GB2581359A - Common rail for gasoline engine - Google Patents

Common rail for gasoline engine Download PDF

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Publication number
GB2581359A
GB2581359A GB1901998.3A GB201901998A GB2581359A GB 2581359 A GB2581359 A GB 2581359A GB 201901998 A GB201901998 A GB 201901998A GB 2581359 A GB2581359 A GB 2581359A
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United Kingdom
Prior art keywords
injector
fuel
common rail
adapter
connector portion
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Granted
Application number
GB1901998.3A
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GB2581359B (en
GB201901998D0 (en
Inventor
Turan Kivanc
Can Gunduz Ahmet
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Delphi Technologies IP Ltd
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Delphi Technologies IP Ltd
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Priority to GB1901998.3A priority Critical patent/GB2581359B/en
Publication of GB201901998D0 publication Critical patent/GB201901998D0/en
Publication of GB2581359A publication Critical patent/GB2581359A/en
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Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02MSUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M55/00Fuel-injection apparatus characterised by their fuel conduits or their venting means; Arrangements of conduits between fuel tank and pump F02M37/00
    • F02M55/02Conduits between injection pumps and injectors, e.g. conduits between pump and common-rail or conduits between common-rail and injectors
    • F02M55/025Common rails
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02MSUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M55/00Fuel-injection apparatus characterised by their fuel conduits or their venting means; Arrangements of conduits between fuel tank and pump F02M37/00
    • F02M55/02Conduits between injection pumps and injectors, e.g. conduits between pump and common-rail or conduits between common-rail and injectors
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02MSUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M2200/00Details of fuel-injection apparatus, not otherwise provided for
    • F02M2200/80Fuel injection apparatus manufacture, repair or assembly
    • F02M2200/8076Fuel injection apparatus manufacture, repair or assembly involving threaded members

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Fuel-Injection Apparatus (AREA)

Abstract

A common rail (or fuel rail) for a gasoline engine comprises a forged tubular 12 body with transversally protruding fuel outlet pieces 24. A plurality of injector adapters 30 are mounted to the body, each adapter having a connector portion 32 assembled by screwing onto a respective fuel outlet piece 24 and an injector portion 34 with an injector cavity 36 or cup configured to receive an injector. The injector cavity axis (C) is transversal to a cavity branch bore 26 and is in fluid communication therewith through a fuel channel 38. The connector portion 32 includes an annular sealing surface 46 surrounding the fuel channel 38 that comes into sealing engagement with an annular sealing surface 42 surrounding the branch bore, when screwing the injector adapter 30 onto the corresponding fuel outlet piece 24. The assembly allows for an offset coupling to fuel injectors and improved sealing between the annular sealing surfaces.

