WO2018116179A1 - Structures de buse avec bagues de soudage minces et injecteurs de carburant les utilisant - Google Patents

Structures de buse avec bagues de soudage minces et injecteurs de carburant les utilisant Download PDF

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Publication number
WO2018116179A1
WO2018116179A1 PCT/IB2017/058168 IB2017058168W WO2018116179A1 WO 2018116179 A1 WO2018116179 A1 WO 2018116179A1 IB 2017058168 W IB2017058168 W IB 2017058168W WO 2018116179 A1 WO2018116179 A1 WO 2018116179A1
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WO
WIPO (PCT)
Prior art keywords
face
nozzle structure
holes
nozzle
opening
Prior art date
Application number
PCT/IB2017/058168
Other languages
English (en)
Inventor
Jun-Ying Zhang
Przemyslaw P. Markowicz
Thomas J. Miller
Barry S. Carpenter
Scott M. Schnobrich
Brian K. Nelson
Barbara A. FIPP
Original Assignee
3M Innovative Properties Company
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Publication date
Application filed by 3M Innovative Properties Company filed Critical 3M Innovative Properties Company
Publication of WO2018116179A1 publication Critical patent/WO2018116179A1/fr

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Classifications

    • 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
    • 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
    • F02M61/18—Injection nozzles, e.g. having valve seats; Details of valve member seated ends, not otherwise provided for
    • F02M61/1853—Orifice plates
    • 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

