EP1279825B1 - Method for producing a fuel distributor with integrated injection valves - Google Patents

Description

Technical area

In internal combustion engines are fuel injectors used, for recording serve injection valves, via which the individual combustion chambers of Verbrennungskraftnaaschine be fueled. The aim is that the fuel allocation to the individual injectors as evenly as possible, which both for conventional fuel supply systems as well as for non-return fuel supply systems should be valid. Be used to fuel injectors injectors subsequently arranged on the fuel feeder by securing clamps. After that takes place the electrical contacting of the injectors via individual plugs from the wiring harness the internal combustion engine.

State of the art

DE 37 25 980 A1 has a device for electrically contacting electromagnetically the subject of actuatable fuel injection valves. To avoid the electrical Contacting fuel injection valves for fuel injection systems of Internal combustion engines are proposed one after the other on each of the individual Fuel injection valves each one connected to an electronic control unit individual plug in electrical plug. According to this solution, the individual, each Fuel injector associated plug on a common Kontaktierungsleiste arranged. The common Kontaktierungsleiste is by means of screws on the internal combustion engine fixable. About a cable harness is the common contact strip to connect to the electronic control unit.

DE 39 07 764 A1 relates to a fuel distributor for fuel injection systems of internal combustion engines. This includes at least one fuel injection valve and a valve support having at least one axially open and with a fuel supply line connected graduated receiving bore for the fuel injection valve having. The receiving bore is surrounded by a front flange, on which the Fuel injection valve axially supported by a collar member. The front flange of the Valve carrier and the collar of the fuel injection valve are as corresponding to each other Parts of a bayonet closure formed.

DE 43 25 980 A 1 relates to a device for common electrical contacting several electrically excitable units of internal combustion engines.

The device for the common electrical contacting of several units comprises Contact pins for electrical contacting. Further, a conductor tracks is having Circuit board provided, which runs over all aggregates and with one, the printed circuit board protective housing which extends in the longitudinal direction of the circuit board and at least partially encloses them. The several electrically excitable aggregates, in particular electromagnetically actuated fuel injection valves, are immediate connected via the contact pins with the conductor tracks of the circuit board, wherein the circuit board includes elastic stretch loops for length compensation. The contact pins of the aggregates are inserted into contact pin receiving openings of the circuit board and through Welding connected to the conductor tracks.

DE 195 46 441 A 1 discloses a fuel distributor for fuel injection systems of Internal combustion engine with which at least two fuel injection valves are supplied. The fuel distributor includes a fuel supply channel with one of the number of supplying fuel injectors corresponding number of valve seats. The Valve receptacles connect directly to the fuel supply channel standing valve receiving openings, in which the fuel injection valves so used in that the valve seats at least partially surround the fuel injectors. Electrical lines for making electrical contact with the at least two fuel injection valves in formed as a plastic molding fuel distributor are immediate integrated into these, with the electrical wires over most of their Extension of plastic will be wrapped. The electrical cables are in shape Flachbändem in the fuel distributor. The electrical lines are largely along the longitudinal extent of the fuel distributor, i. along the fuel supply channel, wherein each electrical line in the region of a valve receiving an angled Course has supplied to contact elements of the fuel injection valves to become.

Presentation of the invention

The proposed solution according to the invention allows the integration of the functional group Injection valve in the function group fuel distributor waiving assembly components, such as fuse terminals or single plug connections to the individual injectors. When integrating the function group injection valve into the function group Fuel feeder, the geometry of the respective module is not changed. In one Assembly step can now be the electrical and the hydraulic contact under Saving several intermediate steps done, allowing a rationalization of manufacturing can be achieved by fuel supply lines with fuel dispensers.

With the proposed solution according to the invention can also reduce the Size of fuel can be achieved, so that their space requirement in the cylinder head area of internal combustion engines is lower. Furthermore, previously required Assembly items such as fuse terminals, single plugs and sub harnesses account for the internal combustion engine, since the electrical control the individual injectors in the fuel rail on one outside the fuel rail attached central plug can be done.

