Multi-Fuel Injector Combining Pilot and Primary Fuels
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Solution Overview
Problem
Internal combustion engines face inefficiencies when using alternative fuels due to reduced energy density, slower vaporization, and lower cetane numbers, which can be mitigated by injecting two fuels, but existing systems require complex designs with multiple injectors, leading to accuracy issues.
Innovation Solution
A multi-fuel injector system that includes a primary fuel inlet, a pilot fuel inlet, a spill valve, a control valve, and an injection valve, allowing for the simultaneous injection of two different liquid fuels from a single nozzle, with an electronic control module to adjust pressures and quantities for optimized injection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If two separate fuel injectors or multiple individually-actuated injector tips are used to inject two different fuels, then the ability to inject different fuels is improved, but the device complexity increases and fuel injection accuracy decreases
Solution Approach 1:
The patent combines two separate fuel injection systems into a single injector body with a common nozzle tip. The injector includes a first fuel inlet for pilot fuel and a second fuel inlet for main fuel, with separate control valves (first and second valves) that both discharge through the same nozzle. This merging approach maintains the ability to inject different fuels while reducing the number of separate injector components, thereby reducing device complexity and improving fuel injection accuracy through a unified discharge point.
Solution Approach 2:
The single injector body performs multiple functions by accommodating both pilot fuel injection and main fuel injection through the same nozzle tip. The injector design allows it to handle different fuel types (diesel and alternative fuel) with different properties, making it a universal component that replaces what would traditionally require separate specialized injectors.
2Adaptability or versatility
If two separate fuel injectors are used to inject different fuels, then fuel injection capability is improved, but reliability decreases due to additional failure points
Solution Approach 1:
By merging the pilot fuel injection and main fuel injection functions into a single injector assembly with a common nozzle, the patent reduces the total number of components that could potentially fail. The unified design eliminates the need for multiple separate injector bodies, mounting flanges, and electrical connections, thereby improving overall system reliability while maintaining multi-fuel capability.
3Adaptability or versatility
If multiple individually-actuated injector tips are used, then different fuels can be injected, but manufacturing precision and injection accuracy are reduced
Solution Approach 1:
The patent achieves precise fuel injection by combining both fuel streams through a single nozzle tip with precisely engineered discharge orifices. This unified discharge path ensures consistent spray patterns and accurate fuel metering, as the nozzle geometry can be precisely controlled during manufacturing. The single nozzle approach eliminates alignment tolerances between multiple tips and ensures repeatable injection characteristics.
Solution Approach 2:
The nozzle tip features locally optimized discharge characteristics with specific orifice geometries designed for precise fuel atomization. The local quality of the discharge region is enhanced through carefully designed orifice shapes and surface finishes that ensure consistent fuel flow and spray quality, regardless of the fuel type being injected.
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 more complete combustion, improved engine performance, and reduced greenhouse gas emissions by allowing precise control over the injection of two fuels, simplifying the injector design and enhancing fuel delivery accuracy.
Implementation Method 1
a control valve configured to control a pressure of fluid within a hydraulic control chamber
Implementation Method 2
an injection valve abutting the hydraulic control chamber, the injection valve being configured to move to an injection position to inject both the primary fuel and the pilot fuel
Implementation Method 3
a spill valve in fluid communication with the primary fuel inlet
Data Source
AI summary
A multi-fuel injector includes a primary fuel inlet configured to receive a liquid primary fuel, a pilot fuel inlet configured to receive a liquid pilot fuel that is a different fuel than the primary fuel, and a spill valve in fluid communication with the primary fuel inlet. The fuel injector also includes a control valve configured to control a pressure of fluid within a hydraulic control chamber, and an injection valve abutting the hydraulic control chamber, the injection valve being configured to move to an injection position to inject both the primary fuel and the pilot fuel.