Description

Common rail for gasoline engine
Technical field
The present invention generally relates to the field of fuel injection in internal combustion engines. The invention particularly relates to common rails for gasoline engines.
Background of the Invention
Common rail direct fuel injection has been originally designed for diesel engines. Such direct injection system comprises a high pressure pump feeding high pressure fuel to a fuel rail, referred to as common rail. The common rail in turn provides the high pressure fuel to a plurality of fuel injectors which are cyclically driven to inject fuel into a respective cylinder.
As is well known, the common rail typically comprises an elongated cylindrical body with a bore along its longitudinal axis defining an inner volume configured to receive high pressure fuel. The rail further comprises an inlet port and a plurality of tubular connection pieces forming outlet ports protruding from the cylindrical surface of the body. The outlet ports are commonly formed as cylindrical sleeves extending in a direction perpendicular to the longitudinal axis of the fuel rail.
In gasoline engines, common rails are used in gasoline direct injection (GDI) engine technology. Due to space restrictions inside engine compartments and also to the multiple engine configurations offered, fuel rails need to be made with a relative amount of flexibility with regards to their mounting and positioning possibilities.
In GDI engines, the common rail is directly on top of the fuel injectors. When the engine configuration allows it, the fuel rail is arranged directly above the injectors, and the rail fuel outlets are designed as straight sleeves. In other configurations, the fuel rail is slightly offset, and is thus equipped with additional pipes portions.
For GDI engines, the pressure commonly used inside the fuel rail may be around 350 bar, allowing the use of brazed fuel rails. Brazed rails are very flexible when it comes to the mounting process. The final outline of the rail is defined by assembling complex geometries to a main tube with brazing method. Brazed rails can therefore be customized to a particular engine environment and are able to fit in tight spaces.
Nonetheless, brazed rails are limited by their maximum operation pressure, particularly because of the lower stress resistance of the brazed connections. Accordingly, forged common rails are preferred for reliability when operating at higher pressures. Indeed, the nature of forging operations provides increased radii values in forged rails when compared to brazed rails and reduces the areas with low stress resistance.
However, compact designs may be more complex to achieve with forged fuel rails, due to the monolithic structure of forged rail which requires extra machining in order to allow for an offset between the common rail body and the fuel injectors.
Object of the invention An object of the present invention is to provide an improved common rail design for gasoline engines that allows for an offset coupling to fuel injectors.
General Description of the Invention
According to the present invention, a common rail, in particular for a gasoline engine, comprises a forged tubular body extending along a longitudinal axis and having an inner longitudinal bore for, in use, containing pressurized fuel. The body is provided with a plurality of transversally protruding fuel outlet pieces, wherein each fuel outlet piece comprises a branch bore extending along a direction transversal to the longitudinal axis and in communication with the longitudinal bore, wherein a first annular sealing surface surrounds the branch bore.
A plurality of injector adapters fixedly mounted to the body, each adapter having a connector portion assembled by screwing onto a respective fuel outlet piece and an injector portion with an injector cavity configured to receive therein an injector end, wherein said injector cavity extends along an axis transversal to the branch bore and is in fluid communication therewith through a fuel channel extending through the connector portion and opening in the injector cavity.
The connector portion includes a second annular sealing surface surrounding the 5 fuel channel, said second annular sealing surface coming into sealing engagement with said first annular sealing surface when screwing the adapter onto the corresponding fuel outlet piece.
The present invention uses a common rail of fairly simple design, i.e. a forged rail body with transversally protruding fuel outlet pieces. Injector adapters are assembled/connected onto each outlet piece to allow mounting of a respective fuel injector. The injector adapters have an injector portion with a cavity for coupling to the injector that extends transversally to the fuel outlet piece on which the adapter is mounted. The present common rail and injector assembly thus allows mounting of fuel injectors in an offset manner. The term offset means herein that the injector axis is not aligned with the direction of the fuel outlet piece it is associated with, but forms an angle relative to the transversal direction of fuel outlet piece.
The offset mounting of fuel injector is thus allowed without requiring complex manufacturing operations of the common rail and without compromising the strength of the forged rail body.
The assembly of the injector adapter to the fuel rail body is conveniently done by screwing. Each fuel outlet piece may comprise a first threaded section that cooperates with a matching second threaded section associated with the connector portion in such a way that screwing the second threaded section on the first threaded section brings the first and second annular sealing surfaces into sealing engagement. Hence, the fluid tight connection is spontaneously obtained when the adaptor is fixed to the fuel rail body.
