Fuel Injector Tip Dual Oxide Coating for Emission Control
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Solution Overview
Problem
Fuel injectors in internal combustion engines face challenges with deposit formation and uncontrolled combustion, leading to increased emissions of volatile organic substances (HC emissions) due to soot deposits, which existing coatings have not adequately addressed.
Innovation Solution
A fuel injector with a dual oxide coating system, comprising a first oxide coating of titanium oxide (TiO2) or aluminum oxide (Al2O3) and a second catalytic coating of cerium oxide (CeO2), praseodymium oxide (PrO2), or zirconium oxide (ZrO2), along with impregnations like copper oxide (CuO) and platinum group metals, applied to the injector tip to reduce deposit formation and lower the light-off temperature of combustible constituents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a single oxide coating is applied to the injector tip, then deposit formation is reduced, but HC emissions are not sufficiently lowered
Solution Approach 1:
The patent applies a composite coating system consisting of a first oxide coating (e.g., Al2O3, TiO2) and a second catalytic coating (e.g., CeO2, PrO2, ZrO2). The first coating provides protective properties against deposit formation, while the second coating adds catalytic functionality to reduce HC emissions. This composite structure allows both functions to work synergistically, resolving the contradiction between reducing deposits and lowering emissions.
Solution Approach 2:
The coating system is divided into two distinct functional layers: a first oxide coating layer that primarily prevents deposit formation, and a second catalytic coating layer that specifically targets HC emission reduction. This segmentation allows each layer to be optimized for its specific function, with the first layer providing structural protection and the second layer providing catalytic activity for emission control.
2Productivity
If the injector tip is exposed directly to the combustion chamber, then fuel injection efficiency is maintained, but the injector tip suffers from high temperatures and corrosive combustion products
Solution Approach 1:
The dual oxide coating system acts as an intermediary protective barrier between the injector tip and the harsh combustion chamber environment. The coatings shield the injector tip material from direct exposure to high temperatures and corrosive combustion products, while still allowing the injector to maintain its fuel injection function. This intermediary layer preserves both productivity and reliability.
Solution Approach 2:
The patent changes the surface parameters of the injector tip by applying oxide coatings with specific thermal and chemical properties. These coatings have high temperature resistance and corrosion resistance, fundamentally altering the surface characteristics to withstand the combustion chamber environment while maintaining injection efficiency.
3Reliability
If conventional coatings are used on the injector tip, then some protection is provided, but they fail to adequately prevent deposit formation and reduce emissions
Solution Approach 1:
The patent transitions from conventional coatings to oxide-based coatings with specific catalytic properties. The second coating layer comprises oxides such as CeO2, PrO2, or ZrO2, which have proven catalytic activity for reducing HC emissions. This parameter change in coating material composition enables both protective function and emission reduction.
Solution Approach 2:
The invention uses a composite coating system where the first oxide coating provides protective properties and the second oxide coating provides catalytic properties for emission reduction. This composite approach overcomes the limitations of conventional single-function coatings by integrating multiple functionalities into a unified coating system.
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 dual oxide coating system significantly reduces volatile organic substance emissions by preventing deposit formation and lowering the combustion temperature of soot, thereby improving engine efficiency and reducing emissions.
Implementation Method 1
a second catalytic coating of cerium oxide (CeO2), praseodymium oxide (PrO2), or zirconium oxide (ZrO2)... lower the light-off temperature of combustible constituents
Implementation Method 2
significantly reduces volatile organic substance emissions by preventing deposit formation... A fuel injector with a dual oxide coating system... applied to the injector tip to reduce deposit formation
Data Source
AI summary
The invention relates to a fuel injector (1) for an internal combustion engine. The fuel injector (1) is comprised of an injector body (5) with an injector tip (6). The injector tip (6) is used for the injection of fuel into the combustion chamber (4) of the internal combustion engine. For this reason, the injector tip (6) is designed so as to be at least partially extended into the combustion chamber (4). If the injector tip (6) is designed to be flush with the surface of the combustion chamber (4), the injector tip (6) is arranged so that it directly faces toward the combustion chamber (4). Furthermore, the injector tip (6) is at least partially coated with a first oxide layer (9). According to the invention, a catalytic second oxide coating (10) composed of cerium oxide (CeO2), praseodymium oxide (PrO2), zirconium oxide (ZrO2), or any bi-component combination thereof is applied on top of the first oxide coating (9). The present invention also discloses a method of producing a fuel injector (1) which is at least partially coated with a first oxide coating (9) and a second oxide coating (10) applied over the first oxide coating (9), where the second oxide coating (10) is composed of at least one or more compounds from the group comprising cerium oxide (CeO2), praseodymium oxide (PrO2), or zirconium oxide (ZrO2) and is applied as a washcoat.