Fuel Injection Nozzle Orifice Layout for Angled Laser Drilling
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Solution Overview
Problem
Existing nozzle designs face challenges during laser drilling of orifices, as the laser cannot be deactivated quickly enough to prevent damage to the opposite blind hole wall, leading to potential drilling through the wall and increased emission values due to surface roughness issues.
Innovation Solution
The nozzle design features an orifice with a longitudinal axis directed towards the side of the reception hole remote from the nozzle tip, allowing the laser drilling axis to be aligned at an angle, thereby avoiding damage to the seat region and blind hole, and enabling smoother surfaces through laser drilling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser drilling is used to produce orifices, then surface smoothness and manufacturing precision are improved, but the risk of damaging the opposite blind hole wall increases due to inability to deactivate laser quickly enough
Solution Approach 1:
The patent applies asymmetry by drilling the orifice at an angle (10° to 30°) relative to the longitudinal axis of the nozzle, rather than perpendicular to it. This angled drilling approach directs the laser beam away from the opposite blind hole wall, preventing laser damage while maintaining smooth orifice surfaces. The asymmetric drilling angle creates a safety margin that eliminates the need for back wall protection screens.
Solution Approach 2:
The patent introduces a new dimensional parameter - the drilling angle - to solve the problem. By changing from a conventional perpendicular drilling approach to an angled drilling approach, the laser beam path is redirected away from the vulnerable blind hole wall region, thereby preventing damage without compromising orifice quality.
2Ease of manufacture
If conventional erosion process is used to produce orifices, then manufacturing simplicity is maintained, but emission values increase due to surface roughness
Solution Approach 1:
The patent replaces the mechanical erosion process with laser drilling. This substitution eliminates the need for subsequent hydro-erosive rounding operations, directly producing smooth orifice surfaces that reduce emission values while maintaining manufacturing efficiency. The laser drilling process inherently creates smoother surfaces compared to mechanical erosion methods.
3Shape
If laser drilling penetrates complete orifice and enlarges it by circular or helical movement, then orifice geometry is achieved, but drilling time increases and reproducibility decreases
Solution Approach 1:
The patent changes the drilling parameter from circular or helical movement to a straight-line angled drilling approach. This parameter change simplifies the drilling process, reduces cycle time, and improves reproducibility while still achieving the required orifice geometry through the angled penetration approach.
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 design reduces waste and potential damage during laser drilling, resulting in smoother orifices with reduced emission values and improved reproducibility, while maintaining the functionality of the nozzle.
Implementation Method 1
produce the orifices by means of laser drilling
Implementation Method 2
the orifices typically produced using an erosion process are therefore hydro-erosively rounded in which an abrasive fluid mixed with grinding particles is pumped through the orifices at a high pressure up to (120 bar)
Data Source
AI summary
The present invention relates to a nozzle for injecting fuel comprising an orifice in the region of a nozzle tip for leading fuel out of the nozzle and a reception hole for receiving a nozzle needle, wherein the reception hole has a seat region for a sealing closing by a nozzle needle to enable a fuel supply to the orifice in dependence on a position of the nozzle needle, characterized in that the longitudinal axis of the orifice is directed toward a region of the reception hole that adjoins the side of the seat region remote from the nozzle tip.