CA2099416A1 - Laser drilled fuel injector nozzles - Google Patents
Laser drilled fuel injector nozzlesInfo
- Publication number
- CA2099416A1 CA2099416A1 CA 2099416 CA2099416A CA2099416A1 CA 2099416 A1 CA2099416 A1 CA 2099416A1 CA 2099416 CA2099416 CA 2099416 CA 2099416 A CA2099416 A CA 2099416A CA 2099416 A1 CA2099416 A1 CA 2099416A1
- Authority
- CA
- Canada
- Prior art keywords
- aperture
- substrate
- fuel injector
- fuel
- producing
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Landscapes
- Fuel-Injection Apparatus (AREA)
- Loading And Unloading Of Fuel Tanks Or Ships (AREA)
Abstract
Abstract of the Disclosure A method for fabricating a fuel injector nozzle is provided wherein a crystalline substrate is positioned in alignment with a laser having a wavelength absorbable by the substrate. The nozzle apertures are produced by the laser independently of the crystal lattice structure and thickness of the substrate. Preferably, a carbon dioxide laser and a single crystal sapphire substrate are used.
Description
~0-497 ~ 9 3 !1 1. `J
LASER DRILLED FUEL INJECTOR NOZZLES
Backqround of the Invention The present invention relates generally to fuel injector nozzles for use in fuel injectors, and more S particularly to a method and apparatus for laser drilling apertures in a single crystal sapphire substrate to form a fuel injector nozzle.
Fuel injectors employing fuel injector nozzles for ^
metering and dispersing fuel as it is ejected are known in the prior art. Fuel injector nozzles are typically fabricated from a monocrystalline silicon substrate using conventional anisotropic etching techniques. Commonly assigned U.S. Patent No. 4,628,576 issued to Giachino et al discloses a typical fabrication sequence for manufacturing a silicon fuel injector nozzle using anisotropic etching techniques. Basically, the fabrication sequence consists of progressive steps of growing an oxide on a silicon substrate and then depositing or removing material until the required aperture pattern is achieved. This technique is limited in that only an aperture with an axis perpendicular to the nominal plane of the silicon substrate can be produced.
Commonly assigned U.S. Patent No. 4,808,260 issued to Sickafus et al discloses a method for anisotropically etching apertures in a silicon substrate such that the aperture plane is at a preselected angle with respect to the crystalline planes of the substrate. Each aperture consists of two offset aperture pits etched in opposing planar surfaces of the silicon substrate. By offsetting the aperture pits, an aperture is formed at an angle relative to the crystalline planes of the silicon substrate.
A disadvantage of this method is that the angle and cross sectional area of the aperture is limited by the thickness of the substrate, the relative angles between the crystalline planes of the substrate and the offset distance between the two aperture pits. A further disadvantage is that the aperture does not have a uniform taper since the aperture abruptly narrows at the offset point. Additionally, silicon substrates have experienced problems with cleavage fracture, or splitting along a crystalline plane. Problems have also arisen where the apertures have irregular side walls. Any irregularity in the aperture walls causes uneven fuel dispersion from the fuel injector resulting in inefficient fuel combustion.
Although fabricating fuel injector nozzles by anisotropic etching is the preferred method in the industry, other fabrication techniques may be employed.
For example, electrodischarge machining techniques have been used to fabricate metallic fuel nozzles. However, these manufacturing techniques are complicated, labor intensive, and time consuming. Moreover, metallic fuel injector noæzles are expensive and subject to reliability problems due to wear from exposure to fuel and fuel contaminants.
Accordingly, the need exists in the art to provide a method and apparatus for fabricating fuel injector nozzles having apertures of controlled taper, uniform cross section and extremely smooth walls, but without the limitations and problems associated with the previous fabrication methods and apparatuses.
Summary of the Invention The present invention meets that need by providing a method for fabricating fuel injector nozzles by laser drilling apertures into a crystalline substrate.