With the proposed method according to the invention is further a reduction of Fuel permeation through the junction between fuel rail and injector assembly given, as these now directly on the fuel meter component either via a cohesive connection or by encapsulation of the sealing ring at flanged cohesive connection is added. The integration of the injector module directly into the fuel meter component also leads to an increase in the Stiffness of the fuel meter and thus to a better dynamic behavior of the Fuel allocator inevitably occurring during operation of a motor vehicle Vibrations and vibrations. By the summary of the electrical Einzelkontaktierungen the injectors on the fuel feeder by a central plug can In addition, a material saving can be achieved in that partial cable harnesses and Single supply connections to the individual injection valves of the internal combustion engine can be omitted in the cylinder head area. The electrical contacts of the Injectors are protected against mechanical damage by a cover provided on the fuel rail and climatic influences, for example the penetration of moisture better protected.

drawing

Figur 1

zeigt einen Kraftstoffzuteiler mit integriertem Einspritzventil, die über eine stoffschlüssige Verbindung im Halsbereich einer Hülse miteinander verbunden sind,

Figur 2

zeigt einen Längsschnitt durch einen Kraftstoffzuteiler, der mehrere Einspritzventile mit Kraftstoff versorgt,

Figur 2.1

zeigt einen Schnitt durch den Kraftstoffzuteiler gemäß der Darstellung in Figur 2 entlang des Schnittes A-A,

Figur 2.2

zeigt eine in vergrößertem Maßstab wiedergegebene Darstellung der stoffschlüssigen Verbindung zwischen Ventilkörper und Kraftstoffzuteiler,

Figur 3

zeigt einen Querschnitt durch Kraftstoffzuteiler und ein darin integriertes Einspritzventil samt Elektro-Kontaktierungen,

Figur 4

zeigt die Kernpositionen von Einlegekernen und als Einlegeventil beschaffener vormontierter Einspritzventilbaugruppe und

Figur 5

zeigt ein einstückig als Spritzgußteil mit angespritztem Zentralstecker ausgebildeten Kraftstoffzuteiler mit integriertem Einspritzventil.

With reference to the drawing, the invention will be described below in more detail.

FIG. 1

shows a fuel injector with integrated injection valve, which are connected to each other via a cohesive connection in the neck region of a sleeve,

FIG. 2

shows a longitudinal section through a fuel feeder which supplies fuel to a plurality of injection valves,

Figure 2.1

shows a section through the fuel meter according to the illustration in Figure 2 along the section AA,

Figure 2.2

shows a reproduced on an enlarged scale representation of the cohesive connection between the valve body and fuel rail,

FIG. 3

shows a cross section through fuel injector and an integrated therein injector including electrical contacts,

FIG. 4

shows the core positions of insert cores and as inlet valve designed pre-assembled injection valve assembly and

FIG. 5

shows an integrally formed as an injection molded part with molded central connector fuel meter with integrated injection valve.

variants

The illustration according to Figure 1 is a fuel injector with integrated injection valve to remove.

In the upper part of the injection valve 2.1, a sleeve 5 is attached. The lower area the injection valve 2.1 has a cavity 3; laterally is an electrical contact intended. About the sleeve 5 are the valve body of the injector 2.1 and a here shown in cross section fuel distributor 1 via a through hole 4 with each other in connection. The fuel feeder 1 and the injection valve 2.1 are at the neck of the sixth the sleeve 5 cohesively connected to each other. The cohesive connection 11 between the fuel feeder 1 and the upper sleeve 5 in the neck region 6 can, for example be produced by laser welding a correspondingly configured welding device.

The illustration according to Figure 2 is a fuel feeder in longitudinal section with several in to take these integrated injectors.

The fuel feeder 1, which may be made of plastic, for example, contains a Cavity 12, which via a connection 23 to a Krahstoffreservoir not shown here or a fuel pump via an intermediate filter element 24 with Fuel can be filled. From the cavity 12 within the made of plastic Fuel injectors are the individual injectors 2.1, 2.2 and 2.3 with fuel provided. At the fuel feeder 1 as shown in Figure 2 is a central plug received, consisting of a housing-side connector component 13 and one of these covering Cover 14 is made.

FIG. 2.1 shows a cross section through the fuel distributor in the region of the injection valve 2.1 along the section line A-A.

From the sectional view according to Figure 2.1 shows that a central connector 15 on the one hand by a central connector housing 13 and a aufbringbares on this Cover element 14 is formed. From the central connector terminal extends a punched grid recording 16 in the fuel meter 1, in which a punched grid 17 for electrical Contacting of the respective injection valve 2.1 or 2.2 or 2.3 is included. The punched grid 17 extends to the foot of the fuel meter 1. The cross section According to the illustration in FIG. 2.1, furthermore, the connection 23 can be removed, over which the cavity 12 of the fuel meter 1 can be acted upon with fuel. In the illustration according to FIG. 2.1, the reference numeral 24 is that between fuel connection 23 and cavity 12 of the fuel meter 1 arranged filter element.

