Side-Fitted Fuel Injector for Compact Cylinder Head Packaging
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Solution Overview
Problem
Achieving increased power density in internal combustion engines while managing high fuel injection pressures and temperatures, and minimizing emissions of oxides of nitrogen and particulate matter, poses challenges in component design and packaging, particularly in the cylinder head assembly.
Innovation Solution
A fuel injector with a canted clamp configuration and a fuel connector axis oriented normal to the longitudinal axis, allowing for robust attachment and efficient fuel supply in a compact space, along with a nozzle design featuring exactly seven spray outlets to optimize fuel distribution and minimize plume interaction, is employed. The fuel injector includes a cylindrical upper and lower section with a middle section, an externally threaded connector end, and a pressurized fuel conduit nut for secure connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If fuel injection amount is increased to enable more fuel to be burned and increase power output, then power density is improved, but extremely high injection pressures and specialized equipment are required
Solution Approach 1:
The fuel connector axis is oriented normal to the longitudinal axis of the fuel injector, changing the dimensional orientation from axial to radial. This allows the fuel supply to approach the injector from the side rather than from above, enabling compact packaging while maintaining the capability to supply sufficient fuel at high pressures for increased power output
2Power
If increased fuel injection amounts are used to increase power output, then power density is improved, but enhanced cooling strategies are required to dissipate increased heat
Solution Approach 1:
By reorienting the fuel connector axis normal to the longitudinal axis, the patent enables a compact side-fed configuration that accommodates enhanced cooling strategies within the cylinder head. The side orientation allows cooling channels and thermal management components to be integrated more effectively, dissipating the increased heat generated by higher fuel injection amounts and power output
3Power
If compact packaging is implemented in the cylinder head assembly, then power density is improved, but component placement and geometry must be carefully tailored to avoid overheating
Solution Approach 1:
The side-oriented fuel connector configuration repositions the fuel supply path from the traditional axial approach to a radial approach. This dimensional change creates favorable spacing and geometry around the fuel injector, allowing adequate room for cooling channels and thermal management features to be integrated into the cylinder head assembly, thereby preventing overheating while achieving compact packaging for high power density
4Device complexity
If side-oriented fuel connector configuration is used for tight packaging, then device complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The fuel connector axis is deliberately oriented normal to the longitudinal axis, creating an asymmetric configuration that simplifies the overall packaging arrangement. This asymmetric side-fed design reduces the complexity of routing fuel lines and positioning components within the cylinder head, while the standardized connector geometry with externally threaded end section maintains manufacturability despite the non-traditional orientation
Data Source
AI summary
A fuel injector includes an injector housing having a fuel connector, and an outer housing surface extending around a longitudinal axis of the injector housing. The outer housing surface includes a cylindrical upper section, a cylindrical lower section, and a middle section. The fuel connector defines a connector axis oriented normal to a longitudinal axis of the injector housing and extending between a first connector end attached to the middle section, and a terminal connector end radially outward of the outer housing surface and having therein a fuel inlet. The fuel connector includes an outer connector surface having an unthreaded base section, and an externally threaded end section adjacent to the terminal connector end.