By laser drilling the apertures in the crystalline substrate, the diameter and taper of an aperture can ~e controlled independently of the crystal lattice structure and thickness of the substrate.
90-497 3 ~ .3~ t~
In accordance with one aspect of the invention, a method for fabricating a fuel injector nozzle is provided wherein a crystalline substrate is positioned in alignment with a laser beam having a wavelength .
absorbable by the substrate. The laser beam produces the necessary apertures in the substrate independently of its crystal lattice structure and thickness. Preferably, a carbon dioxide laser is used on a single crystal sapphire substrate.
The present invention also provides a fuel injector for use in an internal combustion engine having a fuel injector nozzle produced by the aforementioned method. The fuel injector includes an injector body having an inlet for communicating with a fuel source, an outlet for ejecting fuel from the body and an inner passageway between the inlet and the outlet. A fuel valve regulates the fuel ejection from the outlet to the fuel injector nozzle. The fuel injector nozzle, preferably comprised of single crystal sapphire, meters and disperses the fuel upon ejection from the outlet. A
retainer secures the fuel injector nozzle against the fuel injector body, thereby substantially sealing the interface between the fuel injector nozzle and the outlet from fuel leakage.
Accordingly, the present invention advantageously provides a fuel in~ector nozzle with apertures of controlled taper, uniform cross-sectional area and extremely smooth side walls. Further, the taper and cross-sectional area of the aperture is independent of the crystal lattice structure and thickness of the substrate. These, and other advantages of the present invention, will become apparent from the following detailed description, the accompanying drawings, and the appended claims.
~rief Description of the Drawings 90-497 -4- (~ J~"~
Fig. 1 is a top perspective view of a fuel injector nozzle in accordance with an embodiment of the present invention;
Fiy. 2 is a perspective view of a laser drilling apertures in a substrate to produce a fuel injector nozzle such as illustrated in Fig. 1; and Fig. 3 is a cross-sectional view of a fuel injector containing the fuel injector nozzle of the present invention.
Detailed Description of the Invention Referring now to Fig. 1, a fuel injector nozzle, generally designated by reference numeral 100, for metering and dispersing fuel in an internal combustion engine (not shown) is illustrated. The fuel injector nozzle 100 includes a substantially planar substrate 102 comprised of a crystalline material, preferably single crystal sapphire. The single crystal nature of sapphire provides a uniform material devoid of inclusions and grain structure. Additi~nally, the rhombohedral crystal structure of sapphire provides a greater increased resistance to cleavage as compared to prior nozzle materials. The nozzle 100 may be fabricated from conventional single crystal sapphire sheets or ribbons such as those produced by the well-known Saphikon edge-defined film-fed growth method.
An array of apertures 108 having tapered walls 112 and clrcular cross-sectional areas serve to guide the fuel as it flows through nozzle 100. While fuel injector nozzle 100 is illustrated as having an array of four tapered apertures 108, it will be apparent to one skilled in the art that other aperture patterns may also be advantageously utilized.
Reference is now made to Fig. 2 which illustrates a laser-based system 200 for fabricating fuel injector nozzle 100 in accordance with the present ~ ~ 3 ~
invention. A crystalline substrate 204, preferably comprised of single crystal sapphire, is aligned with a laser 202, which produces a laser beam 206 having a wavelength absorbable by substrate 204. Consequently, when laser beam 206 strikes substrate 204, the energy of laser beam 206 is absorbed by substrate 204 and converted into heat. The intense heat created by laser beam 206 vaporizes substrate 204 and produces aperture 20B. For a substrate comprised of single crystal sapphire, laser 202 is preferably a conventional carbon dioxide laser which produces a laser beam with a wavelength of 10.6 ~m.
Preferably the exit diameter of aperture 208 is approximately .2mm. However, the diameter of aperture 208 and the taper of aperture walls 210 are controlled by focusing laser beam 206 in a conventional manner.
