High-Flow Fuel Injector With Integrated Needle for Stable Low-Pressure Flow
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Solution Overview
Problem
Traditional fuel injectors for high-performance engines suffer from low fuel flow, inconsistent flow and injection time, complexity, and difficulty in maintenance due to numerous components, leading to inefficiency and instability.
Innovation Solution
A high-flow fuel injector with a simplified design featuring a single-piece needle, optimized valve seat, funnel-shaped chamber, and silver-plated connectors to minimize noise and heating, along with a linear fuel flow mechanism, ensuring stable and efficient fuel delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional fuel injector design is used, then the structure is well-established, but the fuel flow is low and the number of components is high
Solution Approach 1:
The patent merges multiple traditional components (needle valve, valve body, seal, guide ring, sieve) into a single integrated needle valve body. The fuel injection nozzle is formed as one piece with internal channels, spray holes, and sealing surfaces all integrated into the needle valve body structure, eliminating the need for separate components while maintaining fuel flow control functionality
Solution Approach 2:
The single needle valve body performs multiple functions simultaneously: it controls fuel flow through internal channels, provides sealing through integrated sealing surfaces, guides the needle valve movement, and filters fuel through built-in sieve structures. This multi-functional design replaces what traditionally required separate specialized components
2Ease of repair
If traditional fuel injector design is used, then the structure is well-established, but the maintenance is difficult
Solution Approach 1:
By integrating all functional components into a single needle valve body, the patent reduces the number of parts that can fail or wear. There are no separate seal rings, guide rings, or sieve components to replace - the entire needle valve body can be removed and serviced as one unit, significantly simplifying maintenance procedures
3Reliability
If traditional fuel injector design is used, then the components are standardized, but the flow is inconsistent and efficiency is lost
Solution Approach 1:
The patent incorporates local quality variations within the needle valve body through strategically positioned internal channels of varying diameters and spray holes with specific angles. The internal channel diameter changes along the needle valve body length to optimize fuel flow at different positions, while spray holes are angled to direct fuel flow precisely where needed, ensuring consistent and efficient fuel delivery
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 injector achieves high fuel flow rates of 170-340 lb/h at low pressures, with improved efficiency, reduced maintenance complexity, and enhanced performance by minimizing turbulence and component wear.
Implementation Method 1
coil (131), cylindrical in shape and having a central hole A (1311), central hole B (1313), and projection with passage of the connector (1312), which has a tear in the coil (1314)
Implementation Method 2
spring (16), which connects to the internal channel of reduced diameter D (1243)
Data Source
AI summary
This invention refers to a high flow fuel injector, designed and engineered to meet the needs of combustion engines in automobiles in general, especially high-performance engines that benefit from a high and stable flow of fuel at low pressures. The object of this invention patent overcomes the limitations and disadvantages existing in the state of the art, allowing high fuel flows at low pressures, through optimized geometry and construction, improved manufacturing and materials chosen and simplification of the number of components. The high flow fuel injector (1) consists of a connector housing (11), coil body (12), coil and connector assembly (13), needle (14), needle body (15) and spring (16).