Fuel system having a connection between a fuel injector and a fuel distribution conduit

Abstract

A fuel system includes a fuel injector having an inlet conduit which extends along an inlet conduit axis and has an inlet conduit shoulder which is travers to the inlet conduit axis. A fuel distribution conduit supplies fuel to the fuel injector, extends along a fuel distribution conduit axis, and has external threads which threadably engage internal threads of a connection nut. A retention member is a segment of an annulus and includes a central passage extending axially therethrough and external threads which threadably engage the internal threads of the connection nut. The retention member is terminated in a direction circumferentially about the fuel distribution conduit axis by first and second end surfaces which together form a retention member slot therebetween sized to permit the inlet conduit to pass therethrough in a direction perpendicular to the fuel distribution conduit axis.

Claims

1. A fuel system for supplying fuel to a fuel consuming device, said fuel system comprising: a fuel injector having a fuel injector inlet conduit, a nozzle opening, and a valve needle which is moveable to selectively permit and prevent flow of fuel from said fuel injector inlet conduit through said nozzle opening, said fuel injector inlet conduit extending along a fuel injector inlet conduit axis and said fuel injector inlet conduit having a fuel injector inlet conduit shoulder which is travers to said fuel injector inlet conduit axis; a fuel distribution conduit which supplies fuel to said fuel injector, said fuel distribution conduit extending along a fuel distribution conduit axis and having fuel distribution conduit external threads thereon; a connection nut having connection nut internal threads which are complementary to, and are threadably engaged with, said fuel distribution conduit external threads; and a retention member which is a segment of an annulus and which includes a retention member central passage extending axially therethrough, said retention member being terminated in a direction circumferentially about said fuel distribution conduit axis by a retention member first end surface and by a retention member second end surface which together form a retention member slot therebetween which is sized so as to permit said fuel injector inlet conduit to pass therethrough in a direction perpendicular to said fuel distribution conduit axis, said retention member having retention member external threads thereon which are complementary to, and are threadably engaged with, said connection nut internal threads, wherein said retention member engages said fuel injector inlet conduit shoulder such that tightening of said connection nut to said fuel distribution conduit causes a fuel-tight connection between said fuel injector and said fuel distribution conduit.

2. A fuel system as in claim 1, wherein said retention member first end surface and said retention member second end surface are parallel to each other.

3. A fuel system as in claim 1, wherein said retention member slot extends from a retention member outer peripheral surface of said retention member to a retention member inner peripheral surface of said retention member.

4. A fuel system as in claim 1, wherein said retention member extends axially from a retention member upper end surface to a retention member lower end surface and said retention member includes a retention member mating surface which engages said fuel injector inlet conduit.

5. A fuel system as in claim 4, wherein said retention member includes a retention member shoulder which is travers to said fuel distribution conduit axis and which extends outward from said retention member external threads in a direction outward from said fuel distribution conduit axis such that said retention member external threads extend from said retention member upper end surface to said retention member shoulder.

6. A fuel system as in claim 5, wherein: said connection nut extends from a connection nut upper end which is distal from said nozzle opening to a connection nut lower end which is proximal to said nozzle opening; and said connection nut lower end engages said retention member shoulder.

7. A fuel system as in claim 4, wherein said retention member mating surface is complementary to said fuel injector inlet conduit shoulder such that angular misalignment between said fuel injector inlet conduit and said fuel distribution conduit is accommodated while retaining said fuel injector.

8. A fuel system as in claim 7, wherein said retention member mating surface is a segment of a frustum.

9. A fuel system as in claim 1, wherein: said fuel injector inlet conduit includes a fuel injector inlet conduit sealing surface; said fuel distribution conduit includes a fuel distribution conduit sealing surface; and tightening of said connection nut to said fuel distribution conduit causes said fuel injector inlet conduit sealing surface and said fuel distribution conduit sealing surface to be sealingly compressed against each other to form an interface such that fuel passing from said fuel distribution conduit to said fuel injector inlet conduit does not leak past said interface.

10. A fuel system as in claim 1, wherein said retention member central passage is sized so as to allow angular misalignment between said fuel injector and said fuel distribution conduit.

