Multi-Aperture Fuel Injector Design for Pressure and Wear Control
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Solution Overview
Problem
High-pressure fuel injectors face issues such as clogging, wear and tear, leakage, inconsistent fuel delivery, injector noise and vibrations, and high maintenance costs, which affect engine performance and emissions.
Innovation Solution
A high-pressure fuel injection system with a novel design featuring a plurality of apertures with varying diameters and lengths in the injection nozzle, a high-pressure piston, volume displacement valve, low-pressure piston, and a single solenoid valve to control fluid flow, eliminating sac volume and optimizing fuel atomization and delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-pressure fuel injectors operate at pressures between 25-35 ksi, then fuel atomization and combustion efficiency are improved, but maintenance costs increase and component wear accelerates
Solution Approach 1:
The injection nozzle is divided into multiple aperture groups with different aperture diameters (first subgroup with first diameter, second subgroup with second diameter). This segmentation allows different portions of fuel to be atomized differently, achieving complete combustion while reducing the overall pressure requirement compared to conventional single-orifice injectors operating at 25-35 ksi.
Solution Approach 2:
Different regions of the injection nozzle have different aperture characteristics. The first subgroup of apertures has a first diameter while the second subgroup has a second diameter, creating local variations in fuel flow characteristics. This allows optimized fuel delivery across different zones without requiring uniform high pressure throughout the system.
2Power
If conventional common rail injectors operate at 29 ksi, then fuel delivery is achieved, but expensive maintenance is required to maintain operation at higher pressures
Solution Approach 1:
The system uses a progressive fuel delivery approach where fuel is injected in stages through different aperture groups. The injection process dynamically transitions from the first subgroup of apertures to the second subgroup, allowing the system to achieve complete fuel delivery without requiring sustained high pressure operation that would demand expensive maintenance.
Solution Approach 2:
The invention changes the pressure parameter profile during injection by using multiple aperture diameters. Instead of maintaining constant high pressure (29 ksi or higher), the system varies the effective flow area during injection, achieving the same or better fuel delivery with lower peak pressure requirements and reduced maintenance needs.
3Object-generated harmful factors
If high-pressure fuel injectors are used to improve combustion, then emissions are reduced, but clogging and deposits accumulate in the injector nozzles
Solution Approach 1:
The injection nozzle is segmented into multiple aperture groups with different diameter ranges. This segmentation prevents any single aperture from becoming completely blocked by deposits, as the multi-group design provides alternative fuel pathways. The different aperture diameters also create varied flow velocities that help prevent deposit accumulation through enhanced fuel dynamics.
Solution Approach 2:
The system uses a progressive injection approach where fuel is delivered through different aperture groups in sequence or combination. This partial action through multiple pathways ensures complete fuel delivery even if some apertures experience partial clogging, maintaining emissions performance while being more tolerant of deposit accumulation.
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
The system enhances engine efficiency, reduces emissions, lowers operating costs, and improves performance by ensuring precise fuel delivery and uniform combustion, eliminating the need for complex timing systems and high-pressure pumps.
Implementation Method 1
an injection nozzle assembly having a plurality of apertures, wherein a first subgroup of the plurality of apertures each have a first diameter, wherein a second subgroup of the plurality of apertures each have a second diameter, and wherein the first subgroup and second subgroup are configured to atomize fuel differently
Implementation Method 2
a high-pressure piston configured to be in fluid communication with the injection nozzle assembly
Implementation Method 3
a volume displacement valve disposed between the injection nozzle assembly and the high-pressure piston
Implementation Method 4
a low-pressure piston disposed around the high-pressure piston
Implementation Method 5
a shut-off valve disposed within the needle barrel
Data Source
AI summary
A fuel injector is provided. The fuel injector is operable to inject fuel at extremely high pressures which creates very small droplet sizes, allowing for efficient self-ignition of the fuel and allows for clean, efficient combustion due to the small droplet sizes. The fuel injector uses pressure from within a combustion chamber to actuate the spraying of fuel from the injector, thereby solving many problems experienced by typical fuel injectors and eliminating many problem-components of prior art fuel injectors.