Definitions

  • This invention generally relates to nozzle structures suitable for use in a fuel injector for an internal combustion engine.
  • the invention is further applicable to fuel injectors incorporating such nozzle structures.
  • This invention also relates to methods of making such nozzle structures, as well as methods of making fuel injectors incorporating such nozzle structures.
  • the invention further relates to methods of using nozzle structures and fuel injectors in vehicles.
  • PFI port fuel injection
  • GDI gasoline direct injection
  • DI direct injection
  • the present invention is directed to fuel injector nozzle structures (including, e.g., nozzle plates, valve guides, and combinations thereof) and fuel injectors using the nozzle structures.
  • GDI engines can, as compared to PFI engines, reduce or avoid fuel wall film in the manifold, improve accuracy of air/fuel ratio during dynamics, reduce throttling losses of the gas exchange by stratified and homogeneous lean operation. As a result, GDI engines may offer improvements in fuel efficiency and reduction of C02, and HC emissions.
  • the fuel injector nozzle structure is in the combustion chamber of the engine. Therefore, when the piston compresses the air/fuel mixture and the spark plug ignites it; a significant amount of heat is generated, which can have damaging effects on the nozzle structure.
  • the nozzle structure must be able to withstand the pressures generated in the combustion chamber, which can be as high as 200 bars.
  • the injector nozzle structures for GDI engines are typically thicker, making it more difficult to produce a high quality weld (e.g., a laser weld) of the nozzle structure onto the injector body, welding ring
  • the nozzle structures described herein may be operatively adapted (e.g., dimensioned, configured or otherwise designed) so as to strike a balance of the above needs.
  • laser welding of the welding ring of the nozzle structure to an injector body may be less likely to result in unacceptable deformation of the through-holes in the port region, both during welding and use in, e.g., a GDI engine.
  • Maintaining integrity of the through-holes during and after welding of the nozzle structure to an injector body may improve performance of the fuel injector as compared to fuel injectors with through-holes deformed as a result of laser welding of a nozzle structure.
  • one or more embodiments of the nozzle structures described herein may include a first face and a second face located on opposite sides of the nozzle structure, wherein the nozzle structure further comprises: a plurality of through-holes formed through the nozzle structure from the first face to the second face, wherein each through-hole of the plurality of through-holes comprises a first or inlet opening on the first face and a second or outlet opening on the second face; and a port region surrounded by a welding ring; wherein the port region contains the first and second openings of each through-hole of the plurality of through-holes; wherein the welding ring comprises an average welding ring thickness that comprises an average of the shortest distances between the first face and the second face of the nozzle structure as measured about a perimeter of the port region; wherein the shortest distance from the geometric center of the first opening of each of the through-holes to the second face of the nozzle structure is greater than the average welding ring thickness.
  • one or more embodiments of a fuel injector as described herein may include: an injector body comprising an opening; an injector valve comprising a valve sealing surface facing the opening, wherein the injector valve is movable in the injector body towards and away from the opening such that the valve sealing surface moves towards and away from the opening; and a nozzle structure attached to the injector body over the opening, wherein the nozzle structure comprises a first face and a second face, wherein the first face and the second face are located on opposite sides of the nozzle structure, and wherein only one of the first face and the second face faces the injector valve.
  • the nozzle structure further comprises: a plurality of through-holes formed through the nozzle structure from the first face to the second face, wherein each through-hole of the plurality of through-holes comprises a first or inlet opening on the first face and a second or outlet opening on the second face; and a port region surrounded by a welding ring, wherein the welding ring is attached to the injector body and the port region is suspended in the opening; wherein the port region contains the first and second openings of each through-hole of the plurality of through-holes; wherein the welding ring comprises an average welding ring thickness that comprises an average of the shortest distances between the first face and the second face of the nozzle structure as measured about a perimeter of the port region; wherein the shortest distance from the geometric center of the first opening of each of the through-holes to the second face of the nozzle structure is greater than the average welding ring thickness.
  • the port region of the first face of the nozzle structure comprises a continuously curved surface.
  • the port region of the second face of the nozzle structure comprises a continuously curved surface.
  • the port region of the first face of the nozzle structure comprises a flat surface.
  • the shortest distance from the geometric center of the first opening of each of the through- holes to the second face of the nozzle structure for all through-holes of the plurality of through-holes is the same.
  • the average welding ring thickness is 1 millimeter or less.
  • the shortest distance from the geometric center of the first opening of each of the through- holes to the second face of the nozzle structure is 2 millimeters or less.
  • the shortest distance from the geometric center of the first opening of each through hole of the plurality of through-holes to the second face of the nozzle structure is 100 micrometers or more.
  • each through-hole of the plurality of through-holes comprises a through-hole length measured from the geometric center of the first opening to a geometric center of the second opening along a centerline of the through-hole, wherein the centerline follows a geometric center of a cross-section of the through-hole, and wherein each through-hole of the plurality of through-holes comprises an average cross-sectional area measured transverse to the through-hole length, and further wherein an L/d ratio of the through-hole length to diameter of the average cross-sectional area for all of the through-holes of the plurality of through-holes is 0.1 or greater.