11. A fuel system as in claim 1, wherein said retention member external threads are interrupted in a direction circumferentially about said fuel distribution conduit axis by said retention member slot.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) This invention will be further described with reference to the accompanying drawings in which:

(2) FIG. 1 is a schematic view of a fuel system in accordance with the present disclosure;

(3) FIG. 2 is an isometric view of a fuel rail with fuel injectors in accordance with the present disclosure;

(4) FIG. 3 is an exploded isometric view of the fuel rail, fuel injector, and an arrangement which secures the fuel injector to the fuel rail;

(5) FIG. 4 is an axial cross-sectional view of the fuel rail, fuel injector, and arrangement which secures the fuel injector to the fuel rail;

(6) FIG. 5 is an enlarged view of circle V of FIG. 4;

(7) FIG. 6 is an enlarged view of circle VI of FIG. 4;

(8) FIGS. 7-9 show a progression of steps of assembly; and

(9) FIG. 10 is an enlarged isometric view of a retention member of FIG. 3.

DETAILED DESCRIPTION OF INVENTION

(10) Referring initially to FIG. 1, a fuel system 10 is shown in simplified schematic form for supplying fuel to a fuel consuming device, for example an internal combustion engine 12, by way of non-limiting example only, for a motor vehicle. Fuel system 10 includes a fuel tank 14 for storing a volume of fuel, a low-pressure fuel pump 16 which may be located within fuel tank 14 as shown, a high-pressure fuel pump 17 which receives fuel from low-pressure fuel pump 16, a fuel rail 18 attached to internal combustion engine 12 and in fluid communication with high-pressure fuel pump 17, and a plurality of fuel injectors 20 in fluid communication with fuel rail 18. In operation, low-pressure fuel pump 16 draws fuel from fuel tank 14 and pumps the fuel to high-pressure fuel pump 17 under relatively low pressure, for example about 500 kPa. High-pres sure fuel pump 17, which may be a piston pump operated by a cam of internal combustion engine 12, further pressurizes the fuel and supplies the fuel to fuel rail 18 under relatively high pressure, for example, above about 14 MPa and even reaching 35 MPa or higher. Each fuel injector 20 receives fuel from fuel rail 18 and injects the fuel into a respective combustion chamber 22 of internal combustion engine 12 for combustion of the fuel within combustion chambers 22.

(11) Referring now to FIGS. 4 and 5, fuel injector 20, the internal workings of which are shown in schematic form only in FIG. 4, includes a fuel injector body 24 which is configured to be inserted into a fuel injector receiving bore of a cylinder head 26 of internal combustion engine 12 such that a nozzle tip 28 of fuel injector body 24 communicates with combustion chamber 22 and includes one or more nozzle openings 30 therein from which fuel is selectively discharged from fuel injector 20 into combustion chamber 22. The discharge of fuel from nozzle openings 30 is controlled by a valve needle 32 located within fuel injector body 24 where valve needle 32 is selectively seated with a valve seat 34 (valve needle 32 being shown in solid lines in FIG. 5) to stop discharge of fuel through nozzle openings 30 and is selectively unseated with valve seat 34 (valve needle 32 being shown in phantom lines in FIG. 5) to discharge fuel from fuel injector 20 into combustion chamber 22. Movement of valve needle 32 is controlled by an actuator 36, illustrated herein as a solenoid actuator. As embodied herein, actuator 36 includes a wire winding 38, a pole piece 40 which is stationary, an armature 42 which is moveable with valve needle 32, and a return spring 44 which urges valve needle 32 in a direction to be seated with valve seat 34. When wire winding 38 is energized with an electric current, armature 42 is magnetically attracted to pole piece 40, thereby unseating valve needle 32 from valve seat 34. Conversely, when the electric current to wire winding 38 is stopped, the magnetic attraction between armature 42 and pole piece 40 is stopped, thereby allowing return spring 44 to move valve needle 32 to be seated with valve seat 34. While actuator 36 has been illustrated herein as a solenoid actuator, it should be understood that actuator 36 may take other forms, which may be, by way of non-limiting example only, a piezoelectric actuator. Furthermore, while actuator 36 has been illustrated as directly actuating valve needle 32, it should be understood that actuator 36 may be indirectly acting such that the actuator may be used to control fuel pressure in a control chamber such that the fuel pressure in the control chamber affects the position of valve needle 32. Fuel injector 20 includes a fuel injector inlet conduit 50 which receives fuel from fuel rail 18 for selective injection into combustion chamber 22 such that fuel injector inlet conduit 50 is configured to sealingly mate with fuel rail 18 as will be described in greater detail later. Fuel injector inlet conduit 50 is made of a metal material, and may preferably be stainless steel in order to minimize or prevent corrosion due to contact with corrosive fuels such as gasoline.

