WO2011121839A1 - 電磁式燃料噴射弁及びその製造方法 - Google Patents

電磁式燃料噴射弁及びその製造方法 Download PDF

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Publication number
WO2011121839A1
WO2011121839A1 PCT/JP2010/070568 JP2010070568W WO2011121839A1 WO 2011121839 A1 WO2011121839 A1 WO 2011121839A1 JP 2010070568 W JP2010070568 W JP 2010070568W WO 2011121839 A1 WO2011121839 A1 WO 2011121839A1
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WIPO (PCT)
Prior art keywords
coil
cylindrical body
valve
magnetic
fuel injection
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.)
Ceased
Application number
PCT/JP2010/070568
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English (en)
French (fr)
Inventor
和彦 佐藤
光智 川原
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Astemo Ltd
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Keihin Corp
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Publication date
Application filed by Keihin Corp filed Critical Keihin Corp
Priority to BR112012023058A priority Critical patent/BR112012023058A8/pt
Priority to CN201080065792.0A priority patent/CN102822498B/zh
Publication of WO2011121839A1 publication Critical patent/WO2011121839A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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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
    • 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
    • F02M51/0675—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 valve body having cylindrical guiding or metering portions, e.g. with fuel passages
    • 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
    • F02M61/04—Fuel-injectors not provided for in groups F02M39/00 - F02M57/00 or F02M67/00 having valves, e.g. having a plurality of valves in series
    • F02M61/10—Other injectors with elongated valve bodies, i.e. of needle-valve type
    • F02M61/12—Other injectors with elongated valve bodies, i.e. of needle-valve type characterised by the provision of guiding or centring means for valve bodies
    • 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
    • F02M2200/00—Details of fuel-injection apparatus, not otherwise provided for
    • F02M2200/08—Fuel-injection apparatus having special means for influencing magnetic flux, e.g. for shielding or guiding magnetic flux
    • 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
    • F02M2200/00—Details of fuel-injection apparatus, not otherwise provided for
    • F02M2200/80—Fuel injection apparatus manufacture, repair or assembly
    • F02M2200/8046—Fuel injection apparatus manufacture, repair or assembly the manufacture involving injection moulding, e.g. of plastic or metal
    • 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
    • F02M2200/00—Details of fuel-injection apparatus, not otherwise provided for
    • F02M2200/80—Fuel injection apparatus manufacture, repair or assembly
    • F02M2200/8061—Fuel injection apparatus manufacture, repair or assembly involving press-fit, i.e. interference or friction fit
    • 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
    • F02M2200/00—Details of fuel-injection apparatus, not otherwise provided for
    • F02M2200/80—Fuel injection apparatus manufacture, repair or assembly
    • F02M2200/8084—Fuel injection apparatus manufacture, repair or assembly involving welding or soldering
    • 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
    • F02M2200/00—Details of fuel-injection apparatus, not otherwise provided for
    • F02M2200/80—Fuel injection apparatus manufacture, repair or assembly
    • F02M2200/8092—Fuel injection apparatus manufacture, repair or assembly adjusting or calibration

Definitions

  • the present invention relates to an electromagnetic fuel injection valve mainly used for a fuel supply system of an internal combustion engine, and in particular, a valve seat member having a valve hole from the front end to the rear end of the fuel injection valve, a magnetic cylinder, and a nonmagnetic A cylinder housing, a fixed core, and a fuel inlet cylinder are sequentially connected to each other, a valve housing having a fuel flow path inside, a coil disposed on the outer periphery of the valve housing, and the coil is accommodated, and the front end is welded.
  • a coil housing fixed to the outer periphery of the magnetic cylinder and magnetically connecting the magnetic cylinder and the fixed core; and a front end of the fixed core slidably fitted to the inner peripheral surface of the magnetic cylinder
  • a valve assembly that opens and closes the valve hole when the fixed core is demagnetized and excited, and includes a fixed core, a movable core, a magnetic cylinder, and a coil housing.
  • the inner peripheral surface of the magnetic cylinder of such an electromagnetic fuel injection valve slidably supports the movable core of the valve assembly.
  • the front end of the coil housing is In order to avoid the occurrence of distortion on the inner peripheral surface of the magnetic cylinder due to the welding heat during welding to the outer peripheral surface of the magnetic cylinder, the connecting end surface between the non-magnetic cylinder and the magnetic cylinder is connected to the front end of the coil.
  • the sliding part of the movable core on the inner circumferential surface of the magnetic cylinder is arranged rearward from the surface so as to be moved backward from the welded part at the front end of the coil housing.
  • An object of the present invention is to provide an electromagnetic fuel injection valve and a method for manufacturing the same.
  • the present invention provides a valve seat member having a valve hole, a magnetic cylinder, a nonmagnetic cylinder, a fixed core, and a fuel inlet cylinder from the front end to the rear end of the electromagnetic fuel injection valve.
  • a valve housing that is successively connected and has an internal fuel flow path, a coil that is disposed on the outer periphery of the valve housing, and that accommodates the coil, and the front end is fixed to the outer periphery of the magnetic cylindrical body by welding.
  • a coil housing that magnetically connects between the magnetic cylinder and the fixed core; and a movable core that is slidably fitted to the inner peripheral surface of the magnetic cylinder and is opposed to the suction surface at the front end of the fixed core.
