Injector Swirl-Chamber Structure for Low-Pressure Atomization
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Solution Overview
Problem
Existing fuel, gasoline, and water injectors in the low-pressure range face challenges in achieving fine atomization and precise spray angle without complex geometries, which can increase manufacturing costs and affect flow rates.
Innovation Solution
A vortex injector design with a spray hole component featuring swirl chambers and material reduction regions on the outer side, allowing precise adjustment of spray hole length through machining, ensuring fine atomization and spray angle without altering internal geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the spray hole component has complex internal geometry with swirl chambers and channels, then atomization quality improves, but manufacturing complexity and cost increase
Solution Approach 1:
The spray hole component is divided into two independently manufacturable parts: the spray hole plate with simple cylindrical holes and the pot-shaped component with swirl chambers. This segmentation allows each part to be manufactured separately using simpler processes, reducing overall manufacturing complexity while maintaining atomization quality through the reconfigurable assembly of these components.
Solution Approach 2:
The injector design allows dynamic reconfiguration of the spray hole component geometry by selectively combining different spray hole plates and pot-shaped components. This enables adaptation to different atomization requirements without redesigning the entire internal geometry, simplifying manufacturing for each specific application while maintaining high atomization quality.
2Manufacturing precision
If the spray hole length is adjusted by machining the inner side, then spray angle precision improves, but the internal geometry including swirl chambers and channels is affected and manufacturing complexity increases
Solution Approach 1:
The spray hole length adjustment function is separated from the internal geometry formation. The spray hole plate with cylindrical holes is manufactured independently, and only the outer side is machined to adjust spray hole length. This segmentation prevents any interference with the swirl chambers and channels in the pot-shaped component, maintaining simple manufacturing while achieving precise spray angle control.
Solution Approach 2:
The spray hole length adjustment operation is extracted from the internal geometry formation process. By machining only the outer side of the spray hole component, the length adjustment is performed independently without affecting the internal swirl chambers and channels, thus maintaining both precision and manufacturing simplicity.
3Manufacturing precision
If multiple spray holes are used to ensure fine atomization in low-pressure range, then atomization quality improves, but injector geometry becomes complex
Solution Approach 1:
The multi-spray hole system is segmented into a spray hole plate with simple cylindrical holes and a pot-shaped component with swirl chambers. This segmentation allows each component to be manufactured independently with simple geometry, while the combination of multiple spray holes with swirl chambers achieves fine atomization quality without requiring complex integrated geometry.
4Manufacturing precision
If the spray hole component thickness is reduced to adjust spray hole length, then spray angle precision improves, but manufacturing complexity increases
Solution Approach 1:
Instead of reducing thickness from the inner side which would complicate internal geometry, the spray hole length is adjusted by machining the outer side of the spray hole component. This inverted approach maintains simple internal geometry with cylindrical spray holes and swirl chambers, while achieving precise spray angle control through outer surface machining only.
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
Enables fine atomization and precise spray angle in low-pressure conditions while maintaining flow rate, simplifying manufacturing and reducing costs.
Implementation Method 1
Vortex chambers are formed around the spray holes on an inner side of the spray hole component facing the closing element. The vortex chambers on the inner side of the spray hole component can impart a predetermined swirl to the emerging spray.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to an injector for injecting a fluid, comprising a closing element (2), which closes and releases a fluid passage at a valve seat (5), and an injection hole component (3) with a plurality of injection holes (4), wherein swirl chambers (40) are formed on the injection holes (4) on an injection hole component (3) inner face (6) facing the closing element (2), and a material reduction region (8) is formed at the injection hole (4) on an injection hole component (3) outer face (7) facing away from the closing element (2) in order to reduce the thickness (9) of the injection hole component (3) so as to adjust the length (10) of the injection hole (4). The invention additionally relates to a method for producing such an injector.