Long Fuel Injector Modular Electrical Connection
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Solution Overview
Problem
In internal combustion engines, existing fuel injectors face challenges in being inserted deeply due to restricted space within the cylinder block and densely arranged equipment, limiting the injector's length and efficiency.
Innovation Solution
A long injector design comprising a base portion and an extension portion with an electrically conductive terminal and contact clips, where the electrical connection is encapsulated to prevent protrusion and ensure deep insertion, using a latch mechanism and overmolded encapsulation for stability and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the injector length is extended to enable deep insertion into the combustion chamber, then the injection efficiency is improved, but the device complexity increases due to the need for extension portions and electrical connection components
Solution Approach 1:
The injector is divided into a base portion and an extension portion that can be connected together. The extension portion includes an electrically conductive terminal with contact clips that mate with electrical contacts on the base portion, allowing the injector to achieve greater length while maintaining manageable assembly complexity through modular construction
Solution Approach 2:
The electrical connection system is integrated into the mechanical connection structure. The contact clips are formed as part of the electrically conductive terminal on the extension portion, combining electrical connectivity with mechanical attachment functions in a single integrated component rather than separate systems
2Ease of manufacture
If the electrical connection components are exposed, then the assembly is simpler, but the electrical connection is vulnerable to corrosion and damage from engine environment
Solution Approach 1:
An encapsulation body is provided that encloses the electrical connection between the base portion and extension portion. This protective shell shields the electrical contacts and contact clips from corrosive engine environments including moisture, heat, and chemical exposure, while allowing the connection to be formed through standard overmolding processes
3Reliability
If the electrical connection is encapsulated, then the protection against corrosion is improved, but the assembly process becomes more complex
Solution Approach 1:
The encapsulation body is formed through an overmolding process that integrates the electrical connection protection into the manufacturing flow. By controlling the molding parameters and sequence, the encapsulation is applied automatically during assembly rather than requiring separate complex steps, maintaining manufacturing efficiency while providing comprehensive protection
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 deep insertion and stable operation of the long injector within the engine, protecting the electrical connection from corrosion and facilitating precise positioning, while reducing material costs and assembly time.
Implementation Method 1
the one or more contact clips (6) comprise an elastic material (14), and wherein the latch mechanism (11) is realized by the elastic material (14) of the one or more contact clips (6) in such a way, that the one or more electrical contacts (10) are compressed by the elastic material (14) of the one or more contact clips (6)
Data Source
AI summary
Various embodiments may include a long injector for fuel injection comprising: a base portion and an extension portion electrically connected to the base portion. An end of the extension portion may include an electrically conductive terminal with contact clips. The contact clips are spaced at a distance from each other or from a side wall of the electrically conductive terminal. An end of the base portion comprises electrical contacts positioned so each of the electrical contacts can slide into a contact clip of the electrically conductive terminal. The electrically conductive terminal includes a latch mechanism. An electrical connection between the base portion and the extension portion is created when the electrical contacts are inserted into the contact clip and held by the latch mechanism. The long injector further comprises an overmolded body encapsulating the electrical connection between the base portion and the extension portion.