  • a valve assembly that opens and closes the valve hole in accordance with demagnetization and excitation of the fixed core, and the fixed core, the movable core, the magnetic cylindrical body, and the coil housing, when the coil is energized, Magnet for exciting
  • the magnetic cylinder and the non-magnetic cylinder are arranged so that a boundary surface between the two and the non-magnetic cylinder protrudes forward from the coil, and the inner end in the radial direction of the front end of the coil housing.
  • a first feature is that a journal portion that is slidably supported on the inner peripheral surface of the magnetic cylindrical body at one side is formed on the movable core.
  • the present invention has a second feature in that the fixed core is arranged so that the suction surface at the front end thereof protrudes forward from the coil.
  • the present invention provides the electromagnetic fuel injection valve according to the first or second feature, wherein the front end of the coil housing is fixed to the outer peripheral surface of the magnetic cylindrical body by welding,
  • a third feature is that the peripheral surface and the suction surface of the fixed core are finished by cutting.
  • the boundary surface between the magnetic cylindrical body and the nonmagnetic cylindrical body is disposed in front of the coil, and the magnetic cylindrical body is located at a radially inward position of the front end portion of the coil housing.
  • the suction surface at the front end of the fixed core is disposed in front of the front end surface of the coil, the magnetic field in the section from the front end of the coil housing to the fixed core through the movable core is arranged.
  • the path length is further shortened and the magnetic path resistance is further reduced to improve the valve opening responsiveness of the valve assembly.
  • the residual magnetism of the movable core is quickly lost.
  • the three-dimensional valve closing response can also be improved.
  • the suction surface at the front end of the fixed core comes forward from the front end surface of the coil, the axial length of the valve assembly is reduced and its weight is reduced. Can be reduced.
  • the front end of the coil housing is fixed to the outer peripheral surface of the magnetic cylinder by welding, and then the inner peripheral surface of the magnetic cylinder and the suction surface of the fixed core are finished by cutting.
  • the fixed portion by welding between the front end portion of the coil housing and the magnetic cylindrical body approaches the circumferential surface of the magnetic cylindrical body or the attracting surface of the fixed core, thereby Even if distortion occurs on the peripheral surface of the cylindrical body and the suction surface of the fixed core due to welding heat, the distortion can be removed by the above-described cutting process, thus ensuring accurate operation of the valve assembly and high performance electromagnetic A fuel injection valve can be obtained.
  • FIG. 1 is a longitudinal sectional view of an electromagnetic fuel injection valve according to the present invention.
  • FIG. 2 is an enlarged view of part 2 of FIG.
  • FIG. 3 is an explanatory diagram of a cutting process during the manufacturing process of the electromagnetic fuel injection valve.
  • a valve housing 2 of an electromagnetic fuel injection valve (hereinafter simply referred to as a fuel injection valve) I for an engine is fitted to a cylindrical valve seat member 3 and a rear end portion of the valve seat member 3.
  • a magnetic cylinder 4 that is liquid-tightly welded, a non-magnetic cylinder 6 that is abutted against the rear end of the magnetic cylinder 4 and is liquid-tightly welded, and an inner peripheral surface of the non-magnetic cylinder 6
  • a cylindrical fixed core 5 fitted with a front end portion and welded in a liquid-tight manner, and a fuel inlet cylinder 9 integrally connected to the rear end of the fixed core 5 with the same material.
  • the valve seat member 3 includes a valve hole 7 that opens to the front end surface thereof, a conical valve seat 8 that is connected to the inner end of the valve hole 7, and a large-diameter portion of the valve seat 8. And a cylindrical large-diameter hole 17 having a diameter larger than that of the valve-body guide 15 and connected to the rear end of the valve-body guide 15 via a tapered hole 16.
  • a steel plate injector plate 10 having a plurality of fuel injection holes 11 communicating with the valve hole 7 is welded to the front end face of the valve seat member 3 in a liquid-tight manner.
  • a portion that does not fit with the fixed core 5 remains at the front end portion of the nonmagnetic cylindrical body 6, and the valve assembly V is accommodated in the valve housing 2 extending from the portion to the valve seat member 3.
  • the valve assembly V is welded to the movable core 12 opposed to the suction surface 5a at the front end of the fixed core 5, the valve rod 13 protruding integrally with the front end of the movable core 12, and the valve rod 13.
  • the basic shape slidably supported by the guide 15 so as to open and close the valve hole 7 in cooperation with the valve seat 8 is composed of a spherical valve body 14.
  • An annular journal portion 12 a that is slidably supported on the inner peripheral surface 4 a of the magnetic cylindrical body 4 is formed.
  • valve assembly V is slidably supported on the valve housing 2 at two points of the valve body 14 and the journal portion 12a that are largely separated from each other, so that the opening / closing posture of the valve assembly V is stabilized.
  • a plurality of flat flow path portions 18, 18... Permitting the passage of fuel are formed at equal intervals.
  • the first fixed hole 5 is provided with a first vertical hole 19 connected to the hollow portion of the fuel inlet tube 9.