- Referring now to Fig. 3, a fuel injector, generally designated by reference numeral 300, is shown wherein the fuel injector nozzle of the present invention may be advantageously used. Fuel injector 300 comprises 20 an injector body 304 having an inlet 306 for communicating with a fuel source (not shown) and an outlet 308 for providing fuel to nozzle 302. The fuel injector 300 further includes an inner passageway 310 which communicates with inlet 306 and outlet 308.
Positioned within inner passageway 310 of injector body 300 is needle valve 312, which serves to regulate the amount of fuel ejected from outlet 308.
Needle valve 312 comprises a needle 314 and seat 316, upon which needle 314 sits while located at its closed position. A well-known solenoid-type actuator and spring return means (not shown) is included within the injector body 304 to move needle 314 upwardly and downwardly within inner passageway 310 and thus regulate the fuel being ejected from outlet 308.
3s Fuel injector nozzle 302 is retained against a bottom wall 316 of injector body 304 by retaining ring ~ ~ J$~4.~;
90~497 -6-31~. As previously described, fuel injector nozzle ~02 includes an array of apertures 108 for metering and dispersing fuel into a spray as it is ejected from outlet 308. In response to a signal to eject fuel from the fuel r S injector 300, the conventional actuator means lifts the needle 314 from its seat 316 to allow fuel to flow through apertures 108. As the fuel exits apertures 108, it is atomized to increase combustion efficiency. It is further contemplated by the present invention, that the 10 fuel injector nozzle may be comprised of two nozzle plates bonded together. Such a fuel injector nozzle is disclosed in commonly assigned U.S. Patent No. 4,828,184 issued to Gardner et al, the disclosure of which is hereby incorporated by reference.
lS While certain representative embodiments and details have been shown for purposes of illustrating the invention, it will be apparent to those skilled in the art that various changes in the methods and apparatus disclosed herein may be made without departing from the 20 scope of the invention, which is defined in the appended claims.
What is claimed is:
LASER DRILLED FUEL INJECTOR NOZZLES
Backqround of the Invention The present invention relates generally to fuel injector nozzles for use in fuel injectors, and more S particularly to a method and apparatus for laser drilling apertures in a single crystal sapphire substrate to form a fuel injector nozzle.
Fuel injectors employing fuel injector nozzles for ^
metering and dispersing fuel as it is ejected are known in the prior art. Fuel injector nozzles are typically fabricated from a monocrystalline silicon substrate using conventional anisotropic etching techniques. Commonly assigned U.S. Patent No. 4,628,576 issued to Giachino et al discloses a typical fabrication sequence for manufacturing a silicon fuel injector nozzle using anisotropic etching techniques. Basically, the fabrication sequence consists of progressive steps of growing an oxide on a silicon substrate and then depositing or removing material until the required aperture pattern is achieved. This technique is limited in that only an aperture with an axis perpendicular to the nominal plane of the silicon substrate can be produced.
Commonly assigned U.S. Patent No. 4,808,260 issued to Sickafus et al discloses a method for anisotropically etching apertures in a silicon substrate such that the aperture plane is at a preselected angle with respect to the crystalline planes of the substrate. Each aperture consists of two offset aperture pits etched in opposing planar surfaces of the silicon substrate. By offsetting the aperture pits, an aperture is formed at an angle relative to the crystalline planes of the silicon substrate.
A disadvantage of this method is that the angle and cross sectional area of the aperture is limited by the thickness of the substrate, the relative angles between the crystalline planes of the substrate and the offset distance between the two aperture pits. A further disadvantage is that the aperture does not have a uniform taper since the aperture abruptly narrows at the offset point. Additionally, silicon substrates have experienced problems with cleavage fracture, or splitting along a crystalline plane. Problems have also arisen where the apertures have irregular side walls. Any irregularity in the aperture walls causes uneven fuel dispersion from the fuel injector resulting in inefficient fuel combustion.
