Fuel Injector Pre-Chamber Assembly With Sacrificial Weld Tabs
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Solution Overview
Problem
The existing manufacturing processes for pre-chamber assemblies in fuel injectors are costly and inefficient due to the use of laser welding, which requires a third material for forming a weld seam, increasing complexity and cost.
Innovation Solution
A pre-chamber assembly with a sacrificial member that extends axially from the cylindrical body member, allowing for attachment to the body portion through resistance or friction welding, eliminating the need for a third material and simplifying the manufacturing process by melting the sacrificial tabs to form a weld seam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If laser welding is used to attach the pre-chamber to the body portion, then the pre-chamber assembly can be manufactured, but the manufacturing cost increases and the process complexity increases due to requiring a third material for weld seam formation
Solution Approach 1:
The pre-chamber and body portion are made from the same material (cast iron), eliminating the need for a third material in welding. This homogeneous material composition simplifies the welding process by allowing direct welding between identical materials without requiring intermediate weld seam materials or complex multi-material joining procedures.
Solution Approach 2:
The invention extracts and eliminates the third material (weld seam material) from the traditional laser welding process. By making both the pre-chamber and body portion from the same cast iron material, the complex multi-material welding procedure is replaced with simpler single-material welding, reducing process complexity.
2Ease of manufacture
If laser welding with third material is used to join pre-chamber and body portion, then the components can be attached, but the manufacturing cost increases
Solution Approach 1:
Both the pre-chamber and body portion are manufactured from the same cast iron material, eliminating the need for a third weld seam material. This reduces material variety from three different materials to just one, thereby reducing manufacturing costs associated with sourcing, storing, and processing multiple material types.
Solution Approach 2:
The invention uses a sacrificial member made from the same cast iron material that can be easily melted and removed after serving its joining purpose. This approach replaces expensive multi-material welding with a simpler process using a disposable sacrificial element, reducing overall manufacturing costs.
3Reliability
If a third material is used to form a weld seam between pre-chamber and body portion, then the joint can be formed, but the manufacturing process becomes more complex
Solution Approach 1:
The pre-chamber, body portion, and sacrificial member are all made from the same cast iron material, creating a homogeneous joining system. This eliminates the complexity of managing multiple materials with different properties while maintaining joint strength, as the same material ensures consistent metallurgical bonding without interface complications.
Solution Approach 2:
The sacrificial member automatically performs the joining function by being melted during the welding process, creating the bond between pre-chamber and body portion without requiring external weld seam materials. This self-service approach simplifies the manufacturing setup by eliminating the need for separate weld seam material supply and handling systems.
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 method reduces manufacturing costs and complexity by using the same material for the pre-chamber and body portion, enhancing the strength and sealing of the joint while eliminating the need for a third material, thus improving the efficiency and cost-effectiveness of the pre-chamber assembly.
Implementation Method 1
melting a sacrificial portion of the pre-chamber to join the body portion with the pre-chamber
Implementation Method 2
The pre-chamber is attached to the body portion via a welding process such as laser welding
Implementation Method 3
allowing for attachment to the body portion through resistance or friction welding
Implementation Method 4
allowing for attachment to the body portion through resistance or friction welding
Data Source
AI summary
A pre-chamber for a fuel injector is disclosed. The pre-chamber includes a cylindrical body member extending axially from a first end portion to a second end portion opposite to the first end portion. The pre-chamber further includes a bottom plate located proximal to the first end portion of the cylindrical body member. The pre-chamber also includes a sacrificial member extending axially outwards from the second end portion of the cylindrical body member.