Injector for a combustion engine

Abstract

An injector for a combustion engine may include a valve housing, a valve needle, an electromagnetic actuator, and a damping element. The valve needle may be axially movable within a valve cavity of the housing. The electromagnetic actuator may comprise a pole piece coupled with the valve housing and an armature axially movable within the valve cavity. The pole piece may have a central recess extending axially there through. The central recess may include a step defining a first portion and a second portion, the first having a larger cross-sectional area than the second, and a stop surface defined by a radially extending surface of the step. The valve needle may include an armature retainer in the first portion of the central recess. The armature may be axially displaceable with respect to the valve needle and interact with the valve needle by means of the retainer for actuating the valve needle. The damping element may be arranged between the stop surface and the armature retainer to interact with the valve needle and the pole piece during movement.

Claims

1. An injector for a combustion engine, the injector comprising: an injection valve housing with an injection valve cavity, a valve needle axially movable within the injection valve cavity, an electromagnetic actuator assembly comprising a pole piece fixedly coupled with respect to the injection valve housing in the injection valve cavity and an armature axially movable within the injection valve cavity, and a damping element comprising a viscoelastic material, wherein the damping element is axially compressed by and seated on opposing surfaces of a stop surface of the pole piece and an armature retainer fixed to the valve needle to resist nearing movement between the valve needle and the pole piece, wherein the pole piece has a central recess extending axially through the pole piece, and the central recess includes a step defining a first portion and a second portion, the first portion having a larger cross-sectional area than the second portion, the stop surface defined by a radially extending surface of the step of the central recess, the armature retainer disposed at least partially in the first portion of the central recess of the pole piece, the armature is axially displaceable with respect to the valve needle and operable to interact mechanically with the valve needle by means of the armature retainer for actuating the valve needle.

2. The injector according to claim 1, further comprising the damping element arranged inside the injection valve cavity, and wherein the damping element is disposed to abut the stop surface of the pole piece.

3. The injector according to claim 2, further comprising the stop surface disposed at an inner surface of the pole piece.

4. The injector according to claim 1, further comprising the damping element axially fixed with respect to the pole piece.

5. The injector according to claim 1, further comprising the damping element providing mass damping during movement of the valve needle towards the stop surface of the pole piece.

6. The injector according to claim 5, wherein the mass damping is provided for more than the final 20 m of movement of the valve needle towards the stop surface of the pole piece.

7. The injector according to claim 5, wherein the movement of the valve needle towards the stop surface of the pole piece relates to an opening of the injector.

8. The injector according to claim 1, wherein an armature movement towards the pole piece within the injection valve cavity is transferred to the valve needle during an opening of the injector.

9. The injector according to claim 1, wherein the damping element comprises an O-ring.

10. The injector according to claim 1, wherein the damping element comprises a material adapted for a temperature range between 40 C. and +150 C.

11. An internal combustion engine comprising: a combustion chamber; and a fuel injector dosing fuel into the combustion chamber, the fuel injector comprising: a housing with a valve cavity and a longitudinal axis; a valve needle moving axially within the valve cavity; a pole piece fixedly to the housing within the valve cavity; an armature moving axially within the valve cavity; a central recess extending axially through the pole piece, the central recess including a step defining a first portion and a second portion, the first portion having a larger cross-sectional area than the second portion; a stop surface disposed on the pole piece defined by a radially extending surface of the step; an armature retainer disposed on the valve needle and at least partially positioned in the first portion of the central recess; and a damping element comprising a viscoelastic material, wherein the damping element is axially compressed by and seated on opposing surfaces of the stop surface of the pole piece and the armature retainer fixed to the valve needle to resist a nearing movement between the valve needle and the pole piece; wherein the armature moves axially with respect to the valve needle and interacts mechanically with the valve needle by means of the armature retainer for actuating the valve needle.

12. The internal combustion engine according to claim 11, further comprising the damping element arranged inside the valve cavity, and wherein the damping element is disposed to abut the stop surface of the pole piece.

13. The internal combustion engine according to claim 12, further comprising the stop surface disposed at an inner surface of the pole piece.

14. The internal combustion engine according to claim 11, further comprising the damping element axially fixed with respect to the pole piece.

15. The internal combustion engine according to claim 11, further comprising the damping element providing mass damping during movement of the valve needle towards the stop surface of the pole piece.

16. The internal combustion engine according to claim 15, wherein the mass damping is provided for more than the final 20 m of movement of the valve needle towards the stop surface of the pole piece.

