Injector Support Sleeve with Integrated Fuel Filter
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Solution Overview
Problem
In existing injection injectors for internal combustion engines, a residual volume between the locking piston and the nozzle needle prevents the locking piston from being displaced into its locking position, leading to postponed further injections due to fuel flow issues, and there is a need for an additional function without significant additional components.
Innovation Solution
The support sleeve is designed with a filter surface, incorporating fine-pored perforations or porous materials to perform both support and filtering functions, allowing for a dual role without additional components, and can be manufactured with laser-introduced bores or using sintered materials, with optional filtering layers or inserts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate filter component is added to the injector, then fuel filtering performance is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the support sleeve (which provides mechanical support and tolerance compensation) with a filter element integrated into its structure. The filter element is positioned within the support sleeve, creating a combined component that performs both support and filtration functions simultaneously, thereby improving fuel filtering performance without adding separate filter components to the injector system.
Solution Approach 2:
The support sleeve is designed to serve multiple functions: it provides mechanical support for the valve rod assembly, compensates for manufacturing tolerances through its bracing capability, and now also functions as a fuel filter. This multi-functional design eliminates the need for separate filter components while maintaining all necessary injector functions.
2Reliability
If additional filtering components are integrated into the injector, then fuel flow control is improved, but manufacturing complexity and processing steps increase
Solution Approach 1:
The filter element is integrated directly into the support sleeve structure, which is already a necessary component of the injector. This merging approach allows both components to be manufactured and assembled together as a single unit, reducing the total number of manufacturing steps and avoiding the need for separate filter installation procedures.
Solution Approach 2:
The support sleeve is redesigned to serve dual purposes: mechanical support and fuel filtration. By making the support sleeve itself filter-capable through integration of the filter element, the design eliminates additional manufacturing complexity while improving fuel flow control through the combined component.
3Device complexity
If the support sleeve is designed with filtering capability, then component count is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The support sleeve and filter element are designed as integrated components where the filter is positioned within the sleeve structure. This merging allows for standardized integration methods that balance component reduction with achievable manufacturing precision, avoiding excessive complexity while maintaining filtration effectiveness.
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 dual-function support sleeve effectively compensates for tolerances and ensures proper fuel flow, preventing residual volumes and ensuring timely piston displacement, thus maintaining efficient injection operations without additional processing or space.
Implementation Method 1
The support sleeve is designed as a fuel filter with a filter surface assigned to the sleeve wall
Implementation Method 2
for example by means of bores introduced by means of a laser beam
Implementation Method 3
The support sleeve is designed as a fuel filter with a filter surface assigned to the sleeve wall... which can be manufactured with laser-introduced bores or using sintered materials
Data Source
Figure 1~2
AI summary
An injector for internal combustion engines has an insert (8) which is held at the housing side and which is supported axially by means of a support sleeve (18) which is formed as a fuel filter with a filter surface facing the sleeve wall.