  • the valve assembly V has a second vertical hole 20 that starts from the rear end surface of the movable core 12 and ends at the middle of the valve rod 13, and the second vertical hole 20 is opened to the large-diameter hole 17 of the valve seat member 3. Lateral holes 21 are provided.
  • an annular spring seat 24 facing the fixed core 5 is formed in the middle of the second vertical hole 20.
  • a slotted pipe retainer 23 is press-fitted into the first vertical hole 19 of the fixed core 5, and the movable core 12 is urged toward the valve closing side of the valve body 14 between the retainer 23 and the spring seat 24.
  • the valve spring 22 is contracted. At that time, the set load of the valve spring 22 is adjusted by the fitting depth of the retainer 23 into the first vertical hole 19.
  • the movable core 12 is embedded with a ring-shaped stopper member 27 made of a nonmagnetic material that slightly protrudes from the rear end surface thereof and faces the suction surface 5 a of the fixed core 5.
  • the stopper member 27 has a predetermined gap between the opposed end surfaces of the fixed core 5 and the movable core 12 by the stopper member 27 coming into contact with the suction surface 5a of the fixed core 5 when the fixed and movable cores 5 and 12 are attracted to each other. Is to remain.
  • a coil assembly 28 is fitted to the outer periphery of the soot valve housing 2 so as to correspond to the fixed core 5 and the movable core 12.
  • the coil assembly 28 includes a bobbin 29 fitted to the outer peripheral surface from the rear end portion of the magnetic cylindrical body 4 to the fixed core 5, and a coil 30 wound around the bobbin 29.
  • a base end portion of the coupler terminal 33 protruding to one side is held, and the terminal of the coil 30 is connected to the coupler terminal 33.
  • a synthetic resin primary coating layer 34 covering the outer periphery of the coil assembly 28 is molded so as to embed the coil 30.
  • a coupler 35 that accommodates and holds the coupler terminal 33 and protrudes to one side of the coil assembly 28 is integrally formed with the primary coating layer 34.
  • a magnetic coil housing 31 for accommodating and holding the coil assembly 28 is attached to the valve housing 2.
  • the coil housing 31 includes a body portion 31a that surrounds the coil assembly 28, and a pair of front and rear end walls 31b that bend radially inward from both ends of the body portion 31a to support both front and rear end surfaces of the coil assembly 28. , 31b 'and a pair of front and rear connecting cylindrical portions 31c, 31c' which protrude axially outward from both end walls 31b, 31b 'and fit to the outer peripheral surfaces of the magnetic cylindrical body 4 and the fixed core 5.
  • the distal end portions of the connecting tube portions 31c and 31c ′ are cut off at the outer periphery into thin portions 31d. These thin portions 31d are fixed to the outer peripheral surfaces of the magnetic cylindrical body 4 and the fixed core 5 by laser welding 32. Laser welding at the thin portion 31d requires relatively little heat input, and the thermal distortion of the magnetic cylindrical body 4 and the fixed core 5 can be kept small.
  • the coil housing 31, the magnetic cylindrical body 4, the movable core 12, and the fixed core 5 form a magnetic path 39 for exciting the fixed core 5 when the coil 30 is energized.
  • the magnetic cylinder 4 and the non-magnetic cylinder 6 are arranged such that the boundary surface B between them 4 and 6 comes out of the coil 30 by a distance S1, and the fixed core 5 is attracted to the front end thereof.
  • the surface 5a is disposed so as to protrude a distance S2 ahead of the coil 30.
  • journal portion 12a on the outer periphery of the movable core 12 that is slidably supported on the inner peripheral surface of the magnetic cylindrical body 4 is disposed at the front end portion of the coil housing 31, that is, the radially inner position of the connecting cylinder portion 31c. Is done.
  • the outer periphery of the magnetic cylinder 4 extends from the rear half of the magnetic cylinder 4 to the rear end of the fixed core 5 and is made of a synthetic resin that embeds the roots of the coil assembly 28, the coil housing 31, and the coupler 35.
  • the secondary coating layer 36 is formed by molding.
  • An annular seal groove 41 for mounting a seal member 40 such as an O-ring is formed on the outer periphery of the rear end portion of the fuel inlet tube 9.
  • the front end wall of the seal groove 41 is constituted by a flange 42 a at the rear end of a collar 42 made of synthetic resin that is press-fitted into the front outer peripheral surface of the fuel inlet cylinder 9, and the rear end wall is the inlet of the fuel inlet cylinder 9. It is comprised by the attachment flange 43a of the fuel filter 43 press-fit in. Therefore, when the seal member 40 is mounted, the collar 42 is press-fitted into the front outer peripheral surface of the fuel inlet tube 9 and then the seal member 40 is fitted to the rear outer peripheral surface of the fuel inlet tube 9.
  • the mounting flange 43 a is press-fitted into the inlet of the fuel inlet cylinder 9. By doing so, it is possible to mount the seal member 40 in the seal groove 41 without forcibly expanding the seal member 40.
  • a seal member 44 that is in close contact with the front end surface of the secondary coating layer 36 is attached to the outer periphery of the magnetic cylindrical body 4.
