Fuel Injector High-Pressure Connection with Undercut Sealing
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Solution Overview
Problem
High-pressure fuel injector systems require strong forces for metal-metal connections to prevent leakage, leading to complex and costly multi-component assemblies for force transmission.
Innovation Solution
A flange element with a two-part or one-piece design that engages with an undercut on a connecting piece, allowing for reliable metal-metal sealing and compensating for angular misalignment between the rail and injector, using a metallic ball-cone sealing mechanism and bayonet joint for simplified mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal-metal connection with multiple ring segments is used for force transmission, then sufficient tightness at high pressure is achieved, but manufacturing costs increase and mounting complexity increases
Solution Approach 1:
The patent combines multiple ring segments into a single integrated connecting piece with an undercut geometry. This connecting piece integrates the force transmission function that previously required multiple separate ring segments, thereby reducing the number of components while maintaining the necessary tightness at high pressure.
Solution Approach 2:
The connecting piece features an undercut geometry that segments the force transmission path into distinct zones (the undercut region and the sealing surface). This geometric segmentation allows the single piece to perform multiple functions: providing structural strength, enabling angle compensation, and ensuring reliable sealing without requiring multiple physical components.
2Reliability
If metal-metal connection with multiple ring segments is used for force transmission, then sufficient tightness at high pressure is achieved, but manufacturing costs increase
Solution Approach 1:
The patent combines multiple ring segments into a single integrated connecting piece with an undercut geometry. This connecting piece integrates the force transmission function that previously required multiple separate ring segments, thereby reducing the number of components while maintaining the necessary tightness at high pressure.
3Reliability
If strong forces are applied to metal sealing surfaces with cap nut and multiple ring segments, then sufficient tightness is achieved, but the number of components increases
Solution Approach 1:
The patent combines multiple ring segments into a single integrated connecting piece with an undercut geometry. This connecting piece integrates the force transmission function that previously required multiple separate ring segments, thereby reducing the number of components while maintaining the necessary tightness at high pressure.
4Reliability
If traditional metal-metal connection is used, then sealing is achieved, but angular misalignment between rail and injector cannot be compensated
Solution Approach 1:
The connecting piece is designed with an undercut geometry that allows it to flex and adapt to angular misalignments between the rail and injector. The undercut region acts as a compliant zone that can accommodate angular variations while maintaining the metal-to-metal sealing contact, providing dynamic adaptation to installation tolerances.
Solution Approach 2:
The undercut geometry incorporates curved surfaces that facilitate angular compensation. The curved geometry of the undercut allows the connecting piece to rotate or flex slightly to accommodate misalignment angles while maintaining sealing effectiveness.
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 solution reduces manufacturing costs and complexity while ensuring a leak-proof connection at high pressures, minimizing the risk of part misalignment and damage, and simplifying the mounting process.
Implementation Method 1
The metal-metal sealing is preferably a metallic ball-cone sealing, the spherical area preferably being provided on the connecting piece and the cone on the rail.
Implementation Method 2
a flange element is furthermore provided to fasten the injector on the rail, the flange element engaging with an undercut on the one-piece connecting piece and pressing the connecting piece against the rail to enable a reliable metal-metal sealing
Data Source
AI summary
A fuel injection device includes a rail having at least one outflow opening, at least one injector situated on the rail, a connecting piece situated on the injector, and a flange element for fastening the injector on the rail. The flange element includes a central opening through which the connecting piece is guided. A metal-metal sealing is provided between the connecting piece and the rail. The connecting piece is designed in one piece with an undercut, and the flange element engages with the undercut of the connecting piece. The connecting piece presses against the rail in a sealing manner.