  • the plurality of through-holes in the nozzle structure are not deformed as a result of welding the welding ring to the injector body.
  • the face of the nozzle structure facing the injector valve comprises a nozzle sealing surface and wherein the injector valve comprises a valve sealing surface, wherein the nozzle sealing surface and the valve sealing surface seal the valve body when in contact with each other in the valve body.
  • one or more embodiments of a fuel injection system may include a plurality of the nozzle structures or a plurality of the fuel injectors as described herein.
  • one or more embodiments of methods of manufacturing a fuel injector nozzle as described herein may include: positioning a nozzle structure as described herein on an opening of a fuel injector body wherein the port region of the nozzle structure is suspended over the opening and the welding ring is in contact with the fuel injector body; and welding the nozzle structure to the injector body by directing laser energy at the welding ring.
  • the plurality of through-holes are not deformed after the welding.
  • the present invention is even further directed to fuel injection systems.
  • the fuel injection system comprises any one of the herein- disclosed nozzles or fuel injectors.
  • the fuel injection system of the present invention comprises a fuel injection system of a vehicle, wherein the fuel injection system comprises:
  • FIG. 1 is a side view of one embodiment of an exemplary nozzle structure as described herein in the form of a nozzle plate;
  • FIG. 2 is a plan view of the nozzle plate of FIG. 1;
  • FIG. 3 is a side view of another embodiment of an exemplary nozzle structure as described herein;
  • FIGS. 4 and 5 are plan views of opposing faces of the nozzle structure of FIG. 3;
  • FIG. 6 is a side view of another embodiment of an exemplary nozzle structure as described herein;
  • FIG. 7 is a plan view of another embodiment of an exemplary nozzle structure as described herein;
  • FIG. 8 is a side view of the nozzle structure of FIG. 7;
  • FIG. 9 is a side view of another embodiment of an exemplary nozzle structure as described herein;
  • FIG. 10 is a side view of another embodiment of an exemplary nozzle structure as described herein;
  • FIG. 11 is a side cross-sectional view of one embodiment of an exemplary nozzle structure as described herein in a fuel injector as described herein.
  • FIG. 12 is a schematic of one embodiment of an exemplary fuel injector system as described herein.
  • FIG. 13 is a schematic of one embodiment of an exemplary vehicle comprising a fuel injector system as described herein.
  • FIGS. 1 and 2 One embodiment of an exemplary nozzle structure in the form of a nozzle plate for a fuel injector comprising an injector valve as described herein is depicted in FIGS. 1 and 2.
  • the nozzle plate 10 includes a first or inlet face 12 and a second exterior face 14 located on opposite sides of the nozzle plate 10.
  • the nozzle plate 10 further includes a plurality of through-holes 20 formed through the nozzle plate 10 from the first face 12 to the second face 14.
  • Each through-hole 20 of the plurality of through-holes 20 includes a first or inlet opening 21 on the first face 12 and a second or outlet opening 22 on the second face 14 of the nozzle plate 10.
  • the nozzle plate 10 further includes a port region 16 surrounded by a welding ring 30.
  • the port region 16 on each of the first and face 12 and the second face 14 is the region of each respective face that contains all of the first and second openings 21 and 22 of each through-hole 20 of the plurality of through- holes 20 on that face.
  • the port region 16 of the first face 12 of nozzle plate 10 is the smallest continuous area on the first face 12 that contains all of the first openings
  • the port region 16 of the second face 14 of nozzle plate 10 is the smallest continuous area on the second face 14 that contains all of the second openings 22 of the through-holes 20.
  • the welding ring 30 has an average welding ring thickness 32 that comprises an average of the shortest distances between the first face 12 and the second face 14 of the nozzle plate 10 as measured about a perimeter of the port region 16. Further, the shortest distance from the geometric center of the first opening 21 of each of the through-holes 20 on the first face 12 to the second face 14 of the nozzle plate 10, represented by reference number 29 in FIG. 1, is greater than the average welding ring thickness 32.
  • the port region 16 contains at least the first and second openings 21 and
  • the nozzle structure may include a larger region of increased thickness as compared to the surrounding welding ring 30.
  • Nozzle plate 10 is one example of such a design because the port region 16 could be increased to include the entire thicker portion of the nozzle plate 10 that is surrounded by the thinner welding ring 30.
  • the port region 16 of the first face 12 of the nozzle plate 10 comprises a flat surface.
  • the port region 16 of the first face 12 and the port region 16 of the second face 14 are flat surfaces arranged parallel with each other.
  • nozzle plate 10 Another optional feature of the nozzle structures described herein found in nozzle plate 10 is that the shortest distance 29 from the geometric center of the first opening 21 of each of the through-holes 20 to the second face 14 of the nozzle plate 10 for all through- holes 20 of the plurality of through-holes 20 is the same.
  • Still another optional feature of the nozzle structures described herein found in nozzle plate 10 is that the shortest distance 29 from the geometric center of the first opening 21 of each of the through -holes 20 to the second face 14 of the nozzle plate 10 for any through-hole 20 of the plurality of through-holes 20 differs from an average of the shortest distances 29 of the plurality of through-holes 20 by no more than + 10% of the average.
  • the shortest distance from the geometric center of the first opening of each of the through-holes to the second face of the nozzle structure is 2 millimeters or less, or, alternatively, 1.2