Between the example made of plastic fuel feeder 1 according to the Representation in Figure 2 and an injection valve body 22 of the injection valve 2.1 is along a specially designed connection geometry 20 a material connection 18 trained. The cohesive connection 18 may be, for example, by ultrasonic welding are generated, including a special connection geometry of the fuel meter 1 and the injection valve body 22 in the form of an annular projection 21 provide is. Simultaneously with the cohesive joining of the fuel meter 1 and the Injector body 22 along the separately created connection geometry 20th An electrical contacting of the injector 2.1 by Interthing of the received in the connector receptacle 16 punched grid 17 with the injection valve body 22 projecting connector lugs 19 (see detail in Figure 2.2).

From the cavity 12 of the fuel meter 1 flows through the terminal 23 entering Fuel via the through hole 4 in the direction of the injection valve to 2.1, where perpendicular to the plane shown in Figure 2.1 several injectors 2.1 or 2.2 or 2.3 can be integrated into a fuel feeder 1.

The representation according to Figure 2.2 is the electrical contacting of the injection valve in to take on an enlarged scale.

Along the connection geometry 20 (see illustration according to Figure 3.1) are the fuel meter 1 and the injection valve body 22 of the injection valve 2.1 cohesively connected with each other. To facilitate the production of a cohesive Verbin The connection geometry 20 contains an approximately annular projection 21. Above the annular projection 21, a connector tab 19 is provided. When joining the fuel meter 1 with the valve body 22 of the injection valve 2.1 form the lead frame 17 and the connector lug 19 of the injector 2.1, the electrical Contacting the injection valve 2.1. The stamped grid 17 in the fuel meter 1 comprises several, not shown here tracks, each with the individual injectors 2.1, 2.2 and 2.3, which are supplied via the fuel feeder 1 and on the other hand all converge in the central connector 15 and about this centrally with a wire harness of the internal combustion engine, not shown here keep in touch.

FIG. 3 shows an injection valve which is integrated in the fuel distributor.

The injection valve 2.1 shown in Figure 3 comprises a cavity 3, wherein the injection valve body 22 along the connection geometry 20 at the foot of the fuel meter 1 is attached. To favor the attachment, for example, by a cohesive Connection, generated by ultrasonic welding may be given, is in the joining area provided on the injection valve body 22 an annular recess extending.

By means of a between the foot of the fuel meter 1 and the upper portion of the injection valve body 22 recessed sealing ring 9, the injection valve 22 is sealed and in particular the permeation of fuel be restricted.

When generating the cohesive connection 18 between the fuel meter 1 and the injection valve body 22 in the vertical direction drive the punched grid 17 and the Cable connection 25 of the injection valve 2.1 within a contacting recess 26th together, so that the lead frame 17 and the connector tab of the electrical connection Connect 25 in the region of a contact point 27 and an electrical contact produce. After the electrical contact 27 between the stamped grid 17th and the plug lug 19 of the electrical conductor 25 has adjusted, the contacting recess 26 shed so that the electrical connection against influences of is protected outside. As a cohesively generated connection 18 between the fuel rail 1 and the injection valve body 22 is formed, both the injection valve 2.1 no longer remove from the fuel meter 1, as well as the electrical Contact 27 through punched grid 17 and plug lug 19 no longer pick up.

The illustration according to FIG. 4 shows the production of an integrally configured fuel selector with insert modules.

The injection valve 2.1 forms a preassembled module as shown in FIG 38, are formed on the electrical connections 25. On the other hand, the preassembled module 38 a pre-molded part 33, on which a sealing ring 9 is fixed. The preassembled module 38 of the injection valve 2.1 is attached to a complete extrusion tool positioned, as well as the cores, at insertion positions 36 the cavity 12 of the fuel meter form and the inlet to einzufießenden injection valve 2.1 in the fuel injector 30. When complete injection into the Umspritzuogswerkzeug inserted cores held on the pre-molded part 33 sealing ring 9 is also encapsulated, so that on the one hand a cohesive recording of the preassembled module 38 to be inserted into the injection mold injector 2.1 and on the other hand a direct contacting production of the one-piece fuel meter 30 by contact the conductor tracks 32 with the electrical connection lines 25 on the preassembled Assembly 38 sets. The necessary for pulling the cores holes are through Filled in stopper. The function group 38 of the injection valve 2.1 is before the encapsulation contacted at the contact pins 25 with the electrical conductors 32. After that the preassembled module 38 is completely encapsulated by the injection mold. The injection mold is designed so that the hydraulic contacting of the function group 38 ensured becomes. These additional valve spool are required, which are perpendicular to Main slide, with which the cavity 12 of the fuel meter 30 is generated out become. Subsequently, the breakthroughs at the top of the fuel meter 30, which is used to remove the cores used to manufacture the injectors 2.1 vorzuhaltenden cavities 36 in the one-piece fuel feeder 30 serve closed.