  • High-pressure fuel pumped from a fuel pump (not shown) to the fuel inlet cylinder 9 is filtered by the fuel filter 43, and then the inside of the valve housing 2, that is, the hollow portion of the fuel inlet cylinder 9, the first vertical hole 19 of the fixed core 5, The second vertical hole 20 and the horizontal hole 21 of the valve assembly V, the large-diameter hole 17, the tapered hole 16 and the valve body guide hole 15 of the valve seat member 3 are filled.
  • the coil 30 is demagnetized, the valve assembly V is pressed forward by the urging force of the valve spring 22, and the valve body 14 is seated on the valve seat 8.
  • the magnetic flux generated by the coil 30 sequentially runs on the magnetic path 39, that is, the coil housing 31, the magnetic cylindrical body 4, the movable core 12 and the fixed core 5, and is generated by the magnetic force generated between the cores 5 and 12.
  • the movable core 12 is attracted to the fixed core 5 against the set load of the valve spring 22 by the suction force, and the valve body 14 is separated from the valve seat 8, so that the valve hole 7 is opened and the valve seat member 3
  • High-pressure fuel exits the valve hole 7 and is injected from the fuel injection hole 11 of the injector plate 10 into a throttle body (not shown) equipped with the fuel injection valve I or an intake passage of the engine.
  • the magnetic cylindrical body 4 and the nonmagnetic cylindrical body 6 are arranged so that the boundary surface B between the both 4 and 6 protrudes forward from the coil 30.
  • the magnetic cylindrical body 4 Since the journal portion 12a on the outer periphery of the movable core 12 that is slidably supported on the inner peripheral surface of the coil housing 31 is disposed at the radially inward position of the connecting cylinder portion 31c at the front end portion of the coil housing 31, the front end of the coil housing 31 is provided.
  • the length of the magnetic path in the section extending from the journal portion 12a of the movable core 12 to the fixed core 5 is shorter than the conventional one, and accordingly the magnetic path resistance in the section is reduced.
  • the fixed core 5 has the front end attracting surface 5 a disposed in front of the coil 30, so that the magnetic path length in the section from the front end of the coil housing 31 to the fixed core 5 through the movable core 12. Not only improves the valve opening response of the valve assembly V by further reducing the magnetic path resistance, but also the loss of the residual magnetism of the movable core 12 is accelerated when the coil 30 is energized. The valve closing response of the assembly V can also be improved.