Although fabricating fuel injector nozzles by anisotropic etching is the preferred method in the industry, other fabrication techniques may be employed.
For example, electrodischarge machining techniques have been used to fabricate metallic fuel nozzles. However, these manufacturing techniques are complicated, labor intensive, and time consuming. Moreover, metallic fuel injector noæzles are expensive and subject to reliability problems due to wear from exposure to fuel and fuel contaminants.
Accordingly, the need exists in the art to provide a method and apparatus for fabricating fuel injector nozzles having apertures of controlled taper, uniform cross section and extremely smooth walls, but without the limitations and problems associated with the previous fabrication methods and apparatuses.
Summary of the Invention The present invention meets that need by providing a method for fabricating fuel injector nozzles by laser drilling apertures into a crystalline substrate.
By laser drilling the apertures in the crystalline substrate, the diameter and taper of an aperture can ~e controlled independently of the crystal lattice structure and thickness of the substrate.
90-497 3 ~ .3~ t~
In accordance with one aspect of the invention, a method for fabricating a fuel injector nozzle is provided wherein a crystalline substrate is positioned in alignment with a laser beam having a wavelength .
absorbable by the substrate. The laser beam produces the necessary apertures in the substrate independently of its crystal lattice structure and thickness. Preferably, a carbon dioxide laser is used on a single crystal sapphire substrate.
The present invention also provides a fuel injector for use in an internal combustion engine having a fuel injector nozzle produced by the aforementioned method. The fuel injector includes an injector body having an inlet for communicating with a fuel source, an outlet for ejecting fuel from the body and an inner passageway between the inlet and the outlet. A fuel valve regulates the fuel ejection from the outlet to the fuel injector nozzle. The fuel injector nozzle, preferably comprised of single crystal sapphire, meters and disperses the fuel upon ejection from the outlet. A
retainer secures the fuel injector nozzle against the fuel injector body, thereby substantially sealing the interface between the fuel injector nozzle and the outlet from fuel leakage.
Accordingly, the present invention advantageously provides a fuel in~ector nozzle with apertures of controlled taper, uniform cross-sectional area and extremely smooth side walls. Further, the taper and cross-sectional area of the aperture is independent of the crystal lattice structure and thickness of the substrate. These, and other advantages of the present invention, will become apparent from the following detailed description, the accompanying drawings, and the appended claims.
~rief Description of the Drawings 90-497 -4- (~ J~"~
Fig. 1 is a top perspective view of a fuel injector nozzle in accordance with an embodiment of the present invention;
Fiy. 2 is a perspective view of a laser drilling apertures in a substrate to produce a fuel injector nozzle such as illustrated in Fig. 1; and Fig. 3 is a cross-sectional view of a fuel injector containing the fuel injector nozzle of the present invention.
Detailed Description of the Invention Referring now to Fig. 1, a fuel injector nozzle, generally designated by reference numeral 100, for metering and dispersing fuel in an internal combustion engine (not shown) is illustrated. The fuel injector nozzle 100 includes a substantially planar substrate 102 comprised of a crystalline material, preferably single crystal sapphire. The single crystal nature of sapphire provides a uniform material devoid of inclusions and grain structure. Additi~nally, the rhombohedral crystal structure of sapphire provides a greater increased resistance to cleavage as compared to prior nozzle materials. The nozzle 100 may be fabricated from conventional single crystal sapphire sheets or ribbons such as those produced by the well-known Saphikon edge-defined film-fed growth method.
An array of apertures 108 having tapered walls 112 and clrcular cross-sectional areas serve to guide the fuel as it flows through nozzle 100. While fuel injector nozzle 100 is illustrated as having an array of four tapered apertures 108, it will be apparent to one skilled in the art that other aperture patterns may also be advantageously utilized.