5 shows a perspective view of an integrally manufactured fuel feeder 30, FIG. in which a designed as a preassembled module 38 injection valve 2.1 cohesively is splashed over. At the top of the one-piece fuel meter 30 is a central plug connection 15 formed on the one hand, a connector housing 13 and on the other hand a this shielding cover 14 includes. With reference numeral 34 is a connection to a fuel source, not shown here.

The achievable with the embodiments shown in Figures 2 to 5 advantages are to be seen in that with the proposed solution according to the invention a significant Reduction of the size of currently used fuel injectors done can. By eliminating previously used assembly items, such as fuse terminals and single-valve plugs, can result in a much more rational production of fuel injectors, be executed one or more parts, can be achieved. By the cohesive connection or the cohesive integration of the individual Injectors 2.1, 2.2, 2.3 in the fuel rail 1, 30 can be an improvement or a reduction in fuel permeation by directly connecting the injectors 2.1 in the fuel rail 1 or 30 reach. In particular, better encapsulation the sealing taking over sealing rings 9 can be achieved. By the cohesive Successful integration of designed for example in preassembled modules 38 injectors 2.1, 2.2 and 2.3 can be an increase in the stiffness of the fuel meter reach, thereby improving its dynamic behavior. The abstract the previously intended for the individual injection valves Einzelkontaktierungen to a Central plug eliminates the need for separate sub-harnesses for the individual injectors as well as the saving of assembly steps and parts stocking. By the provided on the central plug 15 cover 14 are the electrical contacts especially against mechanical and climatic, external influences better protected.

LIST OF REFERENCE NUMBERS

1

Fuel distributor

2.1

Injector

2.2

Injector

2.3

Injector

3

cavity

4

Through Hole

5

shell

6

neck

8th

Cup

9

seal

11

cohesive connection

12

cavity

13

Central plug

14

plug cover

15

connector

16

Pressed screen recording

17

lead frame

18

cohesive connection

19

connector lug

20

connecting line

21

ring

22

Injector body

23

connection

24

filter element

25

cable connection

26

Kontaktierungsaussparung

27

electrical contact surface

30

one-piece injection-molded fuel feeder

31

lead frame

32

conductor tracks

33

Preform

34

cap

35

Spritzwerkzeugfuge

36

loading position

37

Position fuel core

38

insert assembly

Claims (10)

1. Method for producing fuel distributors (1, 30) which comprise a cavity (12) which is in communication with the a fuel source via a connection (23) and via which a number of injection valves (2.1, 2.2, 2.3) are supplied with fuel, characterized in that a preassembled module (3, 5, 9; 22, 38) of an injection valve (2.1, 2.2, 2.3), during production of the fuel distributor (1, 30) with central plug connection (15), is integrated in the latter by a cohesive connection (10, 11, 18, 33), with electrical contact-connection (17, 19, 27, 25, 32) of the injection valve (2.1, 2.2, 2.3) being effected at the same time.
2. Method according to Patent Claim 1, characterized in that the cohesive connection (11) between the fuel distributor (1) and the module (3, 5, 9) is effected by means of a thermal joining method.
3. Method according to Patent Claim 2, characterized in that the cohesive connection (11) is effected by laser welding in the neck region (6) between injection valve (2.1, 2.2, 2.3) and the fuel distributor (1).
4. Method according to Patent Claim 1, characterized in that the cohesive connection (18) between a fuel distributor (1) and a valve body (22) of the injection valve (2.1, 2.2, 2.3) takes place along an annular connecting geometry (20).
5. Method according to Claim 4, characterized in that an electrical contact-connection (17, 19) between the fuel distributor (1) and the injection valve (2.1, 2.2, 2.3) is produced during the cohesive joining.
6. Method according to Claim 4, characterized in that the electrical contact-connection (27) is formed during vertical joining of the injection valve body (22) to the fuel distributor (1) within a contact-connection cutout (26) which can be filled by casting.
7. Method according to Claim 1, characterized in that during the production of a fuel distributor (30) which is injection-moulded in a single piece, a preassembled module (38) of an injection valve (2.1, 2.2, 2.3) is cohesively fixed in an inlaid position (36) in the fuel distributor (30) by means of a pre-moulding (33).
8. Method according to Claim 7, characterized in that the cores which define the cavity (12) and the inlaid position (36) of the inlay module (38) in the single-piece fuel distributor (30), and also the electrical contact-connections (31, 32), are positioned and held in an injection mould.
9. Method according to Claim 7, characterized in that a central plug connection (15) is injection-moulded on the fuel distributor (30).
10. Method according to Claim 1, characterized in that the electrical contact-connections (17, 31) in the fuel distributor (1, 30) are formed as leadframes which form interconnects.

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