  • the suction surface 5a at the front end of the fixed core 5 protrudes ahead of the coil 30, the axial length of the valve assembly V is reduced from the conventional one, and the weight thereof is reduced. Is less seated on the valve seat 8, and the operating noise generated due to the stopper member 27 of the movable core 12 abutting against the suction surface 5a of the fixed core 5 is reduced from the conventional one.
  • the front end of the coil housing 31 is fixed to the outer peripheral surface of the magnetic cylindrical body 4 by welding 32, and then the inner peripheral surface 4a of the magnetic cylindrical body 4 and the suction surface of the fixed core 5 are used. Since 5a is finished by cutting, according to the above-described configuration, the fixed portion by welding 32 between the front end portion of the coil housing 31 and the magnetic cylindrical body 4 is the inner peripheral surface 4a of the magnetic cylindrical body 4 and the suction surface of the fixed core 5. By approaching 5a, even if distortion occurs on the inner peripheral surface 4a of the magnetic cylindrical body 4 and the suction surface 5a of the fixed core 5 due to welding heat, the distortion can be removed by the cutting process.
  • valve assembly V is inserted into the magnetic cylinder 4, and the valve seat member 3 is fitted to the front end of the magnetic cylinder 4 and welded.
  • accurate operation of the valve assembly V can be ensured, and a high-performance fuel injection valve I can be obtained.

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

Abstract

弁座部材（３），磁性円筒体（４），非磁性円筒体（６），固定コア（５）及び燃料入口筒（９）を順次連ねてなる弁ハウジング（２）と，その外周に配設されるコイル（３０）と，それを収容すると共に，前端部を磁性円筒体（４）の外周に溶接するコイルハウジング（３１）と，磁性円筒体（４）の内周面（４ａ）に摺動自在に嵌合されて固定コア（５）の吸引面（５ａ）に対置される可動コア（１２）を有する弁組立体（Ｖ）とを備える燃料噴射弁において，磁性円筒体（４）及び非磁性円筒体（６）を，その両者間の境界面（Ｂ）がコイル（３０）の前端面より前方に出るように配置すると共に，前記コイルハウジング（３１）の前端部（３１ｃ）の半径方向内方位置で前記磁性円筒体（４）の内周面に摺動自在に支承されるジャーナル部（１２ａ）を前記可動コア（１２）に形成した。これにより、可動コアからコイルハウジングの前端部に至る磁路の長さが短くなって磁路抵抗が減少し，弁組立体の応答性が良好な電磁式燃料噴射弁を提供する。

Description

電磁式燃料噴射弁及びその製造方法
　本発明は，主として内燃機関の燃料供給系に使用される電磁式燃料噴射弁に関し，特に，燃料噴射弁の前端から後端に向けて，弁孔を有する弁座部材，磁性円筒体，非磁性円筒体，固定コア及び燃料入口筒を順次連ねてなり内部を燃料流路とする弁ハウジングと，この弁ハウジングの外周に配設されるコイルと，このコイルを収容すると共に，前端部を溶接により前記磁性円筒体の外周に固着して前記磁性円筒体及び固定コア間を磁気的に接続するコイルハウジングと，前記磁性円筒体の内周面に摺動自在に嵌合されて前記固定コアの前端の吸引面に対置される可動コアを有し，前記固定コアの消磁及び励磁に伴ない前記弁孔を開閉する弁組立体とを備え，前記固定コア，可動コア，磁性円筒体及びコイルハウジングにより，前記コイルの通電時，前記固定コアを励磁するための磁路を形成する電磁式燃料噴射弁及びその製造方法の改良に関する。
　かゝる電磁式燃料噴射弁は，下記特許文献１に開示されるように既に知られている。
日本特開２００６－８３８０８号公報
　一般にかゝる電磁式燃料噴射弁の磁性円筒体の内周面は，弁組立体の可動コアを摺動自在に支承しており，従来の電磁式燃料噴射弁では，コイルハウジングの前端部の磁性円筒体の外周面への溶接時，その溶接熱により磁性円筒体の内周面に歪みが発生することを極力避けるために，非磁性円筒体及び磁性円筒体相互の接続端面をコイルの前端面より後方に配置して，磁性円筒体内周面における可動コアの摺動部をコイルハウジングの前端部の溶接部から後方に遠ざけるようにしていた。