(12) Now with reference to FIGS. 2-10, fuel rail 18 includes a fuel rail main conduit 54 which extends along a fuel rail main conduit axis 54a. Fuel rail main conduit 54 is tubular, thereby defining a main fuel passage 56 therein which receives high-pressure fuel from high-pressure fuel pump 17. Fuel rail 18 also includes a plurality of fuel distribution conduits 58, one for each fuel injector 20, extending away from fuel rail main conduit 54. Each fuel distribution conduit 58 is substantially identical, and consequently, fuel distribution conduit 58 and respective elements interfacing therewith for making connection to a respective fuel injector 20 will be referred to in singular form with the understanding that the description applies equally to the connections to each fuel injector 20. Fuel distribution conduit 58 extends away from fuel rail main conduit 54 along a fuel distribution conduit axis 58a which is preferably perpendicular to fuel rail main conduit axis 54a. Fuel distribution conduit axis 58a for each fuel distribution conduit 58 is preferably parallel to every other fuel distribution conduit axis 58a of every other fuel distribution conduit 58 of fuel rail 18. Fuel distribution conduit 58 includes a distribution passage 60 extending therethrough which is in fluid communication with main fuel passage 56 and is also in fluid communication with fuel injector inlet conduit 50. In this way, fuel is communicated from main fuel passage 56 to fuel injector inlet conduit 50 via distribution passage 60 for injection of fuel into combustion chamber 22. Fuel rail 18 (including fuel rail main conduit 54 and fuel distribution conduit 58) is made of a metal material, and may preferably be stainless steel in order to minimize or prevent corrosion due to contact with corrosive fuels such as gasoline.

(13) An outer periphery of fuel distribution conduit 58 includes fuel distribution conduit external threads 62 thereon. Furthermore, fuel distribution conduit 58 includes a fuel distribution conduit sealing surface 64 which mates with fuel injector inlet conduit 50 to provide a fuel-tight seal therebetween which prevents fuel leakage as will be described in greater detail later. As illustrated herein, fuel distribution conduit sealing surface 64 may be frustoconical in shape and concave in nature, however, may alternatively be other shapes such as frustospherical or convex in nature.

(14) Fuel injector inlet conduit 50 is tubular and extends along a fuel injector inlet conduit axis 50a which is nominally coincident with fuel distribution conduit axis 58a and is shown as such in the figures, however, some angular or lateral misalignment may be accommodated by the connection arrangement used to connect fuel injector inlet conduit 50 to fuel distribution conduit 58. Fuel injector inlet conduit 50 extends along fuel injector inlet conduit axis 50a from a first end 50b which is most-distal from nozzle openings 30, i.e. first end 50b is the furthest-most portion of fuel injector inlet conduit 50 from nozzle openings 30. Fuel injector inlet conduit 50 includes a fuel injector inlet conduit shoulder 50c which is traverse to fuel injector inlet conduit axis 50a and faces in a direction away from first end 50b. Fuel injector inlet conduit shoulder 50c is formed by an area of reduced diameter which is spaced axially away from first end 50b. Furthermore, fuel injector inlet conduit shoulder 50c may be radiused as shown at its radially outward extent. Fuel injector inlet conduit 50 also includes a fuel injector inlet conduit sealing surface 50d which mates with fuel distribution conduit sealing surface 64. As illustrated herein, fuel injector inlet conduit sealing surface 50d is a radiused corner initiating at first end 50b, however, fuel injector inlet conduit sealing surface 50d may be any shape which complements fuel distribution conduit sealing surface 64 to mate in a fluid-tight interface and allows angular misalignment between fuel injector 20 and fuel distribution conduit 58.