  • the shortest distance from the geometric center of the first opening of each of the through- holes to the second face of the nozzle structure is 800 micrometers or less.
  • the shortest distance from the geometric center of the first opening of each through hole of the plurality of through-holes to the second face of the nozzle structure is 100 micrometers or more. In one or more embodiments of the nozzle structures described herein, the shortest distance from the geometric center of the first opening of each through hole of the plurality of through-holes to the second face of the nozzle structure is 200 micrometers or more. In one or more embodiments of the nozzle structures described herein, the shortest distance from the geometric center of the first opening of each through hole of the plurality of through-holes to the second face of the nozzle structure is 250 micrometers or more.
  • the average welding ring thickness 32 is 1 millimeter or less. In one or more embodiments of the nozzle structures described herein, the average welding ring thickness 32 is 500 micrometers or less.
  • the average welding ring thickness 32 is 100 micrometers or more. In one or more embodiments of the nozzle structures described herein, the average welding ring thickness 32 is 200 micrometers or more. In one or more embodiments of the nozzle structures described herein, the average welding ring thickness 32 is 250 micrometers or more.
  • each through-hole of the plurality of through-holes comprises a through-hole length measured from the geometric center of the first opening to a geometric center of the second opening along a centerline of the through-hole. The centerline follows a geometric center of a cross-section of the through-hole.
  • Each through-hole of the plurality of through-holes comprises an average L/d ratio along its length.
  • the average L/d ratio for all of the through-holes of the plurality of through-holes is, in one or more embodiments, 0.1 or greater. In one or more alternative embodiments, the average L/d ratio for all of the through-holes of the plurality of through- holes is 0.1 or greater, 0.2 or greater, 0.3 or greater, 0.4 or greater, 0.5 or greater, 0.6 or greater, 0.7 or greater, 0.8 or greater, 0.9 or greater, or 1.0 or greater.
  • the average L/d ratio may, in one or more embodiments, be 100 or less, 95 or less, 90 or less, 85 or less, 80 or less, 75 or less, 70 or less, 65 or less, 60 or less, 55 or less, 50 or less, 45 or less, 40 or less, 35 or less, 30 or less, 25 or less, 20 or less, 15 or less, 10 or less, or 5 or less.
  • the shortest distance from the geometric center of the first opening of each of the through-holes to the second face of the nozzle structure is greater than the average welding ring thickness.
  • a ratio of the shortest distance from the geometric center of the first opening of each of the through-holes to the second face of the nozzle structure to the average welding ring thickness is 100 or less, 95 or less, 90 or less, 85 or less, 80 or less, 75 or less, 70 or less, 65 or less, 60 or less, 55 or less, 50 or less, 45 or less, 40 or less, 35 or less, 30 or less, 25 or less, 20 or less, 15 or less, 10 or less, 5 or less, 4 or less, 3 or less, or 2 or less, but not as low as 1 or less than 1.
  • FIGS. 3-5 Another embodiment of an exemplary nozzle structure as described herein in the form of a nozzle plate is depicted in FIGS. 3-5.
  • the nozzle plate 110 includes a first face 112, second face 114, and welding ring 130.
  • the port region 116 is defined by a broken line on each of the first and second faces 112 and 114, although, as discussed herein, the port region 116 may encompass the portion of the nozzle plate 110 located within the inner boundary 134 of the welding ring 130.
  • the port region 116 may also be the smallest area that contains all of the openings on each face 112 and 114 of the nozzle plat 110.
  • the exemplary port region 116 of the second face 114 of the nozzle plate 110 comprises a continuously curved surface.
  • a "continuously curved surface" is a surface that does not include steps, shoulders, or other planar or ruled surfaces.
  • the nozzle plate 210 includes a first face 212, second face 214, and welding ring 230.
  • the port region of the first face 212 of the nozzle plate 210 comprises a continuously curved surface.
  • the second face 214 of the nozzle plate 210 also comprises a continuously curved surface.
  • FIGS. 7 and 8 Another embodiment of an exemplary nozzle structure as described herein in the form of a nozzle plate as described herein is depicted in FIGS. 7 and 8.
  • the nozzle plate 310 includes a first face 312, second face 314, and welding ring 330.
  • the port region of the second face 314 of the nozzle plate 310 containing the through-holes 320 comprises a continuously curved surface and a flat surface.
  • FIG. 9 Another embodiment of an exemplary nozzle structure as described herein in the form of a nozzle plate as described herein is depicted in FIG. 9.
  • the nozzle plate 410 includes a first face 412, second face 414, and welding ring 430.
  • the port region of the first face 412 of the nozzle plate 410 containing the openings of the through-holes 420 comprises a flat surface and the second face 414 containing the openings of the through- holes 420 comprises a continuously curved surface.
  • Counter-bores 424 formed in the through-holes 420 from the second face 414 of the nozzle plate 410.
  • Counter-bores such as, e.g., counter-bores 424, may be used to provide different characteristics in the fluid emitted from through-holes in nozzle plates as described herein.
  • nozzle plate 410 Also depicted in connection with nozzle plate 410 is a measurement indicating that the shortest distance 429 from the geometric center of the first opening 421 of a through- hole 420 on the first face 412 of the nozzle plate 410 to the second face 414 of the nozzle plate 410.
  • the illustrative embodiment depicted in FIG. 9 illustrates the concept that the shortest distance from the geometric center of the first opening 421 of through-hole 420 on the first face 412 of the nozzle plate 410 to the second face 414 of the nozzle plate 410 is not necessarily measured through the through-hole 420 itself. Rather, the measurement of distance 429 may be taken along a line that does not extend through the through-hole of the opening 421 from which it is measured.