The fuel rail and injector adapter are typically from metal, in particular stainless steel, whereby the first and second sealing surfaces provide a metal-to-metal fluid-tight seal. Each of the common rail body and the injector adapter are preferably made in one piece.
For ease of assembly, the first and second sealing surfaces are frustoconical surfaces, preferably with different cone angle.
For an improved sealing, the rail body and the injector adapter are made from metals having different hardness such that one of the first and second annular sealing surfaces is deformed when pressed against the other. It is particularly preferred that the injector adapter has a greater material hardness than the rail body. In this connection, it is noted a different material hardness can be achieved by playing on elemental composition and on thermal treatments or forming processes. Hence, the rail body and injector adapter can be made of steel having same composition, but the different hardness can result from varying treatments.
In particular, the rail body is made from forged stainless steel and obtained by forging whereas the injector adapter is made from stainless steel and obtained by cold working. For a same steel composition, the cold working process generally imparts superior mechanical properties, including a greater strength and hardness.
In embodiments, the branch bore comprises a conical inlet section defining the first sealing surface and the connector portion comprises a conical outer sealing protrusion defining the second sealing surface and engaged into the inlet section. However, other shapes of the sealing surfaces may be contemplated.
The screwed connection of the injector adapter to the rail body can be done in different ways. The first threaded section of the fuel outlet piece can be designed as a male thread, whereas the second threaded section of the injector adapter is a female thread, or inversely.
In one embodiment, the outlet piece comprises an external thread forming the first threaded section, and a union nut is provided around the connector portion that is screwed onto the external thread of the outlet piece to fix the injector adaptor to the rail body. The union nut comprises a ring body with an inner thread forming the second threaded section and an inner annular flange at one end, the inner annular flange being, in the assembled state, in abutment with the peripheral sealing protrusion to maintain the injector adapter against the fuel outlet piece.
In another aspect, the invention also relates to a gasoline engine comprising a fuel rail according to any one of the preceding claims and a number of gasoline fuel injectors corresponding to the number of injector adapters, wherein each gasoline fuel injector has a connecting end that is received the injector cavity of a respective injector adapter (30).
Brief Description of the Drawings
Further details and advantages of the present invention will be apparent from the following detailed description of not limiting embodiments with reference to the attached drawings, wherein: Fig. 1 is a perspective view of a common rail according to a preferred embodiment of the invention; Fig. 2 is a bottom view of the common rail of Fig.1; Fig. 3 is a cross-section view along the plane 3-3 of Fig. 2.
Description of Preferred Embodiments
Fig. 1 shows an embodiment of a common rail 10 (hereinafter also referred to as fuel rail) for use in an internal combustion engine based on gasoline direct injection (GDI) engine technology. The common rail 10 comprises an elongated tubular body 12 extending along a main longitudinal axis A. The body 12 comprises an internal longitudinal bore 14 shown in Fig. 3, which extends parallel to the longitudinal axis A forming an internal chamber receiving, in use, pressurized fuel. The body 12 typically has a relatively thick wall thickness for improved pressure resistance. In the present variant, the longitudinal bore 14 is a through bore extending between two end connection ports, a cavity 16 to plug/close the longitudinal bore 14 at one extremity of the body and a pipe section 18 representing the inlet at the opposite end. The pipe 18 is, in use, connected to a fuel pump, not shown, that provides pressurized fuel to the fuel rail 10.
The rail body 12 is a forged metallic body, for example in stainless steel. Forming 30 of the common rail body by forging is common in the art and conventional for common rails for diesel engines.
The rail body comprises four mounting features 20 provided to fix the rail 10 in the engine. Here the mounting features are formed as sleeves 20 with a centre bore 22, through which a fixing screw (not shown) passes and further engages into a threaded bore in an engine component, e.g. in the cylinder head, not shown.
The rail 10 is provided with a plurality of tubular-shaped protrusions referred to as connecting pieces. One of the connecting pieces 23 is used for mounting a high pressure sensor assembly.
Common rail 10 is further provided with four tubular-shaped protrusions serving as fuel outlet pieces 24 for, in use, providing fuel to respective fuel injectors that allow fuel injection into the combustion chambers of the gasoline engine, not shown.
The fuel outlet pieces 24, better seen in Fig.3, are formed as cylindrical sleeves integral with the body 12, that extend transversally to the longitudinal axis A, in particular radially along axis B, and protrude from the lateral surface of the body 12. Each fuel outlet piece 24 comprises an internal passage or branch bore 26, in communication with the longitudinal bore 14 and opening in the end face 28 of the outlet piece 24. The branch bore 26 is typically centred in the connecting piece 24 and extends radially (along axis B).
