Multipart Insulating Element for Fuel Injection Noise Reduction
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Solution Overview
Problem
Conventional fuel injection apparatus intermediate elements fail to effectively reduce noise emissions due to their complex and costly designs, and they often require multiple parts to achieve adequate acoustic damping, which increases manufacturing costs and assembly complexity.
Innovation Solution
A multi-part insulating element with a nonlinear, progressive spring characteristic curve is designed, comprising an outer ring, an inner ring, and an insulating ring made of a braided wire element, which reduces deflection and stress on weld seams, allowing for improved acoustic damping and positioning of the fuel injection valve with minimal plastic deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If multiple plies of damping material are used to achieve acoustic damping, then noise reduction is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The damping element is segmented into multiple functional layers: a base element providing structural support, a carrier element holding the sealing means, and the sealing means itself that penetrates the nozzle body. This segmentation allows each layer to be optimized for its specific function while working together to achieve acoustic damping with fewer components.
Solution Approach 2:
The damping element combines different materials with complementary properties: a base element and carrier element made of damping material (metal, rubber, or PTFE) for acoustic damping, and a sealing means for sealing function. This composite structure achieves both sealing and damping functions in a single integrated component rather than requiring multiple separate plies.
2Ease of manufacture
If a simple intermediate element design is used, then manufacturing cost is reduced, but acoustic damping effectiveness deteriorates
Solution Approach 1:
The damping element is designed as a universal component that performs multiple functions simultaneously: it provides acoustic damping, sealing, and structural support. The base element and carrier element are designed to work together to achieve both damping and sealing functions in a single component, eliminating the need for separate sealing elements and reducing manufacturing complexity.
Solution Approach 2:
The damping element acts as an intermediary component between the fuel injection valve and the cylinder head, providing both damping and sealing functions. The carrier element with integrated sealing means serves as a mediator that connects the nozzle body to the base element while providing both structural support and sealing, reducing the need for additional intermediary components.
3Ease of operation
If conventional intermediate elements are used, then assembly is simplified, but positioning precision and stress distribution deteriorate
Solution Approach 1:
The damping element incorporates local quality variations through its multi-layer structure: the base element provides rigid structural support at the mounting interface, the carrier element provides flexible sealing at the nozzle interface, and the sealing means provides localized sealing at the penetration point. This local differentiation of material properties and structural characteristics enables both easy assembly and precise positioning with proper stress distribution.
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 solution significantly reduces injector-caused noise during fuel injection by decreasing energy transfer to the cylinder head, enabling accurate positioning with low tolerances and minimizing stress on valve seals, while maintaining the insulating function over the injector's service life without plastic deformation.
Implementation Method 1
The insulating element has a nonlinear, progressive spring characteristic curve that results in several positive and advantageous aspects when the insulating element is installed in a fuel injection apparatus having injectors for direct fuel injection
Implementation Method 2
The example insulating element in accordance with the present invention produces an outstanding reduction in injector-caused noise during fuel injection, by decreasing energy transfer from the fuel injection valve to the cylinder head in the relevant frequency range
Implementation Method 3
The insulating element has a nonlinear, progressive spring characteristic curve
Implementation Method 4
The stresses on weld seams possibly placed for securing purposes between the outer ring and insulating ring, or between the inner ring and insulating ring, can moreover be reduced. The overall flexural stress on the individual components of the multi-part insulating element is decreased
Data Source
AI summary
An insulating element for a fuel injection apparatus is notable in particular for the fact that a low-noise design is achieved. The fuel injection apparatus encompasses at least one fuel injection valve and one receiving bore in a cylinder head for the fuel injection valve, and the insulating element between a valve housing of the fuel injection valve and a wall of the receiving bore. The insulating element possesses an inner insulating ring that is present in encapsulated fashion between an outer ring and an inner ring. The outer ring is directed toward the fuel injection valve and the inner ring is directed toward the wall of the receiving bore, so that corresponding abutment of these components occurs with the insulating element in the installed state. The fuel injection apparatus is suitable in particular for direct injection of fuel into a combustion chamber of a mixture-compressing spark-ignited internal combustion engine.