Slim Fuel Injector Axial Ratio for Tight Packaging
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Solution Overview
Problem
Achieving increased power density in internal combustion engines while managing high fuel injection pressures and elevated combustion temperatures, and meeting stringent emissions regulations poses challenges in component design and packaging, particularly in tight spaces within cylinder heads.
Innovation Solution
A fuel injector design with a specific axial distance to full diameter ratio and a canted clamp configuration allows for robust attachment in confined spaces, optimizing spray outlet positioning and reducing overheating risks, while maintaining efficient fuel distribution and emissions control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If fuel injection amount is increased to enhance power output, then power density is improved, but injection pressure requirements and thermal management challenges worsen
Solution Approach 1:
The patent changes the geometric parameters of the fuel injector, specifically the axial distance to full diameter ratio (AD/FD) optimized between 4.8 to 5.1, and nozzle-to-bore radius ratio (NB/RB) optimized between 0.4 to 0.6. These parameter optimizations enable efficient fuel injection at reduced pressures while maintaining power density and improving thermal management
2Power
If fuel injection amount is increased to enhance power output, then power density is improved, but thermal management challenges worsen
Solution Approach 1:
The patent optimizes geometric parameters including axial distance to full diameter ratio (AD/FD) between 4.8 to 5.1 and nozzle-to-bore radius ratio (NB/RB) between 0.4 to 0.6. These parameter changes enable efficient fuel distribution that improves combustion efficiency at controlled temperatures, reducing thermal management challenges while maintaining power density
3Length of moving object
If injector axial length is reduced for tight packaging, then packaging space is improved, but attachment robustness and spray positioning worsen
Solution Approach 1:
The patent introduces a canted clamp configuration where the clamp axis is offset from the injector longitudinal axis by an angle of 15 to 45 degrees. This asymmetric design allows the injector to achieve robust attachment in confined spaces while maintaining reliable spray positioning, resolving the contradiction between compact length and attachment robustness
4Length of moving object
If injector axial length is reduced for tight packaging, then packaging space is improved, but spray outlet positioning precision worsens
Solution Approach 1:
The patent optimizes the axial distance to full diameter ratio (AD/FD) between 4.8 to 5.1, which precisely controls the nozzle tip position relative to the injector body. This parameter optimization enables accurate spray outlet positioning even in compact injectors with reduced axial length, maintaining manufacturing precision while improving packaging
Data Source
AI summary
A fuel injector includes an injector housing defining a longitudinal axis extending between a first axial injector end and a second axial injector end. The injector housing includes an upper body piece forming the first axial injector end and including a fuel connector defining a connector axis intersecting the longitudinal axis. The injector housing further includes a nozzle having formed therein a plurality of spray outlets, and including a nozzle terminal tip. An injector full diameter (FD) is defined by the upper body piece. An axial distance (AD) is defined between an intersection of the connector axis and the longitudinal axis, and the nozzle terminal tip. A ratio of AD to FD is from 4.8 to 5.1.