Fuel Injector Plastic Sleeve Assembly
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Solution Overview
Problem
The manufacture and assembly of conventional fuel injectors are labor-intensive and costly due to the complex process involving metallic housing components and a labor-intensive plastic extrusion coat.
Innovation Solution
A prefabricated plastic sleeve encompasses the electrical parts of the solenoid circuit, including the solenoid coil, electrical lines, and plug-in connections, simplifying assembly by eliminating the need for a separate plastic extrusion coat and allowing for easy installation and fixation using a circular segment-shaped top with radial clipping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a plastic extrusion coat is applied after assembly of metallic housing components, then the fuel injector achieves structural integrity and sealing, but the manufacture and assembly become labor-intensive and costly
Solution Approach 1:
The plastic sleeve is pre-assembled with the solenoid coil, electrical line, and plug-in connection before being installed on the valve subassembly. This preliminary assembly of electrical components within the plastic sleeve eliminates the need for post-assembly plastic extrusion coating, reducing labor intensity and manufacturing complexity while maintaining structural integrity
Solution Approach 2:
The invention merges the plastic protective sleeve with the electrical components (solenoid coil, electrical line, plug-in connection) into a single integrated assembly. This combination eliminates separate manufacturing steps for the plastic extrusion coat and simplifies the overall assembly process, reducing both labor intensity and cost
2Reliability
If a plastic extrusion coat is used to encapsulate electrical parts, then protection and sealing are achieved, but assembly becomes labor-intensive and error-prone
Solution Approach 1:
The plastic sleeve is pre-formed with the electrical components already positioned within it, including the solenoid coil, electrical line, and plug-in connection. This preliminary preparation ensures proper sealing and protection is built-in from the start, eliminating the need for labor-intensive post-assembly plastic coating operations that are prone to errors
Solution Approach 2:
The plastic sleeve design allows the electrical components to be self-contained and self-protected within the sleeve structure. The sleeve itself provides the sealing and protection function without requiring additional manual plastic extrusion steps, thereby improving assembly efficiency and reducing errors
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 approach significantly reduces assembly steps and labor costs, enhancing efficiency and reducing the likelihood of faulty plastic extrusion coats, while maintaining the structural integrity of the fuel injector.
Implementation Method 1
the electrical parts of the solenoid circuit, i.e., the solenoid coil
Data Source
AI summary
A fuel injector for an internal combustion engine includes a solenoid coil which is actuable by an electrical line, a valve sleeve which forms an outer coat of the fuel injector in a discharge-side region, and a valve housing. The fuel injector further includes a plastic sleeve, which houses the solenoid coil and the electrical line. The plastic sleeve is slid over the valve sleeve in assembly. The plastic sleeve has two parts interconnected by a crosspiece, with a recess formed in a radial region adjacent to the region of the crosspiece.