17. The internal combustion engine according to claim 11, the damping element comprises a material adapted for a temperature range between 40 C. and +150 C.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Features which are described herein above and below in conjunction with different aspects or embodiments, may also apply for other aspects and embodiments. Further features and advantageous embodiments of the subject-matter of the disclosure will become apparent from the following description of the exemplary embodiment in conjunction with the figures, in which:

(2) FIG. 1 shows a longitudinal section of a portion of an injector of the prior art.

(3) FIG. 2A shows a longitudinal section view of an injector according to teachings of the present disclosure.

(4) FIG. 2B shows a magnified portion of the injector shown in FIG. 2A.

(5) FIG. 3 shows a schematic diagram of a flow or fluid as a function of time according to teachings of the present disclosure.

(6) Like elements, elements of the same kind and identically acting elements may be provided with the same reference numerals in the figures. Additionally, the figures may be not true to scale. Rather, certain features may be depicted in an exaggerated fashion for better illustration of important principles.

DETAILED DESCRIPTION

(7) FIG. 1 shows a longitudinal section of an injector of the prior art, particularly, being suitable for dosing fuel to an internal combustion engine. The injector has a longitudinal axis X. The injector further comprises an injection valve housing 11 with an injection valve cavity. The injection valve cavity takes in a valve needle 5 being axially movable within the injection valve cavity relative to the injection valve housing 11. The valve needle 5 extends in axial direction X from a needle ball 14 at one axial end along a shaft 4 to an armature retainer 15 at an opposite axial end of the valve needle. In the present embodiment, the armature retainer 15 is in one piece with the shaft 4 and forms a collar at one end of the shaft. Alternatively, the armature retainer 15 can be a separate piece which is fixed to the shaft 4.

(8) The injector further comprises a valve seat 13, on which the needle ball 14 of the valve needle 5 rests in a closed position and from which the valve needle 5 is lifted for an open position. The closed position may also be denoted as closing position.

(9) The injector further comprises a spring element 12 being designed and arranged to exert a force on the valve needle 5 acting to urge the valve needle 5 in the closed position. The armature retainer acts as a spring seat for the spring element 12. In the closed position of the valve needle 5, the valve needle 5 sealingly rests on the valve seat 13, by this preventing fluid flow through at least one injection nozzle. The injection nozzle may be, for example, an injector hole. However, it may also be of some other type suitable for dosing fluid.

(10) The injector further comprises an electromagnetic actuator assembly, which is designed to actuate the valve needle 5. The electromagnetic actuator assembly, comprises a coil, in particular a solenoid 10. It further comprises a pole piece 1 which is fixedly coupled to the injection valve housing 11. The electromagnetic actuator assembly further comprises an armature 2 which is axially movable within the injection valve cavity by an activation of the electromagnetic actuator assembly.

(11) The armature 2 is mechanically coupled or decoupled with the valve needle 5, preferably movable with respect thereto only within certain limits. In other words, the armature 2 can be positionally fixed with respect to the valve needle 5 or axially displaceable with respect to the valve needle 5, as in the present embodiment.

(12) Axial displacement of the armature 2 with respect to the valve needle 5 in direction towards the pole piece 1 is limited by the armature retainer 15. The valve needle 5 further comprises a stop element 3 which is welded on a shaft 4 of the valve needle 5. The stop element 3 is operable to limit axial displacement of the armature 2 relative to the valve needle in direction away from the pole piece 1.

(13) The injector applies a concept in which the armature momentum is used to generate an opening of the injector or the valve needle 5, or a movement of the valve needle 5 towards the stop face 8 of the pole piece 1 (kick see below). During this movement, a hydraulic load on a valve seat 13 is to be overcome.

(14) The valve needle 5 prevents a fluid flow through a fluid outlet portion and the injection valve housing 11 in the closed position of the valve needle 5. Outside of the closed position of the valve needle 5, the valve needle 5 enables the fluid flow through the fuel outlet portion.

(15) In case that the electromagnetic actuator assembly with the coil gets energized, the electromagnetic actuator assembly may affect an electromagnetic force on the armature 2. The armature 2 is thus displaced towards the pole piece 1. For example, it may move in a direction away from the fuel outlet portion, in particular upstream of a fluid flow, due to the electromagnetic force acting on the armature. Due to the mechanical coupling with the valve needle 5, the armature 2 may take the valve needle 5 with it, such that the valve needle 5 moves in axial direction out of the closed position. Outside of the closed position of the valve needle 5 a gap between the injection valve housing 11 and the valve needle 5 at an axial end of the valve needle 5 facing away from the electromagnetic actuator assembly forms a fluid path and fluid can pass through the injection nozzle.