  • the welding ring 430 of illustrative nozzle plate 410 has an average welding ring thickness 432 that comprises an average of the shortest distances between the first face 412 and the second face 414 of the nozzle plate 410 as measured about a perimeter of the port region.
  • the port region on each face 412 and 414 of the nozzle plate 410 would include the openings of the through-holes on that face.
  • the port region on the first face 412 of nozzle plate 410 is the smallest continuous area on the first face 412 that would contain the first openings 421 of through-holes 420.
  • the shortest distance from the geometric center of the first opening 421 of each of the through-holes 20 on the first face 412 to the second face 414 of the nozzle plate 410, represented by reference number 429 in FIG. 9, is greater than the average welding ring thickness 432.
  • FIG. 10 Still another embodiment of an exemplary nozzle structure as described herein in the form of a nozzle plate as described herein is depicted in FIG. 10.
  • the nozzle plate 510 includes a first face 512, second face 514, and welding ring 530.
  • the port region of the first face 512 of the nozzle plate 510 containing the openings 521a, 521b, and 521c of the through-holes 520a, 520b, and 520c (respectively) comprises a flat surface and the second face 514 containing the openings 522a, 522b, 522c, and 522c' of the through-holes 520a, 520b, and 520c comprises a continuously curved surface.
  • through holes 520a, 520b, and 520c have different features to illustrate the concept that nozzle structures as described herein may include through-holes that are different from each other in one or more respects.
  • through-hole 520a follows a curved path from the first face 512 to the second face 514 while through-hole 520b follows a straight path from the first face 512 to the second face 514.
  • through-hole 520c includes two openings 522c and 522c' at the second face 514.
  • the nozzle structures described herein may, in one or more embodiments, be used in fuel injectors of fuel injector systems.
  • One embodiment of an exemplary nozzle structure as described herein in the form of a nozzle plate 610 attached to an injector body 650 of a fuel injector is depicted in FIG. 11.
  • the injector body 650 comprises an opening 652, an injector valve 660 facing the opening 652.
  • the injector valve 660 is movable in the injector body 650 towards and away from the opening as indicated by the arrow located below the injector valve 660 such that the valve sealing surface 662 moves towards and away from the opening 652.
  • the embodiment of exemplary nozzle plate 610 depicted in FIG. 11 is attached to the injector body 650 over the opening 652.
  • the nozzle plate 610 comprises a first face 612 and a second face 614 located on opposite sides of the nozzle plate 610. Only one of the first face 612 and the second face 614 faces the injector valve 660. In the depicted embodiment, the first face 612 of the nozzle plate 610 faces the injector valve 660, although it should be understood that the second face 614 of the nozzle plate 610 could alternatively face the injector valve 660.
  • nozzle plate 610 includes a plurality of through-holes 620 formed through the nozzle plate 610 from the first face 612 to the second face 614, wherein each through-hole 620 comprises a first or inlet opening 621 on the first face 612 and a second or outlet opening 622 on the second face 614.
  • the port region i.e., the region containing the openings of the through-holes on the first and second faces 612 and 614
  • a welding ring 630 is suspended over the opening.
  • the welding ring 630 comprises an average welding ring thickness that comprises an average of the shortest distances between the first face 612 and the second face 614 of the nozzle plate 610 as measured about a perimeter of the port region. Further, the shortest distance from the geometric center of the first opening 621 of each of the through-holes 620 to the second face 614 of the nozzle plate 610 is greater than the average welding ring thickness.
  • the welding ring 630 is attached to the injector body 650.
  • the welding ring 630 and the injector body 650 are shown as being attached by a side weld 654 formed at the junction of the welding ring 630 and the injector body 650 on the side of the injector body 650.
  • Welding energy e.g., a laser beam, etc.
  • attachment of the nozzle plate 610 may be accomplished using a top weld 656 formed by directing energy at the second face 614 of the nozzle plate (e.g., in the direction of the arrow pointing at top weld 656).
  • the welding ring 630 of the nozzle plate 610 is thinner than the port region, the plurality of through-holes 620 in the nozzle plate 610 are not deformed as a result of welding the welding ring 630 to the injector body 650. In other words, the shapes and dimensions of the through-holes 620 are not changed after welding from their pre- welding shapes and dimensions.
  • the face of the nozzle plate 610 facing the injector valve 660 (first face 612 in the depicted embodiment) comprises a nozzle sealing surface 618 and the injector valve 660 comprises a valve sealing surface 662, wherein the nozzle sealing surface 618 and the valve sealing surface 662 seal the injector body 650 when in contact with each other in the injector body 650 such that fluid cannot pass through the through-holes of the nozzle plate 610.
  • any of the herein-described nozzle structures may further comprise one or more alignment surface features that enable (1) alignment of nozzle structure (i.e., in the x- y plane) relative to a fuel injector body and (2) rotational alignment/orientation of nozzle structure (i.e., a proper rotational position within the x-y plane) relative to a fuel injector body.
  • the one or more alignment surface features may aid in positioning nozzle structure and nozzle through-holes therein.
  • the one or more alignment surface features on nozzle structure may be present along one or both faces of the nozzle structure, the periphery of the nozzle structure, or any combination of one or both faces and the periphery of the nozzle structures.
  • the one or more alignment surface features on nozzle structure may comprise, but are not limited to, a visual marking, an indentation within nozzle structure, a raised surface portion along nozzle structure, or any combination of such alignment surface features.
