CN1078668C - 燃料喷射阀及其制造方法 - Google Patents

燃料喷射阀及其制造方法 Download PDF

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CN1078668C
CN1078668C CN97191008A CN97191008A CN1078668C CN 1078668 C CN1078668 C CN 1078668C CN 97191008 A CN97191008 A CN 97191008A CN 97191008 A CN97191008 A CN 97191008A CN 1078668 C CN1078668 C CN 1078668C
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valve
fuelinjection nozzle
valve member
sleeve pipe
plastic components
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CN1198199A (zh
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斯特凡·迈尔
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Robert Bosch GmbH
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M61/00—Fuel-injectors not provided for in groups F02M39/00 - F02M57/00 or F02M67/00
    • F02M61/16—Details not provided for in, or of interest apart from, the apparatus of groups F02M61/02 - F02M61/14
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M61/00—Fuel-injectors not provided for in groups F02M39/00 - F02M57/00 or F02M67/00
    • F02M61/16—Details not provided for in, or of interest apart from, the apparatus of groups F02M61/02 - F02M61/14
    • F02M61/168—Assembling; Disassembling; Manufacturing; Adjusting
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M51/00—Fuel-injection apparatus characterised by being operated electrically
    • F02M51/06—Injectors peculiar thereto with means directly operating the valve needle
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M51/00—Fuel-injection apparatus characterised by being operated electrically
    • F02M51/06—Injectors peculiar thereto with means directly operating the valve needle
    • F02M51/061—Injectors peculiar thereto with means directly operating the valve needle using electromagnetic operating means
    • F02M51/0614—Injectors peculiar thereto with means directly operating the valve needle using electromagnetic operating means characterised by arrangement of electromagnets or fixed armature
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M51/00—Fuel-injection apparatus characterised by being operated electrically
    • F02M51/06—Injectors peculiar thereto with means directly operating the valve needle
    • F02M51/061—Injectors peculiar thereto with means directly operating the valve needle using electromagnetic operating means
    • F02M51/0625—Injectors peculiar thereto with means directly operating the valve needle using electromagnetic operating means characterised by arrangement of mobile armatures
    • F02M51/0664—Injectors peculiar thereto with means directly operating the valve needle using electromagnetic operating means characterised by arrangement of mobile armatures having a cylindrically or partly cylindrically shaped armature, e.g. entering the winding; having a plate-shaped or undulated armature entering the winding
    • F02M51/0671—Injectors peculiar thereto with means directly operating the valve needle using electromagnetic operating means characterised by arrangement of mobile armatures having a cylindrically or partly cylindrically shaped armature, e.g. entering the winding; having a plate-shaped or undulated armature entering the winding the armature having an elongated valve body attached thereto
    • F02M51/0682—Injectors peculiar thereto with means directly operating the valve needle using electromagnetic operating means characterised by arrangement of mobile armatures having a cylindrically or partly cylindrically shaped armature, e.g. entering the winding; having a plate-shaped or undulated armature entering the winding the armature having an elongated valve body attached thereto the body being hollow and its interior communicating with the fuel flow
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M51/00—Fuel-injection apparatus characterised by being operated electrically
    • F02M51/005—Arrangement of electrical wires and connections, e.g. wire harness, sockets, plugs; Arrangement of electronic control circuits in or on fuel injection apparatus

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Manufacturing & Machinery (AREA)
  • Fuel-Injection Apparatus (AREA)

Abstract

本发明涉及一种用于内燃发动机的燃料喷射装置的燃料喷射阀，它由两个主要部件组合而成。其中，内侧阀部件(70)包括所有直接位于燃料流径上的各单一元件，而外侧塑料部件(60)主要由一个励磁线圈组件及一个外壳(50)组成。阀部件(70)还包含一个薄壁非磁性套管(18)，它对机械及热作用很敏感。因此，阀部件(70)与塑料部件(60)分开制造和调节。复合的阀部件(70)随后推入塑料部件(60)的通孔54内，其中，塑料部件(60)与阀部件(70)的牢固连接通过嵌接、啮合或卡夹来实现。该燃料喷射阀尤其适用于混合压缩强迫点火内燃发动机的燃料喷射装置。