Reference is now made to Fig. 2 which illustrates a laser-based system 200 for fabricating fuel injector nozzle 100 in accordance with the present ~ ~ 3 ~
invention. A crystalline substrate 204, preferably comprised of single crystal sapphire, is aligned with a laser 202, which produces a laser beam 206 having a wavelength absorbable by substrate 204. Consequently, when laser beam 206 strikes substrate 204, the energy of laser beam 206 is absorbed by substrate 204 and converted into heat. The intense heat created by laser beam 206 vaporizes substrate 204 and produces aperture 20B. For a substrate comprised of single crystal sapphire, laser 202 is preferably a conventional carbon dioxide laser which produces a laser beam with a wavelength of 10.6 ~m.
Preferably the exit diameter of aperture 208 is approximately .2mm. However, the diameter of aperture 208 and the taper of aperture walls 210 are controlled by focusing laser beam 206 in a conventional manner.
- Referring now to Fig. 3, a fuel injector, generally designated by reference numeral 300, is shown wherein the fuel injector nozzle of the present invention may be advantageously used. Fuel injector 300 comprises 20 an injector body 304 having an inlet 306 for communicating with a fuel source (not shown) and an outlet 308 for providing fuel to nozzle 302. The fuel injector 300 further includes an inner passageway 310 which communicates with inlet 306 and outlet 308.
Positioned within inner passageway 310 of injector body 300 is needle valve 312, which serves to regulate the amount of fuel ejected from outlet 308.
Needle valve 312 comprises a needle 314 and seat 316, upon which needle 314 sits while located at its closed position. A well-known solenoid-type actuator and spring return means (not shown) is included within the injector body 304 to move needle 314 upwardly and downwardly within inner passageway 310 and thus regulate the fuel being ejected from outlet 308.
3s Fuel injector nozzle 302 is retained against a bottom wall 316 of injector body 304 by retaining ring ~ ~ J$~4.~;
90~497 -6-31~. As previously described, fuel injector nozzle ~02 includes an array of apertures 108 for metering and dispersing fuel into a spray as it is ejected from outlet 308. In response to a signal to eject fuel from the fuel r S injector 300, the conventional actuator means lifts the needle 314 from its seat 316 to allow fuel to flow through apertures 108. As the fuel exits apertures 108, it is atomized to increase combustion efficiency. It is further contemplated by the present invention, that the 10 fuel injector nozzle may be comprised of two nozzle plates bonded together. Such a fuel injector nozzle is disclosed in commonly assigned U.S. Patent No. 4,828,184 issued to Gardner et al, the disclosure of which is hereby incorporated by reference.
lS While certain representative embodiments and details have been shown for purposes of illustrating the invention, it will be apparent to those skilled in the art that various changes in the methods and apparatus disclosed herein may be made without departing from the 20 scope of the invention, which is defined in the appended claims.
What is claimed is:
Claims (17)
1. A method for fabricating a fuel injector nozzle comprising the steps of:
positioning a crystalline substrate in alignment with a laser having a wavelength absorbable by said substrate, said substrate having a crystal lattice structure and a thickness; and producing at least one aperture in said substrate with said laser.
positioning a crystalline substrate in alignment with a laser having a wavelength absorbable by said substrate, said substrate having a crystal lattice structure and a thickness; and producing at least one aperture in said substrate with said laser.
2. The method of claim 1 wherein said step of producing said at least one aperture comprises producing said at least one aperture to have walls which are tapered, said taper of said walls being substantially independent of said crystal lattice structure and said thickness of said substrate.
3. The method of claim 2 wherein said step of producing said at least one aperture further comprises producing said at least one aperture to have a uniform cross section.
4. The method of claim 1 wherein said step of producing said at least one aperture is performed by a carbon dioxide laser.
5. The method of claim 1 wherein said step of producing said at least one aperture is performed on a sapphire substrate.
6. The method of claim 1 wherein said step of producing said at least one aperture is performed on a crystalline substrate comprising a single crystal.
7. The method of claim 2 wherein said step of producing said at least one aperture comprises producing said at least one aperture to have a circular cross section.