(15) In order to sealingly compress together fuel injector inlet conduit sealing surface 50d and fuel distribution conduit sealing surface 64, fuel system 10 includes a connection nut 66 and a retention member 68. In the paragraphs that follow, the features of connection nut 66 and retention member 68 will be described in greater detail.

(16) Connection nut 66 is made of a metal material and includes a connection nut upper portion 66a which circumferentially surrounds fuel distribution conduit 58 and a connection nut lower portion 66b which circumferentially surrounds fuel injector inlet conduit 50 such that connection nut 66 extends from a connection nut upper end 66c which is distal from nozzle openings 30 to a connection nut lower end 66d which is proximal to nozzle openings 30. Connection nut 66 includes a connection nut central passage 66e extending axially therethrough from connection nut upper end 66c to connection nut lower end 66d. Connection nut 66 includes connection nut internal threads 66f within connection nut central passage 66e such that connection nut internal threads 66f extend from connection nut upper end 66c to connection nut lower end 66d, preferably uninterrupted as shown in the figures. Connection nut internal threads 66f are complementary to, and are threadably engaged with, fuel distribution conduit external threads 62. On the outer periphery of connection nut upper portion 66a, a connection nut holding feature 66g is provided which is configured to engage a tool (not shown), for example a wrench for use when tightening connection nut 66 to retention member 68 and to fuel distribution conduit 58. While connection nut holding feature 66g is illustrated as being located on connection nut upper portion 66a, it should be understood that connection nut holding feature 66g may alternatively be located on connection nut lower portion 66b. Furthermore, while connection nut holding feature 66g has been illustrated as a hex-shaped feature, it should be understood that connection nut holding feature 66g may alternatively be any shape or pattern commonly used to engage a tool which is used for tightening a threaded interface.

(17) Retention member 68 is preferably made of a metal material, and as may be most apparent from FIGS. 3 and 10, retention member 68 is a segment of an annulus having a retention member central passage 68a extending axially therethrough. As a result of retention member 68 being a segment of an annulus, retention member 68 includes a retention member inner peripheral surface 68b and a retention member outer peripheral surface 68c. As illustrated in the figures, retention member inner peripheral surface 68b may be circular in shape in a direction perpendicular to fuel distribution conduit axis 58a such that retention member inner peripheral surface 68b is centered about fuel distribution conduit axis 58a. As used herein with respect to retention member inner peripheral surface 68b, circular is not a full circle, but rather a portion of a circle having a constant radius. Retention member 68 is terminated in a direction circumferentially about fuel distribution conduit axis 58a by a retention member first end surface 68d and by a retention member second end surface 68e which together form a retention member slot 68f therebetween which extends from retention member outer peripheral surface 68c to retention member inner peripheral surface 68b. Retention member slot 68f is sized so as to permit the portion of fuel injector inlet conduit 50 that is below fuel injector inlet conduit shoulder 50c to pass through retention member slot 68f in a direction perpendicular to fuel distribution conduit axis 58a. As shown in the figures, retention member first end surface 68d and retention member second end surface 68e may each be planar and parallel to each other such that retention member first end surface 68d faces toward retention member second end surface 68e. It should be noted that retention member first end surface 68d and retention member second end surface 68e need only be spaced apart from each other to an extent which allows fuel injector inlet conduit 50 to pass therebetween to be positioned within retention member central passage 68a.

(18) Retention member 68 extends axially from a retention member upper end surface 68g, which is proximal to fuel rail main conduit 54, to a retention member lower end surface 68h which is distal from fuel rail main conduit 54. As illustrated in the figures, retention member upper end surface 68g may be perpendicular to fuel distribution conduit axis 58a. Similarly, retention member lower end surface 68h may be perpendicular to fuel distribution conduit axis 58a. Retention member 68 includes a retention member mating surface 68i which extends from retention member inner peripheral surface 68b to retention member upper end surface 68g. Retention member mating surface 68i is travers to fuel distribution conduit axis 58a and may have a shape which is complementary to fuel injector inlet conduit shoulder 50c, for example, a segment of a conical frustum or a segment of a spherical frustum, thereby providing for retention of fuel injector 20 while allowing for angular misalignment between fuel injector 20 and fuel distribution conduit 58. Accommodation of angular misalignment between fuel injector 20 and fuel distribution conduit 58 is also provided by retention member central passage 68a being sized sufficiently large to accommodate this misalignment. As can be seen in the figures, retention member mating surface 68i is inclined relative to both retention member inner peripheral surface 68b and retention member upper end surface 68g.