Description

燃料喷射阀及其制造方法
本发明涉及一种燃料喷射阀和一种燃料喷射阀制造方法。
由US-PS4,946,107已经公开了一种可电磁操纵的燃料喷射阀，它尚有一个非磁性套管作为芯子和阀座体之间的连接部件。该套管用其两个轴向端头与芯子和阀座体牢固地连在一起。该套管以恒定不变的外直径和恒定不变的内直径延伸至整个轴向长度。芯子和阀座体设置成具有这样的外直径，即它们两端伸入套管内，以使套管在该伸入区内完全包围芯子和阀座体两部件。一个带有锚件的阀针在套管内部轴向移动，该锚件由套管导向。套管与芯子和阀座体的牢固连接例如借助焊接来实现。芯子和非磁性套管一起围成一个向外的内侧阀部件，它独立制成和调节并在后来构成燃料喷射阀的内侧。该内侧阀部件最终在喷射阀的装配状态下由多个其它单个部件在包围，其中，需要至少一个罐形壳体部件，一个带有线圈体的励磁线圈、一个杯形线圈壳体及一个插接件。包围阀部件的许多单个部件的设置和构造相对昂贵。此外，外侧单个部件与内侧阀部件之间许多连接必须被形成。
由DE-OS4310819同样公开了一种燃料喷射阀，它具有一个非磁性薄壁套管作为阀座支架。总的已调整好的燃料喷射阀连同套管一起大部分由一个塑料压铸件(Kunststoffumspritzung)包围，该压铸件从芯子出发沿轴向越过励磁线圈延伸至喷射阀顺流而下的结尾处。深冲的套管仅具有很薄的壁(＜0.3mm)，以使磁通量以尽可能低的损耗通过该非磁性套管。在用塑料压铸喷射阀时需要高的喷射压力(至350帕)，这会导致套管变形，由此会产生喷射阀的安装及功能方面的问题。
本发明的目的在于，提供一种燃料喷射阀，其成本低廉且易于装配，并且提供一种制造该阀的方法。
根据本发明，提出了一种用于内燃发动机的燃料喷射装置的燃料喷射阀，它具有一个阀纵轴线、一个管形芯子、一个励磁线圈、至少一个构成一电磁回路的传导元件、具有一个阀关闭体，该阀关闭体是可沿阀纵轴线可轴向移动的阀针的一部分并与一个设在一阀座体上的阀座共同起作用，还具有一个轴向伸展的非磁性薄壁套管，阀针在该套管内轴向移动，套管与芯子牢固连接，在此，芯子和套管一起向外围成一个阀部件，还具有一个至少部分地包围燃料喷射阀的塑料压铸件，其中，a)作为塑料外壳的塑料压铸件至少部分地包围该励磁线圈和至少一个传导元件并且与所包围的这些件一起构成一个单独制造的塑料部件；b)塑料部件具有一个内部通孔；c)独立制成的阀部件在通孔内通过固定连接牢固地与塑料部件连在一起。
根据本发明，还提出了一种所述的燃料喷射阀的制造方法，其中，在一个步骤中制造独立的阀部件，而在另一步骤中制造独立的塑料部件，在最后的步骤中将阀部件和塑料部件借助一个固定连接连接在一起。
本发明的燃料喷射阀具有以下优点，即可以简单方式低成本地安装。根据本发明，燃料喷射阀的简单安装通过以下方式来实现，即燃料喷射阀的两个主要部件，阀部件和塑料部件彼此单独制造和调节。其中，内侧阀部件以具有优点的方式设置成带有一个非磁性的薄壁套管，它的采用与已公开的阀相比节省成本，因为能节省材料和部分去除连接各部件的焊缝。具有优点的是，外侧塑料部件具有一个内通孔，阀部件可很简单地插入其内并通过简单而可靠的固定连接而固定住。
通过分成两个主要部件具有以下特别优点，即在制造阀部件的各发挥阀重要功能的元件的塑料外压件时的所有负面影响(大注射压力、热释放)被阻止。因此，由注射压力引起的阀部件的薄壁套管的变形被完全消除。相对较脏的压铸过程能以具有优点的方式在阀部件装配线以外(干净的地方)进行。
固定连接的形成以具有优点的方式通过塑料件上的固定元件在阀部件外圆周上的一个槽内的嵌接、啮合或卡夹来实现。为此，该固定元件可具有不同的轮廓、如方形或圆形。
本发明的一个实施例在图中被简化示出并在后面的叙述中进一步解释。
图1示出了一个本发明的燃料喷射阀，
图2示出外侧管形塑料部件，而
图3示出了内侧阀部件，在此，图2和3中的部件装配并彼此连接成图1所示的燃料喷射阀。