  • the nozzle structures as described herein may include a port region and welding ring that are portions of a one-piece, completely integral article (e.g., a molded, electroformed, etc. article).
  • portions of the nozzle structures described herein may be manufactured as separate articles joined together using any suitable technique or combination of techniques, e.g., pressing (using interference fits), welding, adhesives, etc.
  • a plurality of the fuel injectors using the nozzle structures as described herein may be used in an engine such as, e.g., a GDI or a PFI engine.
  • an exemplary fuel injector system is depicted in FIG. 12.
  • the depicted fuel injector system may include, inter alia, a fuel injector 701 (incorporating one or more nozzle structures 710 as described herein), fuel source/tank 704, fuel pump 703, fuel filter 702, fuel injector electrical source 705, and internal combustion engine 706.
  • FIG. 13 is a schematic depicting the internal combustion engine 706 of FIG. 12 in a vehicle 800, wherein the internal combustion engine 706 includes one or more fuel injectors including one or more of the nozzle structures described herein.
  • the nozzle structures disclosed herein can be fabricated of any suitable weldable material or materials such as, e.g., silver, passivated silver, gold, rhodium, aluminum, enhanced reflectivity aluminum, copper, indium, nickel, chromium, tin, and alloys thereof.
  • the process of manufacturing the nozzle structures described herein may include the construction of molds using multiphoton, such as two photon, processes like those disclosed in International Patent Application Publications WO 2011/014607 and WO 2012/106512.
  • multiphoton processes can be used to fabricate various microstructures, which can at least include one or more hole forming features.
  • Such hole forming features can, in turn, be used as molds to fabricate through-holes for use in nozzle structures as described herein.
  • Microstructured articles are described herein that may, in one or more
  • nozzle structures including, e.g., nozzle plates, valve guides, nozzle plate and valve guide structures, and other structural combinations
  • nozzle structure including, e.g., nozzle plates, valve guides, nozzle plate and valve guide structures, and other structural combinations
  • nozzle structure may have a number of different meanings in the art.
  • U.S. Patent Publication No. 2009/0308953 Al discloses an "atomizing nozzle” which includes a number of elements, including an orifice insert 24 and an occluder chamber 50.
  • the understanding and definition of "nozzle structure” put forth herewith may, for example, include such structure like the orifice insert 24 of Palestrant et al.
  • the nozzle structure of the current description can be understood as including the structure of an atomizing spray system from which the spray is ultimately emitted, see e.g., Merriam Webster's dictionary definition of nozzle ("a short tube with a taper or constriction used (as on a hose) to speed up or direct a flow of fluid.” Further,
  • fluid injection "nozzle” is defined broadly as the multi-piece valve element 10 ("fuel injection valve 10 acting as fluid injection nozzle. . .” - see col. 4, lines 26-27 of Ogihara et al.).
  • nozzle structure as used herein would relate, e.g., to first and second orifice plates 130 and 132, valve body 26, and potentially sleeve 138 (see Figs.
  • nozzle structure Similar structures that may be referred to as "nozzle structure”, as described herein, is disclosed in U.S. Patent No. 5,127, 156 (Yokoyama et al.) to Hitachi, Ltd. (Ibaraki, Japan). There, the nozzle 10 is defined separately from elements of the attached and integrated structure, such as " swirl er" 12 (see Fig. 1). Such separate elements may be formed, in part or completely, as one unitary structure.
  • swirl er such as " swirl er" 12 (see Fig. 1).
  • Such separate elements may be formed, in part or completely, as one unitary structure.
  • the nozzle structures described herein may comprise (or consist essentially of or consist of) any one of the disclosed nozzle features or any combination of two or more of the disclosed nozzle features.
  • the nozzle structures described herein may further comprise one or more nozzle features disclosed in (1) International Patent Application Publication WO 2014/022646 ("GDI Fuel Injectors with Non-Coined Three-Dimensional Nozzle Outlet Face”); (2) International Patent Application Publication WO 2014/022624 ("Targeting of Fuel Output by Off- Axis Directing of Nozzle Output Streams"); (3) International Patent Application Publication WO 2014/022650 ("Fuel Injector Nozzles with at Least One Multiple Inlet Port and/or Multiple Outlet Port”); and (4) International Patent Application Publication WO 2014/022631 ("Fuel Injectors with Improved Coefficient of Fuel
  • nozzle structures described herein may be formed using any method as long as the resulting nozzle structures have one or more combinations of the features as described herein.
  • the methods of making nozzle structures as described herein are not limited to the methods disclosed in International Patent Publication No. WO 2012/106512, nozzle structures as described herein may be formed using the methods as disclosed in International Patent Publication No. WO 2012/106512 (see, in particular, the method steps described in reference to FIGS. 1 A-1M).
  • nozzle structures, fuel injectors and methods as discussed herein may be, in one or more embodiments, used in combination with the methods of manufacturing nozzle structures as discussed in and/or the nozzle structures described in the following copending applications: METHOD OF ELECTROFORMING MICROSTRUCTURED ARTICLES, U.S. Provisional Application No. 62/438,567, filed on December 23, 2016 (Attorney Docket No. 78371US002) and, MAKING NOZZLE STRUCTURES ON A STRUCTURED SURFACE, U.S. Provisional Application No. 62/438,561, filed on December 23, 2016 (Attorney Docket No. 77312US002).
  • a nozzle structure (e.g., a nozzle plate) comprising a first face and a second face located on opposite sides of the nozzle structure, wherein the nozzle structure further comprises:
  • each through-hole of the plurality of through-holes comprises a first opening on the first face and a second opening on the second face;
  • the port region contains the first and second openings of each through- hole of the plurality of through-holes
