Fuel Injector Cup Snap-Fix via Spring Clip Segmentation
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Solution Overview
Problem
Existing fuel injection assemblies for combustion engines face challenges in ensuring precise orientation and secure fixation of high-pressure fuel injectors, which affects engine performance and reliability.
Innovation Solution
A fuel injection assembly comprising an injector body, an injector cup, and a spring clip with a ground plate and recess design that provides a snap-fix mechanism, preventing rotary and axial movements, and is cost-efficiently manufactured with a minimal number of parts for reliable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a stamped tab fixing element is used to couple the fuel cup with the injector, then the manufacturing cost is reduced and ease of manufacture is improved, but the reliability of fixation and prevention of rotary movement is insufficient
Solution Approach 1:
The fixing mechanism is segmented into multiple independent elements: the spring clip with ground plate, the recess in the fuel cup, and the engagement features on the injector body. This segmentation allows each component to perform its specific function (clamping, positioning, preventing rotation) while maintaining overall reliability through distributed fixation points rather than relying on a single stamped tab
Solution Approach 2:
The spring clip introduces dynamic elasticity into the fixing mechanism. The spring element can deform elastically to accommodate assembly tolerances and maintain constant clamping force, providing reliable fixation that adapts to manufacturing variations while preventing both axial separation and rotary movement of the fuel cup
2Reliability
If multiple separate components are used to ensure precise orientation and secure fixation, then the reliability and fixation stability are improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The spring clip integrates multiple fixation functions into a single component: the ground plate provides the clamping surface, the spring element provides elastic retention force, and the engagement features prevent rotary movement. This merging of functions reduces the number of separate parts compared to using multiple independent fixation elements while maintaining reliable and stable fixation
Solution Approach 2:
The spring clip serves multiple functions simultaneously: it retains the fuel cup axially, positions it radially, prevents rotary movement through engagement features, and compensates for tolerance variations. This multi-functionality eliminates the need for separate components for each fixation requirement, simplifying the overall device while improving reliability
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 assembly ensures precise orientation and secure fixation of the injector, enhancing engine performance and reliability while being cost-effective and easy to manufacture, with a snap-fix mechanism that prevents unwanted movements and maintains stability during transportation and installation.
Implementation Method 1
the spring element is operable to exert a spring force on the injector body
Data Source
AI summary
A fuel injection assembly for a combustion engine includes an injector body, an injector cupradially enclosing an axial end of the injector body, and a spring clip coupling the injector cup with the injector body. The spring clip includes a ground plate with a main extension plane perpendicular to a longitudinal axis of the fuel injection assembly, a recess extending inwards from a lateral end of the ground plate to a bottom part having a circle-segment contour extending through an angle between 270° to 180°, and at least one spring element fixed to the ground plate. The spring element of the spring clip has a contact region with the injector cup, and the ground plate has a contact region with the injector body, whereby the spring element exerts a spring force on the injector cup. The ground plate of the spring clip extends into a cutout of the injector cup.