图1中所举例示出的可电磁操纵阀为一种用于混合压缩强迫点火内燃发动机的燃料喷射装置的喷射阀，它具有一个由励磁线圈1包围的、用作燃料进入管的管形芯子2。一个径向呈阶梯状的线圈体3容纳着励磁线圈1的绕组并与芯子2组合成喷射阀的在励磁线圈1区域内的特别紧凑的结构。励磁线圈1连同其线圈体3由至少一个，如设置成卡箍形式并用作铁磁性元件的传导元件5包围，该传导元件在圆周方向至少部分地包围励磁线圈1并用其上端部6紧贴在芯子2上。至少一个传导元件5设置成这样的阶梯形式，即平行于轴伸展的主区段7及上端部6通过径向伸展的连接区段8相连。该相连区段8构成一个励磁线圈区域以上的盖。为构成磁性回路，传导元件5的下端9与一个L形截面的传导环10例如通过一个或多个焊点而连在一起。该传导环构成励磁线圈区域向下，即顺流方向的边界。传导磁流的部件一传导元件5和传导环10至少部分地呈罐形包围缠绕在线圈体3上的励磁线圈1。
一个用作连接部件的管形薄壁套管18例如通过焊接紧密地与芯子2的具有比其作为燃料入口的流入侧的上端略小外径的底部末端15相连并在此利用上部套管区段19部分地轴向包围芯子末端15。线圈体3至少部分地轴向与套管18的区段19搭接。线圈体3在其整个轴向伸展长度上都具有比套管18的上区段19的外径更大的内径。例如由非磁笥钢组成的环形套管18利用其下部套管区段20顺流向下伸展至燃料喷射阀的终端，其中，该下部套管区段20具有比上部套管区段19略微小一点的外径。在传导环10的上端区域的直径以一个小凸缘形式减小，其中，传导环10的内径比线圈体3的内径略小。这种结构有助于喷射阀的可靠装配，这一点在后面将详细论述。
套管18则在其整个轴向长度上设置成管形。套管18在其整个伸展长度上具有一个通孔21，该通孔具有除凸缘23以外的恒定外径并与阀纵轴16同轴心伸展。套管18在凸缘23之后顺流向下包围一个锚件24并进一步向下包围一个阀座体25。一个与阀座体25在其顺流向下的端侧紧密相连的例如罐形喷射孔圆盘26也同样由套管18沿圆周方向包围，在此，阀座体25与喷射孔圆盘26的牢固连接例如通过一个环绕的密封焊缝来实现。套管18因此不仅仅是一个连接部件，还实现尤其对于阀座体25的固定及支撑作用，因此，套管18实际上也是阀座支架。在通孔21内设有一个例如管形阀针28，该阀针在其顺流向下相对喷射孔圆盘26的末端29处与一个例如球形阀关闭体30例如通过焊接相连，其圆周上设有例如5个使所要喷射的燃料从此流过的扁平处31。
该喷射阀以已公开的方式电磁操纵。由励磁线圈1、芯子2、至少一个传导元件5、传导环10和锚件24构成的电磁回路用来使阀针28轴向运动并因使喷射阀克服回位弹簧33的弹力而打开及关闭。锚件24的朝向阀关闭体30的末端与阀针28如通过焊缝相连并与芯子2对齐。阀座体25的导向体34用来在阀针28连同锚件24一起沿阀纵轴线16轴向运动期间对阀关闭体30进行导向。此外，锚件24在套管18内轴向运动时被导向。
球形阀关闭体30与阀座体25的一个沿流动方向截锥形逐渐变小的阀座面35一同起作用，该阀座面沿轴向在导向孔34顺流向下处设置。罐形喷射孔圆盘26除一个底部件41外具有一个环绕的向下的支承缘43，阀座体25固定在该底部件上并在其内部伸展着至少一个，例如4个通过腐蚀或冲压而成的喷射孔42。支承缘43顺流向下呈锥形向外弯曲，因此，它紧贴在套管18的由通孔21确定的内壁上。喷射孔圆盘26的支承缘43的下游末端与套管18的壁例如通过环绕的和密封的，如借助激光形成的焊缝相连。通过在喷射孔圆盘26上的焊缝，避免内燃发动机的燃料直接流过喷射孔以外。
此外，阀座体25及喷射孔圆盘26在套管18内的插入深度对阀针28的行程起决定作用。其中，当励磁线圈1未被励磁时，阀针28的最终位置由阀闭体30与座体25的阀座面35的接触来确定，而当励磁线圈1被励磁时，阀针28的另一最终位置由锚件24与芯子端部15的接触确定。另外，行程调节通过以轻微过盈压入的在套管18的上部区段19内部的芯子2的轴向移动来实现。当在套管18圆周上完成激光焊接时，芯子2在所希望的位置上牢固地与套管18连在一起。也可选择足够大的压配合的过盈量，以便能承受所产生的力并确保完全密封，由此免去焊接。
在用来沿阀座，尤其是阀座面35方向传送燃料的芯子2的与阀纵轴16同心伸展的呈阶梯状变化的流动管38内插入一个调节管39。调节管39用来调节紧贴在该调节管39上的回位弹簧33的预应力，该回位弹簧的另一侧支承在阀针28上。一个燃料过滤器40伸入芯子2的流动管38的流入端并用来过滤出燃料中可能在喷射阀内造成堵塞或损坏的东西。
