body, and forming a fluid flow path from the outer peripheral surface to the inner peripheral surface

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Implementation Method 2

delivering a cooling fluid, such as fuel, to the fuel injector such that some of the heat energy generated by the fuel injector is transferred to the cooling fluid

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS10371110B2Fuel injector having particulate-blocking perforation array

Publication Date: 2019.08.06 CATERPILLAR INC

AI summary

An engine head assembly includes a plurality of fuel injectors each positioned within a fuel injector bore in an engine head, and fluidly coupled with a fluid conduit. Each fuel injector includes a valve assembly within a fuel injector case such that an interior fluid space is formed between the fuel injector case and the valve assembly. The fuel injector case includes an elongate body having a particulate-blocking perforation array formed therein, and that is structured to block particulates in fuel entering the fuel injector from the fluid conduit.