It shall be noted that an injector adapter 30 is assembled by screwing onto each of the fuel outlet pieces 24. The injector adapters 30 form a connecting interface between the fuel rail 10 and the fuel injectors: they are assembled to the rail 10 and are configured for direct coupling to a respective injector. This contrasts with the practice in Diesel engines, where the fuel injectors are connected with the common rail by high pressure pipes.
The present injector adapters 30 are configured to allow mounting the common rail to injectors oriented transversally to the direction of the fuel outlets 24, i.e. transversally to axis B of the branch bore 26.
Accordingly, the injector adapter 30 generally has a connector portion 32 30 assembled by screwing onto a respective fuel outlet piece 24 and an injector portion 34 with an injector cavity 36 configured to receive therein the extremity of a fuel injector (not shown). The injector cavity 36 is cylindrically shaped and extends along an axis C transversal to the branch bore (i.e. transverse to the direction of axis B) and is in fluid communication therewith through a fuel channel 38 extending through the connector portion 32 and opening in the injector cavity 36.
In the present embodiment, the injector portion 34 includes a solid metal body with a cylindrical blind bore forming the injector cavity 36. The inlet 37 of the cavity is designed as an outwardly widening section, namely frustoconical, for insertion of sealing means, not shown, ensuring a fluid-tight mounting of the fuel injector in the cavity 36. The sealing means may be an 0-ring and various assembly methods are available, for example a spring, clips, or hanging pins.
The connector portion 32 is designed as a simple sleeve protruding from the side of the injector portion 34 and extending transversally to the cavity axis C, and namely perpendicularly thereto. The fuel channel 38 thus extends through the length of the connector portion 32 and further straight inside the body of the injector portion 34, to open into the cavity 36. The connector portion 32 is integral with the injector portion 34, typically made in one piece.
In the assembled state shown in Fig.3, the connector portion 32 thus forms an axial extension of the outlet piece 24 and the fuel channel 38 is an axial continuation of the branch bore 26, providing fluid communication between the longitudinal bore 14 and the injector cavity 36.
As a result, the injector adapter 30 is configured to provide a fuel passage between the fuel rail 10 and fuel injectors having a main axis that is offset relative to the radial direction of the fuel outlet pieces 24, i.e. the injector axis is not aligned with the radial direction of the fuel outlet pieces 24.
Furthermore, the bore 26 and fuel channel 38 are each provided with respective annular sealing surfaces that come into sealing engagement when the injector adapter 30 is screwed onto the corresponding fuel outlet piece 24.
In the shown embodiment, the outlet piece 24 comprises an external thread 40 adjacent the end face 28. Reference sign 42 designates a first annular sealing 30 surface that surrounds the branch bore 26 and which is part of an inlet section 44 of the branch bore 26.
A second annular sealing surface 46 is provided at the free end of the adapter connecting portion 32 and is part of a conical outer sealing protrusion 48 surrounding the fuel channel 38.
The first and second sealing surfaces are both frustoconical, the first sealing surface 42 having a cone angle wider than that of the second sealing surface 46. In the assembled state, the tip of the connecting portion 32 is engaged inside inlet section 44 and the second sealing surface 46 engages the first sealing surface 42.
Reference sign 50 designates a union nut with an inner thread 52 that cooperates with the outer thread 40. In the assembled state, the union nut 50 is screwed onto the outer thread 40 of the outlet piece 24, which permits a fixed, secure mounting of the adapter 30 to the fuel rail 10 and provides a force ensuring a sealed interface between first and second sealing surfaces 42, 46.
The union nut 50 is a kind of flare nut, i.e. it is formed as a ring body bearing the internal annular thread 52, and one end of the body comprises an integral annular flange 54 extending inwardly. Union nut 50 is arranged around the adapter connector portion 32 and the flange 54 has an inner diameter larger than the sleeve of the connector portion 32 but smaller than the base of the conical sealing protrusion 48. Accordingly, when the union nut 50 is screwed on the outlet piece 24, the annular flange 54 comes into abutment against the sealing protrusion 48 and allows pushing the second sealing surface 46 against the first sealing surface 42, providing a metal-to-metal seal.
Advantageously, the injector adapter 30 has a different material hardness than the fuel rail body 12, so that one of the sealing surfaces can penetrate into/deform the other one, resulting in an improved metal-to-metal seal. In particular, the injector adapter is preferably made from metal having a greater hardness than the metal of the body. For example, whereas both the fuel rail body and injector adapter may consist of austenitic stainless steel such as AISI 304L, the forging process used to manufacture the body 12 tends to result in a lower material hardness than cold working which is preferably used to produce the injector adapter 30. Accordingly, the cold formed annular protrusion 48 comprising the second sealing surface 46 has a greater hardness than the outlet piece 24 comprising the first sealing surface 42.
It may be noted that whereas cold working provides better mechanical properties than forging, it does not yield in alteration of either mechanical or corrosion properties of the fuel rail assembly, since the corrosion resistance is maintained by the elemental composition of the steel, and remains unaffected by cold working.