  しかしながら，こうした従来のものでは，コイルハウジングの前端部から可動コアを経て固定コアに至る区間の磁路長さが長くなり，これが磁路抵抗を増すので，弁組立体の応答性が低下することが判明した。
　本発明は，かゝる事情に鑑みてなされたもので，可動コアからコイルハウジングの前端部に至る磁路の長さが短くなって磁路抵抗が減少し，弁組立体の応答性が良好な電磁式燃料噴射弁及びその製造方法を提供することを目的とする。
　上記目的を達成するために，本発明は，電磁式燃料噴射弁の前端から後端に向けて，弁孔を有する弁座部材，磁性円筒体，非磁性円筒体，固定コア及び燃料入口筒を順次連ねてなり内部を燃料流路とする弁ハウジングと，この弁ハウジングの外周に配設されるコイルと，このコイルを収容すると共に，前端部を溶接により前記磁性円筒体の外周に固着して前記磁性円筒体及び固定コア間を磁気的に接続するコイルハウジングと，前記磁性円筒体の内周面に摺動自在に嵌合されて前記固定コアの前端の吸引面に対置される可動コアを有し，前記固定コアの消磁及び励磁に伴ない前記弁孔を開閉する弁組立体とを備え，前記固定コア，可動コア，磁性円筒体及びコイルハウジングにより，前記コイルの通電時，前記固定コアを励磁するための磁路を形成する電磁式燃料噴射弁において，前記磁性円筒体及び非磁性円筒体を，その両者間の境界面が前記コイルより前方に出るように配置すると共に，前記コイルハウジングの前端部の半径方向内方位置で前記磁性円筒体の内周面に摺動自在に支承されるジャーナル部を前記可動コアに形成したことを第１の特徴とする。
  また本発明は，第１の特徴に加えて，前記固定コアを，その前端の吸引面が前記コイルより前方に出るように配置したことを第２の特徴とする。
  さらに本発明は，第１又は第２の特徴の電磁式燃料噴射弁を製造するに当たり，前記コイルハウジングの前端部を前記磁性円筒体の外周面に溶接により固着した後，前記磁性円筒体の内周面及び前記固定コアの吸引面を切削加工により仕上げることを第３の特徴とする。
  本発明の第１の特徴によれば，磁性円筒体及び非磁性円筒体間の境界面がコイルより前方に配置されること，並びにコイルハウジングの前端部の半径方向内方位置で前記磁性円筒体の内周面に摺動自在に支承されるジャーナル部が前記可動コアに形成されることにより，コイルハウジングの前端から可動コアのジャーナル部を経て固定コアに至る区間の磁路長さが従来のものより短縮し，これに伴ない上記区間の磁路抵抗が減少し，その結果，コイルの通電時，両コア間に素早く磁束が走り，吸引力の立ち上がり角度が急峻になることで，弁組立体の応答性，特に開弁応答性の向上を図ることができる。
  本発明の第２の特徴によれば，固定コアの前端の吸引面がコイルの前端面より前方に配置されることになるから，コイルハウジングの前端から可動コアを経て固定コアに至る区間の磁路長さが更に短縮し，磁路抵抗が更に減少して弁組立体の開弁応答性を向上させるのみならず，コイルの通電遮断時，可動コアの残留磁気の消失が早くなり，弁組立体の閉弁応答性をも向上させることができる。その上，固定コアの前端の吸引面が，コイルの前端面より前方に来た分，弁組立体の軸方向長さが減少し，その軽量化が図られるので，弁組立体の作動騒音を低減することができる。
  本発明の第３の特徴によれば，コイルハウジングの前端部を前記磁性円筒体の外周面に溶接により固着した後，磁性円筒体の内周面及び前記固定コアの吸引面を切削加工により仕上げるようにしたので，前記第１又は第２の特徴の構成により，コイルハウジングの前端部と磁性円筒体との溶接による固着個所が磁性円筒体内周面や固定コアの吸引面に近づくことで，磁性円筒体内周面及び固定コアの吸引面に溶接熱により歪みが発生しても，その歪みを上記切削加工により取り去ることができ，したがって弁組立体の正確な作動を確保し，高性能な電磁式燃料噴射弁を得ることができる。
図１は本発明に係る電磁式燃料噴射弁の縦断面図である。（第１実施例） 図２は図１の２部拡大図である。（第１実施例） 図３は電磁式燃料噴射弁の製造工程中の切削工程説明図である。（第１実施例）
Ｂ・・・・・磁性円筒体及び非磁性円筒体間の境界面
Ｉ・・・・・電磁式燃料噴射弁
Ｖ・・・・・弁組立体
２・・・・・弁ハウジング
３・・・・・弁座部材
４・・・・・磁性円筒体
４ａ・・・・磁性円筒体の内周面
５・・・・・固定コア
５ａ・・・・固定コアの吸引面
６・・・・・非磁性円筒体
７・・・・・弁孔
１２・・・・可動コア
１２ａ・・・ジャーナル部
３０・・・・コイル
３１・・・・コイルハウジング
３１ｃ・・・コイルハウジングの前端部（連結筒部）
３２・・・・溶接
３９・・・・磁路
　本発明の実施の形態を添付図面に基づいて以下に説明する。
　図１において，エンジン用の電磁式燃料噴射弁（以下，単に燃料噴射弁という。）Ｉの弁ハウジング２は，円筒状の弁座部材３と，この弁座部材３の後端部に嵌合して液密に溶接される磁性円筒体４と，この磁性円筒体４の後端に突き当てゝ液密に溶接される非磁性円筒体６と，この非磁性円筒体６の内周面に前端部を嵌合して液密に溶接される円筒状の固定コア５と，この固定コア５の後端に同一素材をもって一体に連設される燃料入口筒９とで構成される。
　図２に示すように，弁座部材３には，その前端面に開口する弁孔７と，この弁孔７の内端に連なる円錐状の弁座８と，この弁座８の大径部に連なる円筒状の弁体ガイド１５と，この弁体ガイド１５の後端にテーパ孔１６を介して接続される，弁体ガイド１５より大径で円筒状の大径孔１７とが設けられる。
  弁座部材３の前端面には，上記弁孔７と連通する複数の燃料噴孔１１を有する鋼板製のインジェクタプレート１０が液密に溶接される。
　非磁性円筒体６の前端部には，固定コア５と嵌合しない部分が残され，その部分から弁座部材３に至る弁ハウジング２内に弁組立体Ｖが収容される。
