Fuel Injector Nozzle Grooves for Air Mixing

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Solution Overview

Problem

Fuel injectors in combustion engines face inefficiencies in mixing fuel with air due to the smooth, laminar flow of fluid through spray holes, which hinders effective combustion.

Innovation Solution

The introduction of helical or linear grooves within the spray holes of fuel injectors, formed using heating devices like lasers, to disrupt the laminar flow and enhance mixing by imparting rotational flow or breaking it up, thereby improving fuel-air interaction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If smooth spray holes are used in fuel injectors, then manufacturing is simple and reliable, but fuel-air mixing is inefficient due to laminar flow

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidfuel-air mixing efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The spray hole is modified by adding grooves only in specific locations along its length, creating localized turbulence-generating features without fundamentally changing the overall hole structure. This allows efficient mixing while maintaining manufacturing feasibility through targeted modifications rather than complete redesign.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The grooves in the spray hole create turbulence and chaotic flow patterns as fuel passes through, effectively introducing mechanical disturbance to the flow. This turbulence enhances mixing between fuel and air without requiring complex external mixing mechanisms.

Inventive Principle:

Principle #18Mechanical vibration

2Productivity

If grooves are added to spray holes to improve mixing, then fuel-air interaction is enhanced, but manufacturing complexity increases

Engineering Contradiction:

Improvefuel-air mixing efficiencyVSAvoidspray hole structure complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The spray hole is segmented by dividing its inner surface with multiple grooves that create separate flow paths and turbulence zones. This segmentation enhances mixing by breaking up laminar flow into chaotic patterns while keeping each individual groove feature relatively simple in design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The grooves modify key flow parameters such as velocity distribution, pressure gradients, and flow direction within the spray hole. By carefully controlling groove dimensions (depth, width, spacing), the design achieves effective mixing while limiting overall structural complexity.

Inventive Principle:

Principle #35Parameter changes

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 grooved design enhances the mixing of fuel with air, leading to more efficient combustion and improved engine operation by ensuring a better fuel-air mixture, which combusts efficiently.

Implementation Method 1

forming, with the heating device, a groove in a helical configuration along an inner surface of at least a portion of the at least one spray hole

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS20240337232A1Fuel injector having nozzle spray holes with grooves

Publication Date: 2024.10.10 CUMMINS-SCANIA HPCR SYST LLC

AI summary

An injector includes a nozzle body extending along a longitudinal axis and at least one spray hole extending through a portion of the nozzle body to output a fluid from the injector. The spray hole includes at least one groove. The groove is configured to facilitate efficient mixing of the fluid with air or other surrounding materials for enhanced performance of the injector and/or other components associated with the injector.