Fuel Injector With Magnetic-Permeability Zoning for Gaseous Fuel Flow
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Solution Overview
Problem
Existing fuel injectors for gaseous fuels in internal combustion engines do not provide the operating pressure and flow capabilities required for optimal performance and lower fuel consumption due to the different characteristics of hydrogen gas and the combustion process.
Innovation Solution
A fuel injector design with a nozzle body featuring regions of differing magnetic permeability values in the actuator arrangements, optimizing the magnetic flux path to enhance the actuation force and efficiency, using high and low permeability materials or treated regions to direct magnetic flux effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If existing fuel injector designs are used for gaseous fuels, then the injector structure is simple and familiar, but the operating pressure and flow capabilities are insufficient for optimal engine performance
Solution Approach 1:
The patent applies local quality by creating regions of different magnetic permeability within the actuator body. Specifically, a first region with high magnetic permeability (≥500) is positioned radially inner to the coil, while a second region with low magnetic permeability (≤50) is positioned radially between the coil and the first region. This local differentiation optimizes the magnetic flux path to concentrate flux through the armature, significantly enhancing actuation force without requiring a complete redesign of the injector architecture.
Solution Approach 2:
The actuator body employs composite material construction with regions of contrasting magnetic permeability. The high permeability region (such as ferromagnetic material) and low permeability region (such as non-magnetic or weakly magnetic material) are combined within the same actuator body, creating a composite structure that guides and concentrates magnetic flux where needed while preventing flux leakage, thereby achieving high actuation force within the existing design framework.
2Force
If the magnetic permeability of the entire actuator body is increased to enhance actuation force, then the magnetic flux path is improved, but the magnetic flux leaks through the actuator body instead of concentrating through the armature
Solution Approach 1:
The patent resolves magnetic flux leakage by applying local quality - creating a high permeability region only where flux concentration is needed (radially inner region adjacent to the armature), while introducing a low permeability region radially outward between the coil and the high permeability region. This localized approach ensures magnetic flux is guided through the armature to generate force while preventing flux from short-circuiting through the actuator body, thereby eliminating energy loss without compromising actuation force.
Solution Approach 2:
The low permeability region acts as an intermediary or magnetic barrier that prevents magnetic flux from taking a short path through the actuator body. By positioning this low permeability region radially between the coil and the high permeability region, it forces the magnetic flux to travel through the armature instead, ensuring that the magnetic flux serves its intended purpose of generating actuation force rather than leaking away as energy loss.
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 design achieves higher injection pressures and flow capabilities, mitigating competing mechanical and magnetic demands, thereby improving engine performance and reducing fuel consumption.
Implementation Method 1
a first conductive coil mounted concentrically on a first body and a first armature configured to apply the opening force to the valve needle assembly
Implementation Method 2
a magnetic permeability value of the first region is higher than a magnetic permeability value of the second region, in use
Data Source
AI summary
A fuel injector for an internal combustion engine comprising an injection nozzle comprising a nozzle body with a nozzle bore; a valve needle assembly received within the nozzle bore and including a valve needle engageable with a seat region to control fuel delivery through an outlet of the injection nozzle; and a first actuator arrangement operable to apply an opening force to an engagement region of the valve needle assembly to cause an opening movement thereof. The first actuator arrangement comprises a first conductive coil mounted concentrically on a first body and a first armature configured to apply the opening force to the valve needle assembly.The first body comprises a first, radially inner region having a relatively high magnetic permeability and a second region having a relatively low magnetic permeability, the second region being disposed radially between the first coil and the first, radially inner region.