  • the welding ring comprises an average welding ring thickness that comprises an average of the shortest distances between the first face and the second face of the nozzle structure as measured about a perimeter of the port region;
  • a fuel injector comprising:
  • an injector body comprising an opening
  • an injector valve comprising a valve sealing surface facing the opening, wherein the injector valve is movable in the injector body towards and away from the opening such that the valve sealing surface moves towards and away from the opening;
  • a nozzle structure (e.g., a nozzle plate) attached to the injector body over the opening, wherein the nozzle structure comprises a first face and a second face, wherein the first face and the second face are located on opposite sides of the nozzle structure, and wherein only one of the first face and the second face faces the injector valve, wherein the nozzle structure further comprises:
  • each through-hole of the plurality of through-holes comprises a first opening on the first face and a second opening on the second face; and a port region surrounded by a welding ring, wherein the welding ring is attached to the injector body and the port region is suspended in the opening; wherein the port region contains the first and second openings of each through-hole of the plurality of through-holes;
  • the welding ring comprises an average welding ring thickness that comprises an average of the shortest distances between the first face and the second face of the nozzle structure as measured about a perimeter of the port region;
  • a nozzle structure or a fuel injector according to any one of embodiments 1 to 5 wherein the shortest distance from the geometric center of the first opening of each of the through-holes to the second face of the nozzle structure for any through-hole of the plurality of through-holes differs from an average of the shortest distances of the plurality of through-holes by no more than + 10% of the average.
  • a nozzle structure or a fuel injector according to any one of embodiments 1 to 7 wherein the port region of the first face and the port region of the second face are flat surfaces arranged parallel with each other.
  • a nozzle structure or a fuel injector according to any one of embodiments 1 to 8 wherein the average welding ring thickness is 1 millimeter or less, or 500 micrometers or less.
  • a nozzle structure or a fuel injector according to embodiment 9, wherein the average welding ring thickness is 100 micrometers or more, 200 micrometers or more, or 250 micrometers or more.
  • each through-hole of the plurality of through-holes comprises a through-hole length measured from the geometric center of the first opening to a geometric center of the second opening along a centerline of the through-hole, wherein the centerline follows a geometric center of a cross-section of the through-hole, and wherein each through-hole of the plurality of through-holes comprises an average cross-sectional area measured transverse to the through-hole length, and further wherein an L/d ratio of the through-hole length to diameter of the average cross-sectional area for all of the through-holes of the plurality of through-holes is 0.1 or greater , 0.2 or greater, or 0.3 or greater. 14.
  • a gasoline direct injection system comprising a plurality of the nozzle structures according to any one of embodiments 1 to 15 or a plurality of the fuel injectors according to any one of embodiments 2 to 19.
  • a vehicle comprising the gasoline direct injection system according to
  • a port fuel injection system comprising a plurality of the nozzle structures or a plurality of the fuel injectors according to any one of embodiments 1 to 15 or a plurality of the fuel injectors according to any one of embodiments 2 to 17.
  • a method comprising:
  • a nozzle structure according to any one of embodiments 1 to 17 on an opening of a fuel injector body wherein the port region of the nozzle structure is suspended over the opening and the welding ring is in contact with the fuel injector body;
  • nozzles, nozzle structures, fuel injectors, fuel injector systems, and methods are described as “comprising" one or more components, features or steps, the above-described nozzles, nozzle structures, fuel injectors, fuel injector systems, and methods may "comprise,” “consists of,” or “consist essentially of any of the above-described components and/or features and/or steps of the nozzles, nozzle structures, fuel injectors, fuel injector systems, and methods.
  • nozzle, nozzle structure, fuel injector, fuel injector system, and/or method that "comprises” a list of elements (e.g., components or features or steps) is not necessarily limited to only those elements (or components or features or steps), but may include other elements (or components or features or steps) not expressly listed or inherent to the nozzle, nozzle structure, fuel injector, fuel injector system, and/or method.
  • “consists of or “consisting of used in a claim would limit the claim to the components, materials or steps specifically recited in the claim except for impurities ordinarily associated therewith (i.e., impurities within a given component).
  • impurities ordinarily associated therewith i.e., impurities within a given component.
  • transitional phrases consist essentially of and “consisting essentially of are used to define a nozzle, nozzle structure, fuel injector, fuel injector system, and/or method that includes materials, steps, features, components, or elements, in addition to those literally disclosed, provided that these additional materials, steps, features, components, or elements do not materially affect the basic and novel
  • nozzles, nozzle structures, fuel injectors, fuel injector systems, and/or methods may comprise, consist essentially of, or consist of any of the herein- described components and features, as shown in the figures with or without any additional feature(s) not shown in the figures.
  • the nozzles, nozzle structures, fuel injectors, fuel injector systems, and/or methods of the present invention may have any additional feature that is not specifically shown in the figures.
  • the nozzles, nozzle structures, fuel injectors, fuel injector systems, and/or methods of the present invention do not have any additional features other than those (i.e., some or all) shown in the figures, and such additional features, not shown in the figures, are specifically excluded from the nozzles, nozzle structures, fuel injectors, fuel injector systems, and/or methods.

