Fuel Injector Wire Seal for Vibration-Resistant Leak Prevention
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Solution Overview
Problem
Existing fuel injector electrical connections are prone to disconnection and fuel leakage due to engine vibrations, which can lead to poor performance and reliability issues in internal combustion engines.
Innovation Solution
A fuel injector design that includes a seal situated within a passageway configured to convey electrical wires, where the seal surrounds the wires and provides a secure conduit to prevent fuel leakage and maintain electrical connectivity despite engine vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical wires are routed through the fuel injector assembly, then electrical connectivity is achieved, but fuel leakage occurs due to vibrations
Solution Approach 1:
A seal member is introduced as an intermediary component between the electrical wires and the fuel injector housing. This seal member provides a dedicated pathway that simultaneously accommodates electrical wire passage and prevents fuel leakage, resolving the conflict between maintaining electrical connectivity and preventing fuel leakage.
Solution Approach 2:
The seal member is divided into multiple segments or lips that can independently deform to accommodate wire movement while maintaining the sealing barrier. This segmentation allows the seal to adapt to vibrations and wire displacement without compromising the fuel-tight seal.
2Volume of moving object
If electrical connector is positioned close to engine pistons, then space is saved, but disconnection occurs due to severe vibrations
Solution Approach 1:
The seal member functions as a flexible barrier that can deform under vibration while maintaining its sealing function. This flexibility allows the electrical connector to remain in close proximity to engine components without compromising connection stability, as the seal absorbs the mechanical stress from vibrations.
3Object-generated harmful factors
If seal surrounds electrical wires, then fuel leakage is prevented, but wire movement is restricted
Solution Approach 1:
The seal member is segmented into multiple flexible lips or sections that can independently move and deform. This segmentation allows the seal to maintain a tight barrier around the electrical wires while permitting necessary wire movement and flexibility, preventing fuel leakage without restricting wire mobility.
Solution Approach 2:
The seal member is designed with dynamic characteristics, allowing it to deform and adapt its shape in response to wire movement and vibrations. This dynamic behavior enables the seal to maintain continuous contact with the wires and housing, preventing fuel leakage while accommodating wire flexibility and movement.
Data Source
AI summary
A fuel injector includes a body assembly having a proximal end and a distal end comprising a nozzle, an electronically operated valve situated within the body assembly, the electronically operated valve comprising a plurality of electrical wires, and a passageway configured to convey electrical wires from the electronically operated valve proximally through the fuel injector and out the proximal end and external to the body assembly. The fuel injector further includes a seal situated within the passageway and distal a proximal end of the passageway, the seal surrounding the plurality of electrical wires.