Integrated Injector Housing Magnet Body for Lower-Cost Fuel Injection
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Solution Overview
Problem
The high manufacturing costs of fuel injectors are primarily due to the expensive magnetic circuit, which accounts for approximately 42% of the total costs, mainly because of the need for high-quality materials and the complexity of separate magnetic components within the limited space of internal combustion engines.
Innovation Solution
The injector housing and magnet body are formed in one piece, with the coil winding mounted directly on the housing, allowing for a larger pole area and reducing the need for high-quality magnetic materials, thereby integrating the magnetic poles with the housing and simplifying the assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate magnet assembly is used within the injector housing, then the magnetic circuit can be properly formed, but the manufacturing costs increase significantly and the available space for magnetic components is reduced
Solution Approach 1:
The patent merges the injector housing and magnet body into a single integrated component. The housing is formed with an integrated magnet body that includes magnetic poles, eliminating the need for separate magnet assemblies. This integration reduces the number of components, simplifies assembly, and lowers manufacturing costs while maintaining the necessary magnetic circuit functionality for controlling the injector valve.
2Reliability
If high-quality magnetic materials are used to maintain magnetic performance, then the magnetic circuit efficiency is improved, but the manufacturing costs increase significantly
Solution Approach 1:
By integrating the magnet body directly into the housing, the patent enables the use of cost-effective materials such as molded plastic with embedded magnetic particles or standard magnetic materials, eliminating the need for expensive high-quality magnetic materials that would be required if separate precision magnet assemblies were used. This integration maintains sufficient magnetic circuit efficiency while dramatically reducing material costs.
Solution Approach 2:
The patent changes the material parameters by using alternative magnetic material solutions such as plastic materials with embedded magnetic particles or standard magnetic materials instead of high-quality magnetic materials. This parameter change maintains the necessary magnetic performance for valve control while significantly reducing the cost of magnetic components.
3Area of stationary object
If the coil winding is mounted directly on the housing, then the pole area is increased and material costs are reduced, but the magnetic circuit design becomes more complex
Solution Approach 1:
The patent combines the housing structure with the magnet body, allowing the coil winding to be mounted directly on the housing surface. This integration maximizes the pole area by eliminating the space required for separate magnet assemblies, and the simplified structure actually reduces design complexity compared to traditional multi-component magnetic circuits.
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 results in an 85% reduction in manufacturing costs for the solenoid valve and electromagnet, using less expensive materials while maintaining the same dimensions, and simplifying the assembly process.
Implementation Method 1
an electromagnet for controlling a valve for opening and closing the injector, the electromagnet having a coil winding and a magnet body
Implementation Method 2
a certain spring force is required which presses the armature element against the drain throttle
Data Source
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AI summary
The present invention relates to an injector (1) for injecting fuel, comprising an injector housing (2) for receiving at least one injector component, and an electromagnet (3) for controlling a valve (4) for opening and closing the injector, wherein the electromagnet (3) has a coil winding (31) and a magnetic body (32, 33), and wherein the injector housing (2) is designed in one piece with the magnetic body (32, 33).