调节并装配好的喷射阀再由一个塑料外壳50包围，它从芯子2起沿轴向越过励磁线圈1伸展至套管18的下游结尾处，其中，该塑料外壳50还带有一个控制喷射的连接插头51。借助该电连接插头51实现励磁线圈1的电接通并由此实现励磁。如图2所示，塑料外壳50为这样一个管形塑料件，它与已公开的燃料喷射阀的塑料压铸件有很大不同。
图2示出了带有励磁线圈组件的外侧管形塑料部件60、它主要由带有连接插头51的塑料外壳50组成。该塑料部件60具体由励磁线圈，由塑料制成的携带励磁线圈1的绕组的线圈体3，至少一个例如卡箍形传导元件5、传导环10和沿圆周方向向外完全包围这些作为励磁线圈组件的部件的塑料外壳50组成。其中，管形塑料外壳50包括通常设置的连接插头51，它具有例如2个接触插针52，它们用于励磁线圈1的电励磁。接触针52从线圈体3起伸展至连接插头51。
塑料外壳50这样构成，即形成一个轴向伸展的内通孔54。塑料部件60的内通孔54不完全由塑料外壳50的内径确定，而还由传导元件5的上端的内径、线圈体3的内径及传导环10的内径确定。与所述的部件3、5和10的内径的细小差别相对应，形成塑料部件60的多级略微呈阶梯形的通孔54。通孔54的直径在励磁线圈组件以外由塑料外壳50的塑料确定。在此，位于励磁线圈1上游的开孔区段55的内径大于位于励磁线圈1的下游的开孔区段56的内径。
塑料外壳50不仅在圆周方向和在轴向方向包围励磁线圈组件，而且它还在一个传导元件5和励磁线圈1及线圈体3之间的至少一个传导元件5的区域内延伸。在线圈体3的上方，构成通孔54的塑料外壳50这样设置，即一个向通孔54内突出的、环绕360°的固定元件58使通孔54的横截面略有减小。该固定元件58设置成一个环绕的凸缘、隆起或一个内轴环的形式并具有方形或圆形轮廓。同样可考虑在通孔圆周上设置多个固定凸缘。塑料外壳50的外侧轮廓与所希望的装入条件相适配，如在塑料外壳50的底端设一个环槽59，密封环56(图1)可装入其中。
图2中带有固定元件58的这种塑料部件60的结构使得燃料喷射阀能以新的方式且简单地安装。传导磁流的部件一传导元件5和传导环10首先被例如通过弹簧夹或焊接点牢固地连在带有励磁线圈1的线圈体3上。该励磁线圈组件随后被压铸塑料，从而形成所述的塑料部件60的轮廓。内孔54这样获得，即在塑料压铸件中设置一个心棒，该心棒模拟图3所示的阀部件70。
图3所示的与塑料件60分开制造并调节的阀部件70与图1所示的燃料喷射阀的内侧组件相一致。阀部件70主要包括芯子2、燃料过滤器40、调节套管39、回位弹簧33、带有阀关闭体30的阀针28、锚件24、套管18和带有喷射孔圆盘26的阀座体25。各单一部件以上面所述方式一同起作用并按图1所说明的那样彼此相连。
通过采用相对便宜的套管18，可免用喷射阀中常用的车削件，如阀座支架、喷嘴架等，它们由于其外径较大而容积更大且制造上比套管18更贵。薄壁套管18(如壁厚0.3mm)例如通过拉伸形成，其材料采用非磁性材料，如不锈的CrNi(铬镍)钢。该作为薄板冲压件的套管1 8如所希望的那样借助其大的伸长量而用来容纳阀座体25、喷射孔圆盘26、带有锚件24的阀针28、回位弹簧33及芯子2的至少一部分，即锚件24的止动区和构成行程边界的芯子2。套管18在其轴向上端例如具有一个略微径向外弯曲的环缘64。该环缘64通过拉伸时的材料余量切隔而成并用来在喷射阀内形成可靠固定连接。
在行程调节和各单件装配成阀部件70之后，该复合阀部件70从上部开孔区55伸入塑料部件60的通孔54内。阀部件70和塑料件60在对应所希望的伸入长度时形成牢固的固定连接。此时，塑料件60的固定元件58嵌入一个在套管18的环缘64和一个芯子外侧凸台65之间形成的槽66内。在此形成嵌接、啮合或卡夹。槽66也可设置在芯子2圆周的其它位置上。固定元件58及槽66的几何形状这样来设置，即形成绝对可靠的、无滑动连接。在没有附加工具情况下打开连接是不可能的。这种安装形式具有很大优点，即压铸塑料时所需的高注射压力(至350帕)不会引起薄壁套管18变形，因为它仅仅事后与总的阀部件70一起组装在塑料件60内。