Claims (13)

  1. Claims: 1. A common rail for a gasoline engine, the common rail (10) comprising: a forged tubular (12) body extending along a longitudinal axis (A) with an inner longitudinal bore (14) for, in use, containing pressurized fuel, said body comprising a plurality of transversally protruding fuel outlet pieces (24), wherein each fuel outlet piece (24) comprises a branch bore (26) extending along a direction transversal to said longitudinal axis and in communication with said longitudinal bore (14), a first annular sealing surface (42) surrounding said branch bore (26); a plurality of injector adapters (30) fixedly mounted to the body, each adapter having a connector portion (32) assembled by screwing onto a respective fuel outlet piece (24) and an injector portion (34) with an injector cavity (36) configured to receive therein an injector end, wherein said injector cavity extends along an axis (C) transversal to said branch bore (26) and is in fluid communication therewith through a fuel channel (38) extending through said connector portion (32) and opening into said injector cavity (36); wherein said connector portion (32) includes a second annular sealing surface (46) surrounding said fuel channel (38), said second annular sealing surface (46) coming into sealing engagement with said first annular sealing surface (42) when screwing said injector adapter (30) onto the corresponding fuel outlet piece (26).
  2. 2. The common rail according to claim 1, wherein each fuel outlet piece (26) comprises a first threaded section (40) that cooperates with a matching second threaded section (52) associated with said connector portion (32) in such a way that screwing said second threaded section on said first threaded section brings the first and second annular sealing surfaces into sealing engagement.
  3. 3. The common rail according to claim 1 or 2, wherein the common rail body (12) and injector adapter (30) are made from metal, in particular stainless steel, whereby said first and second sealing surfaces provide a metal-to-metal fluid-tight seal.
  4. 4 The common rail according to any one of claims 1 to 3, wherein the first and second sealing surfaces are frustoconical surfaces with different cone angle.
  5. 5. The common rail according to any one of the preceding claims, wherein said adapter (30) is made in one piece.
  6. 6. Fuel rail according to any one of the preceding claims, wherein the rail body (12) and the injector adapter (30) are made from metals having different hardness such that one of the first and second annular sealing surfaces (42, 46) is deformed when pressed against the other.
  7. 7. The common rail according to any one of the preceding claims, wherein the rail body (12) is made from stainless steel and obtained by forging whereas the injector adapter (30) is made from stainless steel and obtained by cold working.
  8. 8. The common rail according to any one of the preceding claims, wherein said branch bore comprises a conical inlet section (44) defining said first sealing surface (42), and said connector portion (32) comprises a conical, peripheral sealing protrusion (48) defining said second sealing surface (46) and engaged into said inlet section.
  9. 9. The common rail according to any one of the preceding claims, wherein said fuel outlet piece (26) comprises an external thread forming said first threaded section (40); and a union nut (50) is provided around the connector portion (32) and is screwed onto said external thread (40) of said outlet piece (26) to fix the injector adaptor to the rail body.
  10. 10. The common rail according to claims 8 and 9, wherein said union nut (50) comprises a ring body with an inner thread forming said second threaded section (52) and an inner annular flange (54) at one end, said inner annular flange being, in the assembled state, in abutment with said peripheral sealing protrusion (48) to maintain said injector adapter against said fuel outlet piece.
  11. 11. The common rail according to any one of the preceding claims, wherein the axis (C) of said injector cavity (36) is substantially perpendicular to the axis (B) of the branch bore.
  12. 12. The common rail according to any one of the preceding claims, wherein the injector cavity (36) of the adapter outlet comprises sealing means to ensure a fluid-tight connection with the injector adapter and the injector.
  13. 13. Gasoline engine comprising a fuel injection system with a fuel rail (10) according to any one of the preceding claims and a number of gasoline fuel injectors corresponding to the number of injector adapters (30), wherein each gasoline fuel injector has a connecting end that is received the injector cavity (36) of a respective injector adapter (30).
GB1901998.3A 2019-02-13 2019-02-13 Common rail for gasoline engine Active GB2581359B (en)