　弁組立体Ｖは，固定コア５の前端の吸引面５ａに対置される可動コア１２と，この可動コア１２の前端に一体に突設される弁杆１３と，この弁杆１３に溶接され，前記弁座８と協働して弁孔７を開閉するよう前記ガイド１５に摺動自在に支承される基本形が球状の弁体１４とで構成される，その可動コア１２の外周面には，磁性円筒体４の内周面４ａに摺動自在に支承される環状のジャーナル部１２ａが形成される。したがって，弁組立体Ｖは，弁体１４及びジャーナル部１２ａの互いに大きく離れた２点で弁ハウジング２に摺動自在に支承され，弁組立体Ｖの開閉姿勢を安定させるようになっている。球状の弁体１４の周囲には，燃料の通過を許容する複数の平坦な流路部１８，１８…が等間隔をおいて形成される。
  固定コア５には，燃料入口筒９の中空部に連なる第１縦孔１９が設けられる。また弁組立体Ｖには，可動コア１２の後端面から始まり弁杆１３の中間部で終わる第２縦孔２０と，この第２縦孔２０を弁座部材３の前記大径孔１７に開放する横孔２１とが設けられる。
  図１及び図２に示すように，第２縦孔２０の途中には，固定コア５側を向いた環状のばね座２４が形成される。固定コア５の第１縦孔１９にはすり割り付きパイプ状のリテーナ２３が圧入され，このリテーナ２３と前記ばね座２４との間に可動コア１２を弁体１４の閉弁側に付勢する弁ばね２２が縮設される。その際，リテーナ２３の第１縦孔１９への嵌合深さにより弁ばね２２のセット荷重が調整される。
  可動コア１２には，その後端面より僅かに突出して固定コア５の吸引面５ａに対向する非磁性材製でリング状のストッパ部材２７が埋設される。このストッパ部材２７は，固定及び可動コア５，１２相互の吸引時，ストッパ部材２７が固定コア５の吸引面５ａに当接することで，固定コア５及び可動コア１２の対向端面間に所定のギャップを残存させるものである。
  弁ハウジング２の外周には，固定コア５及び可動コア１２に対応してコイル組立体２８が嵌装される。このコイル組立体２８は，磁性円筒体４の後端部から固定コア５にかけてそれらの外周面に嵌合するボビン２９と，これに巻装されるコイル３０とからなっており，そのボビン２９の後端部には，その一側方に突出するカプラ端子３３の基端部が保持され，このカプラ端子３３にコイル３０の端末が接続される。このコイル組立体２８には，コイル３０を埋封するよう，その外周を覆う合成樹脂製の１次被覆層３４がモールド成形される。その際，前記カプラ端子３３を収容，保持してコイル組立体２８の一側方に突出するカプラ３５が１次被覆層３４と一体成形される。
　上記コイル組立体２８を収容保持する磁性体のコイルハウジング３１が弁ハウジング２に取り付けられる。このコイルハウジング３１は，コイル組立体２８を囲繞する胴部３１ａと，この胴部３１ａの両端から半径方向内方に屈曲してコイル組立体２８の前後両端面を支持する前後一対の端壁３１ｂ，３１ｂ′と，これら両端壁３１ｂ，３１ｂ′から軸方向外方に突出して磁性円筒体４及び固定コア５の各外周面に嵌合する前後一対の連結筒部３１ｃ，３１ｃ′とよりなっており，これら連結筒部３１ｃ，３１ｃ′の各先端部は，外周が削られて薄肉部３１ｄとなっている。これら薄肉部３１ｄが磁性円筒体４及び固定コア５の各外周面にレーザによる溶接３２により固着される。薄肉部３１ｄでのレーザによる溶接には，必要な入熱が比較的少なくて済み，磁性円筒体４及び固定コア５の熱歪みを小さく抑えることができる。
　上記溶接３２による薄肉部３１ｄの固着後，図３に示すように，前記固定コア５を摺動自在に支承する磁性円筒体４の内周面４ａと，弁体１４の開弁時，可動コア１２のストッパ部材２７が当接する固定コア５の吸引面５ａと，可動コア１２の後端縁を受容する非磁性円筒体６の環状逃げ溝３８とが切削加工により精密に仕上げられるが，上記のように磁性円筒体４及び固定コア５の熱歪みが小さいので，切削加工代を小さくすることができる。
  而して，コイルハウジング３１，磁性円筒体４，可動コア１２及び固定コア５により，コイル３０の通電時，固定コア５を励磁するための磁路３９が形成される。その際，磁性円筒体４及び非磁性円筒体６は，その両者４，６間の境界面Ｂがコイル３０より前方に距離Ｓ１，出るように配置され，また固定コア５は，その前端の吸引面５ａがコイル３０より前方に距離Ｓ２，出るように配置される。それに加えて，磁性円筒体４の内周面に摺動自在に支承される可動コア１２外周のジャーナル部１２ａは，コイルハウジング３１の前端部，即ち連結筒部３１ｃの半径方向内方位置に配置される。
　再び図１において，磁性円筒体４の後半部から固定コア５の後端部に亙りそれらの外周面には，コイル組立体２８，コイルハウジング３１及びカプラ３５の根元を埋封する合成樹脂製の２次被覆層３６がモールド成形により形成される。
  また燃料入口筒９の後端部の外周には，Ｏリング等のシール部材４０を装着する環状のシール溝４１が形成される。このシール溝４１の前端壁は，燃料入口筒９の前部外周面に圧入される合成樹脂製のカラー４２の後端のフランジ４２ａで構成され，またその後端壁は，燃料入口筒９の入口に圧入される燃料フィルタ４３の取り付けフランジ４３ａで構成される。したがって，シール部材４０の装着に際しては，カラー４２を燃料入口筒９の前部外周面に圧入してから，シール部材４０を燃料入口筒９の後部外周面に嵌装し，その後，燃料フィルタ４３の取り付けフランジ４３ａを燃料入口筒９の入口に圧入する。こうすることで，シール部材４０に無理な拡径を強制することなく，それをシール溝４１に装着することができる。また磁性円筒体４の外周には，２次被覆層３６の前端面に密接するシール部材４４が装着される。
  次に，この実施例の作用について説明する。
  図示しない燃料ポンプから燃料入口筒９に圧送される高圧燃料は燃料フィルタ４３で濾過された後，弁ハウジング２の内部，即ち燃料入口筒９の中空部，固定コア５の第１縦孔１９，弁組立体Ｖの第２縦孔２０及び横孔２１，並びに弁座部材３の大径孔１７，テーパ孔１６及び弁体ガイド孔１５等を満たす。そしてコイル３０を消磁した状態では，弁ばね２２の付勢力で弁組立体Ｖは前方に押圧され，弁体１４を弁座８に着座させている。
