Twisted Fuel Injector Nozzle Passages for Soot Reduction
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Solution Overview
Problem
Existing fuel injectors fail to adequately prevent soot production, especially under stringent emissions standards, and do not effectively manage air/fuel mixing in both diesel and spark-ignited engines, leading to increased emissions and manufacturing costs.
Innovation Solution
A fuel injector with nozzle passages having differently shaped inlets and outlets, which twist to redirect fuel flow, increasing turbulence and mixing efficiency, thereby reducing soot production and emissions. The nozzle passages are oriented to optimize fuel penetration and mixing based on piston position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If conventional fuel injectors are used, then manufacturing costs are reduced, but soot production increases and emissions standards are not met
Solution Approach 1:
The nozzle passages incorporate twisted curved paths that redirect fuel flow from straight to helical trajectories. This curvature induces rotational motion and turbulence in the fuel spray, enhancing air-fuel mixing and reducing soot formation without requiring complex external mechanisms
Solution Approach 2:
The injector employs multiple separately controllable nozzle passages (first, second, third passages) that can be independently activated based on engine operating conditions. This segmentation allows optimization of fuel injection patterns for different regimes (idle, partial load, full load) to minimize soot production across the entire operating range
2Object-generated harmful factors
If air is entrained with fuel prior to injection, then soot production is reduced, but fuel penetration and combustion timing are affected
Solution Approach 1:
Different nozzle passages provide different injection characteristics tailored to specific operating conditions. The first nozzle passage is optimized for idle operation with lower penetration, while the third passage provides high penetration for full load conditions. This local optimization ensures soot reduction is achieved without compromising fuel delivery performance across all regimes
Solution Approach 2:
The system dynamically selects which nozzle passage to activate based on real-time engine operating conditions (load, speed, temperature). This dynamic adaptation allows the injector to optimize the balance between fuel penetration and air-fuel mixing for each operating point, preventing soot formation while maintaining appropriate combustion timing
3Object-generated harmful factors
If fuel injection patterns are optimized for soot reduction, then emissions improve, but combustion efficiency and power output may be compromised
Solution Approach 1:
The control system dynamically switches between different nozzle passages based on engine load and speed requirements. At partial load conditions, the first or second passages provide enhanced mixing for low emissions. At full load conditions, the third passage delivers high penetration and energy density for maximum power output, ensuring both emissions compliance and performance requirements are met
Solution Approach 2:
The system changes injection parameters (which nozzle passage is active, injection timing, injection duration) based on operating conditions. By adjusting these parameters, the system achieves optimal balance between emissions reduction and power generation - using turbulence-enhancing passages when emissions are critical and high-penetration passages when power is the priority
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 enhances air/fuel mixing, reduces soot production, and decreases the need for particulate filters, meeting stringent emissions standards while improving combustion efficiency and power output.
Implementation Method 1
The fuel twisting may divide a fuel velocity into a plurality of directions, thereby decreasing fuel penetration in a general direction of fuel injection while increasing turbulence, which may promote increased mixing between the fuel and combustion chamber gases.
Implementation Method 2
the first injector nozzle passage twisting from a first inlet to a first outlet... the outlet shape may comprise a small angle in a direction away from the piston, which may reduce piston wetting. Fuel penetration along an injection spray direction may be mitigated due to the fuel twisting in the fuel nozzle passage
Data Source
AI summary
Methods and systems are provided for an injector. In one example, the injector comprises at least two passages, wherein outlets of each of the passages are differently shaped than corresponding inlets of the passages. Further, in one or more examples, each of the outlets may be shaped and sized differently with respect to each other.