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GB1901998.3A GB2581359B (en) 2019-02-13 2019-02-13 Common rail for gasoline engine

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GB201901998D0 GB201901998D0 (en) 2019-04-03
GB2581359A true GB2581359A (en) 2020-08-19
GB2581359B GB2581359B (en) 2022-04-27

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2022083934A1 (en) * 2020-10-19 2022-04-28 Robert Bosch Gmbh Fluid distributor for an injection system, and injection system for mixture-compressing, spark-ignition internal combustion engines
WO2024165201A1 (en) * 2023-02-06 2024-08-15 Robert Bosch Gmbh Fuel injection system and fuel distributor for gaseous fuels, in particular hydrogen

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4893601A (en) * 1987-05-23 1990-01-16 Usui Kokusai Sangyo Kaisha Ltd. Manifold for conveying a high-pressure fuel
GB2320074A (en) * 1996-12-07 1998-06-10 Usui Kokusai Sangyo Kk Common rail branch unit
KR101628560B1 (en) * 2014-12-08 2016-06-09 주식회사 현대케피코 Fuel rail having noise and vibration reducing structure
KR20170054932A (en) * 2015-11-10 2017-05-18 주식회사 현대케피코 Fuel injector coupling device of fuel rail
DE202017101954U1 (en) * 2017-04-03 2018-07-05 Hirschvogel Umformtechnik Gmbh Fuel rail and closed fuel rail

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4893601A (en) * 1987-05-23 1990-01-16 Usui Kokusai Sangyo Kaisha Ltd. Manifold for conveying a high-pressure fuel
GB2320074A (en) * 1996-12-07 1998-06-10 Usui Kokusai Sangyo Kk Common rail branch unit
KR101628560B1 (en) * 2014-12-08 2016-06-09 주식회사 현대케피코 Fuel rail having noise and vibration reducing structure
KR20170054932A (en) * 2015-11-10 2017-05-18 주식회사 현대케피코 Fuel injector coupling device of fuel rail
DE202017101954U1 (en) * 2017-04-03 2018-07-05 Hirschvogel Umformtechnik Gmbh Fuel rail and closed fuel rail

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2022083934A1 (en) * 2020-10-19 2022-04-28 Robert Bosch Gmbh Fluid distributor for an injection system, and injection system for mixture-compressing, spark-ignition internal combustion engines
US12018634B2 (en) 2020-10-19 2024-06-25 Robert Bosch Gmbh Fluid distributor for an injection system and injection system for mixture-compressing, externally ignited internal combustion engines
WO2024165201A1 (en) * 2023-02-06 2024-08-15 Robert Bosch Gmbh Fuel injection system and fuel distributor for gaseous fuels, in particular hydrogen

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Publication number Publication date
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GB201901998D0 (en) 2019-04-03

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