Direct Injector Nozzle Assembly for Higher Fuel Flow and Spray Control
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Solution Overview
Problem
Conventional gasoline direct injectors are difficult to modify without damaging the precision components, limiting the ability to increase fuel flow rate or alter the spray pattern, which restricts engine performance enhancements.
Innovation Solution
A method involving machining of the conventional direct injector and assembly with a modular adapter and orifice plate to modify the fuel flow rate and spray pattern, maintaining precision and integrity of the pintle seat seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional direct injector is modified to increase fuel flow rate or alter spray pattern, then engine performance and specific output are improved, but the precision components (pintle seat seal, nozzle orifices) are damaged
Solution Approach 1:
The injector is divided into separate functional components: the original precision injector body (with protected pintle seat seal) and a separate modifyable nozzle assembly. This segmentation allows modification of the nozzle while preserving the precision components in the injector body, resolving the contradiction between increasing fuel flow and maintaining manufacturing precision.
Solution Approach 2:
A transitional adapter or interface is introduced between the original injector body and the modified nozzle assembly. This intermediary component enables the connection of high-flow nozzle designs to the precision injector body without directly exposing or damaging the pintle seat seal, allowing increased fuel flow while maintaining seal integrity.
2Adaptability or versatility
If conventional direct injector is modified to alter spray pattern, then fuel delivery control is improved, but the nozzle orifices and precision components are damaged
Solution Approach 1:
The nozzle assembly is segmented as a separate modifyable component from the original precision injector. This allows the creation of custom spray patterns through interchangeable nozzle designs with different orifice configurations, while the original precision nozzle remains protected in the injector body.
Solution Approach 2:
The system enables dynamic adaptation of spray patterns through interchangeable nozzle assemblies that can be selected or adjusted based on specific engine operating conditions, allowing versatility in spray pattern customization without permanently modifying or damaging the original precision components.
3Productivity
If machining is performed on conventional direct injector to increase fuel flow, then productivity is improved, but the injector integrity and durability are compromised
Solution Approach 1:
The injector system is segmented into a non-modifyable precision injector body (maintaining reliability) and a separate modifyable nozzle or adapter component (enabling increased fuel flow). This segmentation allows productivity improvement through modified components while the original injector body retains its integrity and durability.
Solution Approach 2:
A disposable or replaceable adapter/nozzle component is introduced that can be modified or replaced to achieve higher fuel flow rates. This sacrificial component protects the main injector body from damaging modifications, allowing productivity improvements while maintaining the reliability of the core injector system.
Data Source
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AI summary
The present disclosure relates to a method of modifying a conventional injector (e.g., a high pressure direct fuel injector) and to the modified injector resulting therefrom. The modified injector provides a fluid flow rate and/or fluid spray plume (i.e., pattern) which is different than the fluid flow rate and/or fluid spray plume (i.e., pattern) of the original conventional injector. In one embodiment, provided is a modified injector used in internal combustion engines for fuel delivery directly into the combustion chamber.