Integrated Injector Filtration Sleeve for Low-Particle Assembly
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Solution Overview
Problem
Existing direct injection fuel injectors face challenges with high production costs and complex assembly processes, particularly in piezoelectric actuated systems, and generate particles that degrade performance due to non-optimized armature spring positioning and separate components like stop rings and filters.
Innovation Solution
A combined filtration and calibration assembly is introduced, integrating a calibration sleeve, stop ring, and filter into a single piece, with a calibrated orifice and filtration holes, produced through lamination and laser drilling, to simplify assembly and reduce particle generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If piezoelectric actuators are used to achieve high opening force and rapid valve opening, then fuel consumption is reduced, but manufacturing cost increases prohibitively
Solution Approach 1:
The patent combines the calibration sleeve, stop ring, and filter into a single integrated component. This merging reduces the number of parts to be manufactured and assembled, thereby lowering manufacturing costs while maintaining the functional performance required for high-pressure direct injection operation
2Ease of manufacture
If solenoid actuators are used to reduce manufacturing cost, then manufacturing cost decreases, but opening force and performance are insufficient
Solution Approach 1:
The patent optimizes the armature spring positioning parameter by relocating it away from the armature-pole piece interface. This parameter change increases the air gap, thereby enhancing the magnetic field strength and opening force generated by the solenoid actuator, allowing it to achieve performance levels previously only attainable with piezoelectric actuators
3Reliability
If armature spring is positioned above the armature to ensure return to rest position, then reliability of valve closure is improved, but magnetic force is reduced due to reduced air gap
Solution Approach 1:
The patent extracts the armature spring from its traditional position above the armature and relocates it to a different position in the assembly. This separation allows the spring to maintain its function of ensuring reliable valve closure while no longer interfering with the magnetic field generation between the armature and pole piece
4Adaptability or versatility
If multiple separate components (calibration sleeve, stop ring, filter) are assembled during production, then functional requirements are met, but assembly complexity increases and particle generation occurs
Solution Approach 1:
The patent merges the calibration sleeve, stop ring, and filter into a single integrated component that performs all three functions simultaneously. This eliminates the need for separate assembly steps, reduces assembly complexity, and prevents particle generation that would occur during the assembly of multiple separate parts
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 integration reduces assembly complexity, lowers costs, minimizes particle-related degradation, and ensures standardized performance by retaining particles, thus enhancing fuel injector reliability and efficiency.
Implementation Method 1
The electromagnetic actuator 12 comprises a fixed coil 24, a pole piece 26 and an armature 28
Implementation Method 2
drill filtration holes using a laser
Data Source
AI summary
A combined assembly for filtering and calibrating a fuel injector arranged in an internal combustion engine, the combined filtration and calibration assembly extending along a longitudinal axis and comprising a calibration sleeve provided with a longitudinal bore and defining a multitude of filtration holes. The combined filtration and calibration assembly has a calibrated opening in the bore.