Two-Phase Spring for Fuel Injector Sound Control
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Solution Overview
Problem
Rigid fuel injector installations in engines result in poor sound performance at idle conditions due to lack of movement, while allowing movement at low loads can compromise seal performance at high loads, necessitating a spring with varying stiffness to address these issues.
Innovation Solution
A two-phase annular spring washer with alternating waves of different heights providing distinct spring rates, allowing limited movement at low loads and increased stiffness at high loads, which can be self-captured on the fuel injector for improved sound control and seal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rigid alignment system (C-clip and alignment ring) is used to secure the fuel injector, then the injector positioning stability is improved, but the sound performance deteriorates at idle conditions due to lack of movement
Solution Approach 1:
The patent replaces the rigid C-clip alignment system with a dynamic spring-based alignment ring system that allows controlled movement. The spring member enables the alignment ring to move relative to the injector body, providing necessary compliance at idle conditions while maintaining stability when needed.
Solution Approach 2:
The spring member changes its stiffness parameter based on operating conditions. At idle conditions, the spring provides softer compliance for better sound performance, while at higher loads, it maintains sufficient rigidity to ensure proper injector positioning and seal performance.
2Object-affected harmful factors
If slight movement is allowed under idle or low load conditions to improve sound performance, then the sound performance is improved, but the injector tip seal performance may deteriorate at high load conditions
Solution Approach 1:
The spring-based alignment system dynamically adapts its stiffness based on load conditions. At idle, it allows movement for sound performance; at high load, the increased force compresses the spring sufficiently to maintain rigid alignment for seal performance.
Solution Approach 2:
The spring member's effective stiffness parameter changes with applied load. The non-linear spring characteristics provide soft compliance at low loads and increased rigidity at high loads, simultaneously satisfying both sound performance and seal performance requirements.
3Ease of manufacture
If a single spring rate is used for the spring member, then the manufacturing simplicity is improved, but the ability to provide both sound control at idle and seal performance at high load deteriorates
Solution Approach 1:
The spring member is segmented into multiple coils with different characteristics. The first set of coils provides a first spring rate for idle conditions, while the second set of coils provides a second spring rate for high load conditions, enabling dual-performance from a single component.
Solution Approach 2:
The patent extracts the alignment function from the retention function. The alignment ring with spring member handles alignment and sound control, while the C-clip handles retention, allowing each component to be optimized for its specific function.
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 two-phase spring washer enhances sound performance by reducing noise and vibration, providing controlled movement and improved seal performance across varying engine loads, with a significant reduction in noise characteristics at higher frequencies.
Implementation Method 1
an annular two-phase spring washer, having a first spring rate upon initial deflection of the annular spring and a second spring rate upon further deflection of the annular spring
Data Source
AI summary
An annular two-phase spring has a plurality of first waves providing a first spring rate and a plurality of second waves providing a second spring rate. The two-phase spring can be used for installing a fuel injector in a fuel injector bore to improve sound performance.