Claims (11)

1、用于内燃发动机的燃料喷射装置的燃料喷射阀，它具有一个阀纵轴线、一个管形芯子、一个励磁线圈、至少一个构成一电磁回路的传导元件、具有一个阀关闭体，该阀关闭体是可沿阀纵轴线可轴向移动的阀针的一部分并与一个设在一阀座体上的阀座共同起作用，还具有一个轴向伸展的非磁性薄壁套管，阀针在该套管内轴向移动，套管与芯子牢固连接，在此，芯子和套管一起向外围成一个阀部件，还具有一个至少部分地包围燃料喷射阀的塑料压铸件，其特征是，
a)作为塑料外壳(50)的塑料压铸件至少部分地包围该励磁线圈(1)和至少一个传导元件(5，10)并且与所包围的这些件一起构成一个单独制造的塑料部件(60)；
b)塑料部件(60)具有一个内部通孔(54)；
c)独立制成的阀部件(70)在通孔(54)内通过固定连接牢固地与塑料部件(60)连在一起。
2、按照权利要求1所述的燃料喷射阀，其特征是，在塑料部件(60)的通孔(54)内设有至少一个固定元件(58)。
3、按照权利要求2所述的燃料喷射阀，其特征是，在阀部件(70)的圆周上设有至少一个槽(66)。
4、按照权利要求2或3所述的燃料喷射阀，其特征是，通过至少一个固定元件(58)在至少一个槽(66)内的嵌接、啮合或卡夹可获得牢固的固定连接。
5、按照权利要求2所述的燃料喷射阀，其特征是，固定元件(58)为一个突入通孔(54)内的环绕止动凸肩。
6、按照权利要求2所述的燃料喷射阀，其特征是，至少一个固定元件(58)为多个设在通孔(54)的圆周上的止动凸肩。
7、按照权利要求1或3所述的燃料喷射阀，其特征是，套管(18)的上端具有一个回转边缘(64)，它部分地围成一个阀部件(70)外圆周上的槽(66)。
8、按照权利要求2所述的燃料喷射阀，其特征是，在芯子(2)的圆周上设有至少一个槽(66)。
9、按照权利要求1所述的燃料喷射阀，其特征是，阀部件(70)的套管(18)为一个薄板拉伸件。
10、按照权利要求1所述的燃料喷射阀的制造方法，其特征是，在一个步骤中制造独立的阀部件(70)，而在另一步骤中制造独立的塑料部件(60)，在最后的步骤中将阀部件(70)和塑料部件(60)借助一个固定连接连接在一起。
11、按照权利要求10所述的方法，其特征是，固定连接通过阀部件(70)在塑料部件(60)内的嵌入、啮合或卡夹来实现。
CN97191008A 1996-08-02 1997-04-08 燃料喷射阀及其制造方法 Expired - Fee Related CN1078668C (zh)

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KR19990063902A (ko) 1999-07-26
CN1198199A (zh) 1998-11-04
JP3737130B2 (ja) 2006-01-18
JPH11513101A (ja) 1999-11-09
KR100482905B1 (ko) 2005-07-25
US6012655A (en) 2000-01-11
DE59706434D1 (de) 2002-03-28
EP0865574A1 (de) 1998-09-23
WO1998005861A1 (de) 1998-02-12
ES2172788T3 (es) 2002-10-01

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