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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)
  • Fuel-Injection Apparatus (AREA)

Abstract

L'invention concerne des structures de buse d'injecteur de carburant, ainsi que des injecteurs de carburant, des systèmes d'injection, des moteurs et des véhicules utilisant les structures de buse. Les structures de buse comprennent une région d'orifice interne plus épaisse et une bague de soudage externe plus mince pour combattre la déformation inacceptable des trous traversants dans la région d'orifice, à la fois pendant le soudage et pendant l'utilisation.
PCT/IB2017/058168 2016-12-23 2017-12-19 Structures de buse avec bagues de soudage minces et injecteurs de carburant les utilisant WO2018116179A1 (fr)

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US201662438558P 2016-12-23 2016-12-23
US62/438,558 2016-12-23

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2019215642A1 (fr) 2018-05-09 2019-11-14 3M Innovative Properties Company Plaque de buse d'injecteur de carburant et guide de soupape

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US5127156A (en) 1989-09-25 1992-07-07 Hitachi, Ltd. Method for concentrically assembling a pair of cylindrical members and method for assembling a nozzle in a fuel injector
US5716009A (en) 1994-03-03 1998-02-10 Nippondenso Co., Ltd. Fluid injection nozzle
JP2004278464A (ja) * 2003-03-18 2004-10-07 Keihin Corp 燃料噴射弁
US20050040259A1 (en) * 2003-08-19 2005-02-24 Siemens Vdo Automotive Corporation Fuel injector with a deep pocket seat and method of maintaining spatial orientation
US20070095948A1 (en) * 2005-10-27 2007-05-03 Mitsubishi Denki Kabushiki Kaisha Fuel injection valve device
EP1998039A2 (fr) * 2007-05-31 2008-12-03 Hitachi Ltd. Injecteur de carburant et son procédé de réglage de course
US20090308953A1 (en) 2008-06-16 2009-12-17 Amfog Nozzle Technology, Inc. Atomizing nozzle
WO2011014607A1 (fr) 2009-07-30 2011-02-03 3M Innovative Properties Company Buse et procédé de fabrication
WO2012106512A2 (fr) 2011-02-02 2012-08-09 3M Innovative Properties Company Buse et son procédé de fabrication
WO2014022631A1 (fr) 2012-08-01 2014-02-06 3M Innovative Properties Company Injecteurs de carburant avec un coefficient de décharge de carburant amélioré
WO2014022650A1 (fr) 2012-08-01 2014-02-06 3M Innovative Properties Company Buses d'injecteur de carburant présentant au moins un port d'entrée multiple et/ou un port de sortie multiple
WO2014022646A1 (fr) 2012-08-01 2014-02-06 3M Innovative Properties Company Injecteurs de combustible ayant une face de sortie de buse non matricée en trois dimensions
WO2014022624A1 (fr) 2012-08-01 2014-02-06 3M Innovative Properties Company Ciblage d'une sortie de combustible en dirigeant en dehors de l'axe des jets de sortie de buse

Patent Citations (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5127156A (en) 1989-09-25 1992-07-07 Hitachi, Ltd. Method for concentrically assembling a pair of cylindrical members and method for assembling a nozzle in a fuel injector
US5716009A (en) 1994-03-03 1998-02-10 Nippondenso Co., Ltd. Fluid injection nozzle
JP2004278464A (ja) * 2003-03-18 2004-10-07 Keihin Corp 燃料噴射弁
US20050040259A1 (en) * 2003-08-19 2005-02-24 Siemens Vdo Automotive Corporation Fuel injector with a deep pocket seat and method of maintaining spatial orientation
US20070095948A1 (en) * 2005-10-27 2007-05-03 Mitsubishi Denki Kabushiki Kaisha Fuel injection valve device
EP1998039A2 (fr) * 2007-05-31 2008-12-03 Hitachi Ltd. Injecteur de carburant et son procédé de réglage de course
US20090308953A1 (en) 2008-06-16 2009-12-17 Amfog Nozzle Technology, Inc. Atomizing nozzle
WO2011014607A1 (fr) 2009-07-30 2011-02-03 3M Innovative Properties Company Buse et procédé de fabrication
WO2012106512A2 (fr) 2011-02-02 2012-08-09 3M Innovative Properties Company Buse et son procédé de fabrication
WO2014022631A1 (fr) 2012-08-01 2014-02-06 3M Innovative Properties Company Injecteurs de carburant avec un coefficient de décharge de carburant amélioré
WO2014022650A1 (fr) 2012-08-01 2014-02-06 3M Innovative Properties Company Buses d'injecteur de carburant présentant au moins un port d'entrée multiple et/ou un port de sortie multiple
WO2014022646A1 (fr) 2012-08-01 2014-02-06 3M Innovative Properties Company Injecteurs de combustible ayant une face de sortie de buse non matricée en trois dimensions
WO2014022624A1 (fr) 2012-08-01 2014-02-06 3M Innovative Properties Company Ciblage d'une sortie de combustible en dirigeant en dehors de l'axe des jets de sortie de buse

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2019215642A1 (fr) 2018-05-09 2019-11-14 3M Innovative Properties Company Plaque de buse d'injecteur de carburant et guide de soupape

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