Monolithic Fuel Nozzle Assembly With Integrated Heat Shield Interfaces
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Solution Overview
Problem
Conventional fuel injector manufacturing processes are complex, time-consuming, and costly due to the use of multiple components joined by weld or braze joints, requiring multi-step assembly and conventional machining methods.
Innovation Solution
A monolithic body for a fuel injector is manufactured using additive manufacturing, integrating a mount, stem, and heat shield portions, allowing for reduced manufacturing time and cost, with interfaces for easy assembly to a nozzle and manifold, and featuring a heat shield to protect fuel passages from high temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional machining methods and multi-step assembly processes are used to manufacture fuel injectors with multiple components joined by weld or braze joints, then manufacturing precision and reliability are maintained, but manufacturing complexity, time, and cost increase significantly
Solution Approach 1:
The patent combines multiple fuel injector components (mount, stem, heat shield, and nozzle) into a single monolithic body manufactured by additive manufacturing. This eliminates the need for separate components to be joined by weld or braze joints, directly reducing manufacturing complexity and assembly steps while maintaining the functional integrity and reliability of the fuel injector system
2Productivity
If multiple components are joined using weld joints or braze joints in a multi-step process, then functional requirements are met, but manufacturing time and production efficiency decrease
Solution Approach 1:
The monolithic body design integrates multiple components into one unit manufactured in a single additive manufacturing process, eliminating sequential assembly operations. This significantly reduces manufacturing time and improves productivity by producing the entire fuel injector body in one continuous build process rather than through multiple discrete manufacturing and assembly steps
3Ease of manufacture
If conventional machining and multi-step assembly methods are used, then component reliability is ensured, but manufacturing cost increases
Solution Approach 1:
The patent produces the monolithic body in a single additive manufacturing process, eliminating multiple machining and assembly operations. This reduction in manufacturing steps directly lowers manufacturing cost while the integrated design ensures reliability by eliminating potential failure points from welds and braze joints, and the additive manufacturing process inherently maintains material integrity throughout the structure
Data Source
Figure 1
Figure 2
AI summary
A monolithic body (10) and fuel injector (30) with the monolithic body (10) include a mount portion (12), a stem portion (14), and a heat shield portion (16). The stem portion (14) and the heat shield portion (16) extend from the first surface (12A) of the mount portion (12). The heat shield portion (16) circumscribes at least a portion of the stem portion (14). The second surface (12B) of the mount portion (12) defines a first interface (24), and a distal end of the stem portion (14) defines a second interface (22) for joining the monolithic body (10) with components of the fuel injector (30).