  コイル３０を通電により励磁すると，それにより生ずる磁束が前記磁路３９，即ちコイルハウジング３１，磁性円筒体４，可動コア１２及び固定コア５を順次走り，両コア５，１２間に発生する磁力による吸引力により可動コア１２が弁ばね２２のセット荷重に抗して固定コア５に吸引され，弁体１４が弁座８から離座するので，弁孔７が開放され，弁座部材３内の高圧燃料が弁孔７を出て，インジェクタプレート１０の燃料噴孔１１から，この燃料噴射弁Ｉを装着した図示しないスロットルボディ又はエンジンの吸気路に噴射される。
  ところで，前述のように，磁性円筒体４及び非磁性円筒体６は，その両者４，６間の境界面Ｂがコイル３０より前方に出るように配置され，これに加えて，磁性円筒体４の内周面に摺動自在に支承される可動コア１２外周のジャーナル部１２ａが，コイルハウジング３１の前端部の連結筒部３１ｃの半径方向内方位置に配置されるので，コイルハウジング３１の前端から可動コア１２のジャーナル部１２ａを経て固定コア５に至る区間の磁路長さが従来のものより短縮し，これに伴ない上記区間の磁路抵抗が減少する。その結果，コイル３０の通電時，両コア５，１２間に素早く磁束が走り，吸引力の立ち上がり角度が急峻になることで，弁組立体Ｖの応答性，特に開弁応答性の向上を図ることができる。
　また前述のように，固定コア５は，その前端の吸引面５ａが，コイル３０より前方に配置されるので，コイルハウジング３１の前端から可動コア１２を経て固定コア５に至る区間の磁路長さが更に短縮し，磁路抵抗が更に減少して弁組立体Ｖの開弁応答性を向上させるのみならず，コイル３０の通電遮断時，可動コア１２の残留磁気の消失が早くなり，弁組立体Ｖの閉弁応答性をも向上させることができる。その上，固定コア５の前端の吸引面５ａがコイル３０より前方に出た分，弁組立体Ｖの軸方向長さが従来のものより減少し，その軽量化が図られるので，弁体１４が弁座８に着座したり，可動コア１２のストッパ部材２７が固定コア５の吸引面５ａに当接することに起因して発生する作動騒音が従来のものより低減する。
　また燃料噴射弁Ｉの製造に当たっては，コイルハウジング３１の前端部を前記磁性円筒体４の外周面に溶接３２により固着した後，磁性円筒体４の内周面４ａ及び前記固定コア５の吸引面５ａを切削加工により仕上げるようにしたので，上記構成により，コイルハウジング３１の前端部と磁性円筒体４との溶接３２による固着個所が磁性円筒体４の内周面４ａや固定コア５の吸引面５ａに近づくことで，磁性円筒体４の内周面４ａ及び固定コア５の吸引面５ａに溶接熱により歪みが発生しても，その歪みを上記切削加工により取り去ることができる。その切削加工後，磁性円筒体４内に弁組立体Ｖを挿入し，弁座部材３を磁性円筒体４の前端部に嵌合して溶接する。かくして，弁組立体Ｖの正確な作動を確保し，高性能な燃料噴射弁Ｉを得ることができる。
  以上，本発明の実施形態について説明したが，本発明はそれに限定されることなく，その要旨を逸脱しない範囲で種々の設計変更が可能である。

Claims (3)

  1.   電磁式燃料噴射弁（Ｉ）の前端から後端に向けて，弁孔（７）を有する弁座部材（３），磁性円筒体（４），非磁性円筒体（６），固定コア（５）及び燃料入口筒（９）を順次連ねてなり内部を燃料流路とする弁ハウジング（２）と，この弁ハウジング（２）の外周に配設されるコイル（３０）と，このコイル（３０）を収容すると共に，前端部（３１ｃ）を溶接（３２）により前記磁性円筒体（４）の外周に固着して前記磁性円筒体（４）及び固定コア（５）間を磁気的に接続するコイルハウジング（３１）と，前記磁性円筒体（４）の内周面（４ａ）に摺動自在に嵌合されて前記固定コア（５）の前端の吸引面（５ａ）に対置される可動コア（１２）を有し，前記固定コア（５）の消磁及び励磁に伴ない前記弁孔（７）を開閉する弁組立体（Ｖ）とを備え，前記固定コア（５），可動コア（１２），磁性円筒体（４）及びコイルハウジング（３１）により，前記コイル（３０）の通電時，前記固定コア（５）を励磁するための磁路（３９）を形成する電磁式燃料噴射弁において，
      前記磁性円筒体（４）及び非磁性円筒体（６）を，その両者間の境界面（Ｂ）が前記コイル（３０）の前端面より前方に出るように配置すると共に，前記コイルハウジング（３１）の前端部（３１ｃ）の半径方向内方位置で前記磁性円筒体（４）の内周面に摺動自在に支承されるジャーナル部（１２ａ）を前記可動コア（１２）に形成したことを特徴とする電磁式燃料噴射弁。
  2.   請求項１記載の電磁式燃料噴射弁において，
      前記固定コア（５）を，その前端の吸引面（５ａ）が前記コイル（３０）より前方に出るように配置したことを特徴とする電磁式燃料噴射弁。
  3. 　請求項１又は２記載の電磁式燃料噴射弁を製造するに当たり，
    　前記コイルハウジング（３１）の前端部を前記磁性円筒体（４）の外周面に溶接（３２）により固着した後，前記磁性円筒体（４）の内周面（４ａ）及び前記固定コア（５）の吸引面（５ａ）を切削加工により仕上げることを特徴とする電磁式燃料噴射弁の製造方法。
PCT/JP2010/070568 2010-03-29 2010-11-18 電磁式燃料噴射弁及びその製造方法 Ceased WO2011121839A1 (ja)

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EP2700806A1 (en) * 2012-08-23 2014-02-26 Continental Automotive GmbH Fuel injector, fuel injection assembly and use of a sealing ring
EP3064757A1 (en) * 2015-03-05 2016-09-07 Continental Automotive GmbH Method for manufacturing an injector for injecting fluid and injector for injecting fluid
EP3006721A4 (en) * 2013-06-06 2016-11-23 Hitachi Automotive Systems Ltd ELECTROMAGNETIC FUEL INJECTION VALVE

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