Fluid sprinkling – spraying – and diffusing – Processes – Of fuel injection
Reexamination Certificate
1999-12-28
2001-03-20
Douglas, Lisa Ann (Department: 3752)
Fluid sprinkling, spraying, and diffusing
Processes
Of fuel injection
C239S463000, C239S533120, C239S585100, C239S596000, C251S129150
Reexamination Certificate
active
06202936
ABSTRACT:
FIELD OF INVENTION
This invention relates to fuel injectors in general and particularly high-pressure, direct-injection fuel injectors. More particularly, high-pressure, direct-injection fuel injectors having a swirl generator within the body of the fuel injector.
BACKGROUND OF THE INVENTION
It is known in the art relating to high-pressure direct injection fuel injectors to have a swirl generator and needle guide positioned proximate a seat in a body. In known systems, seat, swirl generator, and needle guide combinations include a plurality of structural members. For example, commonly assigned U.S. Pat. No. 5,875,972 discloses two separate flat disks adjacent a seat to provide a swirl generator and a needle guide. The flat disks are thin sheet metal members that are believed to produce minimal drag on the needle of the fuel injector. To assemble this arrangement of the seat, swirl generator, and needle guide seat combination requires each of the three components to be sequentially aligned and laser welded together. Due to the numerous individual assembly steps required, misalignments could occur with the multiple components.
Another manufacturing difficulty that could result from the three components used to form the seat, swirl generator, and needle guide combination is the need to develop new assembly steps for changes in the swirl disk configuration. The three component combination employs an individual flat swirl disk, between a flat guide disk and a seat as the swirl generator. Changes in swirl disk thickness size due to varying fuel swirl requirements for selected direct fuel injection applications requires the assembly steps to be reconfigured. A known two component seat, swirl generator, and needle guide combination, described above has been developed that addresses some of the assembly difficulties of the three component combination. Although some of the assembly difficulties the three component combination may have been overcome, the two components must be oriented during assembly. In addition, the swirl generator and needle guide component employed in known two component combination is believed to create a large drag point for the employed needle. Thus, there is a need for a two component seat, swirl generator, and needle guide combination that eliminates the need to orient the components and minimizes drag forces applied to the needle valve.
SUMMARY OF THE INVENTION
The present invention provides the fuel injector having a body, an armature, a needle, a seat, a flat disk that provides a needle guide and a swirl generator. The body has an inlet portion, an outlet portion and a body passage extending from the inlet portion to the outlet portion along a longitudinal axis. The armature proximate the inlet portion of the body. The needle valve is operatively connected to the armature. The seat is located proximate the outlet portion of the body. The valve seat includes a first seat surface, a second seat surface, a seat passage extending between the first seat surface and the second seat surface in the direction of the longitudinal axis. The flat disk is located proximate the first surface of the seat. The flat disk includes a first disk surface, a second disk surface, a guide aperture extending between the first disk surface and the second disk surface. At least one fuel passage opening extends between the first disk surface and the second disk surface. The flat disk includes a swirl generator formed in the second disk surface that communicates with the at least one fuel opening and the passage of the seat.
In a preferred embodiment, the swirl generator has at least one channel that extends from the at least one fuel passage opening toward the guide aperture. The at least one channel extends substantial tangent to a periphery of the guide passage. The at least one channel comprises a plurality of channels uniformly disposed about the guide aperture. The at least one fuel passage comprises a plurality of fuel passages disposed about axis of the guide aperture. The flat disk has a substantially circular circumferential surface engaging the first seat surface and the second seat surface; and the plurality of fuel passages are located between the axis of the guide aperture and the circumferential surface of the flat disk. The at least one channel has a plurality of channels. One of the plurality of channel corresponds to one of the plurality of fuel passage opening and the guide aperture.
The present invention also provides a flat disk for a fuel injector. The flat disk provides a guide for a needle of the fuel injector and an arrangement to swirl fuel on a seat. The flat disk has a first disk surface, an outer circumference engaging the first disk surface, and a second disk surface engaging the outer circumference. A guide aperture extends between the first disk surface and the second disk surface. The guide aperture has a central axis. A plurality of fuel passages extend between the first disk surface and the second disk surface. A swirl generator formed in the second disk surface that communicates with the guide aperture.
In a preferred embodiment, the swirl generator has a plurality of channels. Each of the plurality of channels corresponds to one of the plurality of fuel passage openings. Each of the plural of channels is substantial tangent to a periphery of the guide aperture, and is laser machined in the second disk surface.
The present invention further provides a method of forming a seat, swirl generator, and needle guide combination. This method is achieved by providing a flat disk with a first disk surface, a second disk surface, and a guide passage and plurality of flue passage opening each extending between the first disk surface and the second disk surface; forming a swirl generator in the second disk surface that communicates with the guide aperture; locating the flat disk on a first seat surface of the seat; and securing the flat disk to the seat.
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Geometrical Effects on Flow Characteristics of Gasoline High Pressure Direct Injecter, W.M. Ren, J. Shen, J.F. Nally Jr., p. 1-7, (97FL-95), (No Date).
Douglas Lisa Ann
Siemens Automotive Corporation
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