(19) An outer periphery of retention member 68 includes retention member external threads 68j which extend from retention member upper end surface 68g to a retention member shoulder 68k which is travers to fuel distribution conduit axis 58a and which extends outward from retention member external threads 68j and in a direction outward from fuel distribution conduit axis 58a. Retention member external threads 68j are interrupted in a direction circumferentially about fuel distribution conduit axis 58a and are complementary to, and are threadably engaged with connection nut internal threads 66f. Retention member shoulder 68k may be perpendicular to fuel distribution conduit axis 58a as illustrated in the figures, or may alternatively be oblique to fuel distribution conduit axis 58a. The outer periphery of retention member 68 also includes a retention member holding feature 681 which is configured to engage a tool (not shown), for example a wrench, for use when tightening connection nut 66 to retention member 68.

(20) Assembly of fuel injector 20 to fuel rail 18 will now be described. In a first step as shown in FIGS. 7 and 8, retention member 68 is assembled to fuel injector by translating retention member 68 laterally, preferably perpendicular, relative to fuel injector inlet conduit axis 50a in a direction indicated by arrow 70 in FIG. 7. As retention member 68 is moved in the direction of arrow 70, a portion of retention member mating surface 68i becomes positioned below fuel injector inlet conduit shoulder 50c such that a portion of retention member mating surface 68i is axially aligned, i.e. in a direction parallel to fuel distribution conduit axis 58a, with fuel injector inlet conduit shoulder 50c as shown in FIG. 8. Next as shown in FIGS. 8 and 9, connection nut 66 is assembled to retention member 68 by moving connection nut 66 toward retention member 68 along fuel distribution conduit axis 58a to allow connection nut internal threads 66f and retention member external threads 68j to engage with each other. Connection nut 66 and/or retention member 68 are then rotated about fuel distribution conduit axis 58a until connection nut lower end 66d engages retention member shoulder 68k as a result of the threaded engagement. In this way, connection nut 66 and retention member 68 are tightened to each other where it should be noted that connection nut holding feature 66g and retention member holding feature 681 may be used in connection with complementary wrenches to assist in the tightening. Next, connection nut 66 is threaded onto fuel distribution conduit 58 and is tightened, as shown in FIG. 6, thereby resulting in fuel distribution conduit sealing surface 64 and fuel injector inlet conduit sealing surface 50d to be sealingly compressed against each other to form an interface such that fuel passing from fuel distribution conduit 58 to fuel injector inlet conduit 50 does not leak past the interface, i.e. the fuel cannot leak to the environment and the fuel is contained within fuel distribution conduit 58 and fuel injector inlet conduit 50 until being deliberately released from fuel injector 20 through nozzle openings 30.

(21) While fuel distribution conduit 58 has been embodied herein as being an integral and unitary element with fuel rail 18, it should be understood that fuel distribution conduit 58 may alternatively be a pipe that is formed independent of fuel rail 18 and sealed thereto. In a further alternative, fuel distribution conduit 58 may be a supply conduit which is not connected to a fuel rail, but rather receives fuel directly from a fuel pump.

(22) Use of connection nut 66 and retention member 68 as disclosed herein to connect fuel injector 20 to fuel rail 18 provides for robust sealing at ever-increasing pressures while providing simple construction. This arrangement may also allow for minimal design change to existing fuel injector designs, which had previously used convention elastomer O-rings to achieve sealing, to be changed to a metal-to-metal sealing interface. Such design change may be limited to altering the outer profile of fuel injector inlet conduit 50. Consequently, minimal manufacturing equipment change may be required to change the fuel injector design to accommodate a metal-to-metal sealing interface.

(23) While the invention has been described by reference to various specific embodiments, it should be understood that numerous changes may be made within the spirit and scope of the inventive concepts described. Accordingly, it is intended that the invention not be limited to the described embodiments, but rather only to the extent set forth in the claims that follow.