8. A method for fabricating a fuel injector nozzle comprising the steps of:
positioning a single crystal sapphire substrate in alignment with a carbon dioxide laser having a wavelength absorbable by said substrate, said substrate having a crystal lattice structure and a thickness; and producing at least one aperture in said substrate with said laser, said at least one aperture having walls which are tapered in a manner substantially independent of said crystal lattice structure and said thickness of said substrate.
positioning a single crystal sapphire substrate in alignment with a carbon dioxide laser having a wavelength absorbable by said substrate, said substrate having a crystal lattice structure and a thickness; and producing at least one aperture in said substrate with said laser, said at least one aperture having walls which are tapered in a manner substantially independent of said crystal lattice structure and said thickness of said substrate.
9. The method of claim 8 wherein said step of producing said at least one aperture further comprises producing said at least one aperture to have a uniform cross section.
10. The method of claim 9 wherein said step of producing said at least one aperture comprises producing said at least one aperture to have a circular cross section.
11. A fuel injector for use in an internal combustion engine comprising:
an injector body having an inlet for communicating with a fuel source, an outlet for ejecting fuel from said body and an inner passageway between said inlet and said outlet;
fuel valve means located within said inner passageway for controlling fuel ejection from said outlet;
nozzle means positioned adjacent said outlet for dispersing fuel as it is ejected from said outlet, said nozzle means being comprised of a crystalline substrate having at least one aperture produced by a laser; and retainer means connected to said injector body for retaining said nozzle means against said outlet, thereby substantially sealing the interface between said nozzle means and said outlet from fuel leakage.
an injector body having an inlet for communicating with a fuel source, an outlet for ejecting fuel from said body and an inner passageway between said inlet and said outlet;
fuel valve means located within said inner passageway for controlling fuel ejection from said outlet;
nozzle means positioned adjacent said outlet for dispersing fuel as it is ejected from said outlet, said nozzle means being comprised of a crystalline substrate having at least one aperture produced by a laser; and retainer means connected to said injector body for retaining said nozzle means against said outlet, thereby substantially sealing the interface between said nozzle means and said outlet from fuel leakage.
12. The fuel injector of claim 11 wherein said crystalline substrate is sapphire.
13. The fuel injector of claim 11 wherein said laser is a carbon dioxide laser.
14. The fuel injector of claim 11 wherein said crystalline substrate is a single crystal.
15. The fuel injector of claim 11 wherein said at least one aperture of said nozzle means has walls which are tapered in a manner substantially independent of crystal lattice structure and thickness of said nozzle means.
16. The fuel injector of claim 15 wherein said at least one aperture has a uniform cross section.
17. The fuel injector of claim 16 wherein said at least one aperture has a circular cross section.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US90928592A | 1992-07-06 | 1992-07-06 | |
| US07/909,285 | 1992-07-06 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2099416A1 true CA2099416A1 (en) | 1994-01-07 |
Family
ID=25426961
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2099416 Abandoned CA2099416A1 (en) | 1992-07-06 | 1993-06-30 | Laser drilled fuel injector nozzles |
Country Status (2)
| Country | Link |
|---|---|
| JP (1) | JPH0666225A (en) |
| CA (1) | CA2099416A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7716830B2 (en) | 2005-10-11 | 2010-05-18 | Translume, Inc. | Method of manufacturing a glass fuel injector |
-
1993
- 1993-06-18 JP JP14790993A patent/JPH0666225A/en active Pending
- 1993-06-30 CA CA 2099416 patent/CA2099416A1/en not_active Abandoned
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7716830B2 (en) | 2005-10-11 | 2010-05-18 | Translume, Inc. | Method of manufacturing a glass fuel injector |
| US7841544B2 (en) | 2005-10-11 | 2010-11-30 | Translume, Inc. | Fuel injector |
Also Published As
| Publication number | Publication date |
|---|---|
| JPH0666225A (en) | 1994-03-08 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Dead |