(16) In the case when the electromagnetic actuator assembly is de-energized, the spring element 12 may force the valve needle 5 to move in axial direction in its closed position. It is dependent on the force balance between the forces on the valve needle 5including at least the force caused by the electromagnetic actuator assembly with the coil 10 and the force on the valve needle 5 caused by the spring element 12whether the valve needle 5 is in its closed position or not.

(17) The minimum injection of fluid, such as gasoline or diesel dispensed from the injector may relate at each injection pulse to the mass of 1.5 mg at pressures from e.g. 200 to 500 bar.

(18) FIG. 2A shows a portion of a longitudinal section of an injector 100 according to teachings of the present disclosure. In contrast to the injector shown in FIG. 1, the injector 100 of the present embodiment comprises a damping element 7 for damping of the movement of the valve needle during opening of the injector 100.

(19) The damping element 7 is axially fixed with respect to the pole piece 1. The damping element 7 is arranged axially between the stop face 8 of the pole piece 1 and the armature retainer 15 of the valve needle 5. The damping element 7 is further disposed at an inner surface 9 of the pole piece 1.

(20) The damping element 7 is arranged axially above, the valve needle 5, here at a position relative to the valve needle 5 facing axially away from the injector outlet or nozzle. The damping element 7 further abuts a stop face 8 of the pole piece 1 (cf. FIG. 2A).

(21) More specifically, the pole piece 1 has a central recess 22,24 which is defined by the inner surface 9. The central recess 22,24 has a step 20 so that it is separated in a first portion 22 having a surface of the step 20 as a bottom surface and a second portion 24 upstream of the first portion 22. The bottom surface of the first portion represents the stop face 8. The second portion 24 has a smaller cross-sectional area than the first portion 22. The armature retainer 15 is arranged in the first portion 22 of the recess 22,24 of the pole piece 1 and axially guided by the first portion 22.

(22) The spring element 12 extends from a spring seat in the second portion to the armature retainer 15 in the first portion. The armature retainer 15 acts as a further spring seat for the spring element 12.

(23) FIG. 2B shows a portion Y of the injector 100 which is indicated in FIG. 2A in a magnified way. In the depicted situation the valve needle 5 actually abuts the damping element 7. This may relate to a damping operation during the opening of the injector 100. The damping element 7 may comprise a material which is adapted for a temperature range between 40 and +150 C.

(24) The damping element 7 is preferably mounted to the injector 100 in a pre-compressed state, preferably the damping element 7 is pre-compressed by 1 to 2 N.

(25) The damping element 7 may be an O-ring. In the present embodiment, the spring element 12 extends through the central opening of the O-ring.

(26) Furthermore, the damping element 7 may comprise a viscoelastic material such as a rubber compound. The damping element 7 preferably, provides for a mass damping of the valve needle 5, when the valve needle 5 is moved towards the stop face 8 of the pole piece 1. Preferably, the mass damping is provided for more than the final 20 m of movement of the valve needle 5 towards the stop face 8 of the pole piece 1.

(27) In FIGS. 2A and 2B, opening of the injector 100 relates to a movement of the valve needle 5 upwards with respect to the pole piece 1.

(28) The injector 100 may further comprise a further damping arrangement which provides for a hydraulic damping during movement of the valve needle away from the stop face 8 of the pole piece 1, for example during a closing of the injector. The damping arrangement may be represented mating surfaces of the armature 2 and the pole piece 1 which cooperate to provide hydraulic damping when the spring element 12 moves the valve needle towards the closed positionand, thus, the armature 2 out of contact with the pole piece 1 by means of mechanical interaction via the armature retainer 15. In addition, an additional damping arrangement may be provided for damping the movement of the armature 2 relative to the valve needle 5 when the armature 2 moves into contact with the stop element 3 of the valve needle 5.

(29) FIG. 3 shows a schematic course of a fluid flow actually injected as a function of time t according to teachings of the present disclosure. The section of the course indicated by IFO relates to an initial fast opening of the injector, wherein the flow of fluid strongly increases over time t. The section of the cause indicated by FD relates to a final damping regime in which, due to the herein described damping mechanism of the damping element 7, the flow increase is attenuated until the flow is almost constant over time.

(30) In FIG. 3 it is shown that the initial needle opening speed is relatively high which is important to achieve a good distribution of fuel during or after the injection. Due to the fact that the electromagnetic actuator assembly is active during the opening after the movement of the armature 2, the armature 2 is further accelerated during its movement in the injector valve housing 11, when the electromagnetic actuator assembly is active. For this reason it is not easy to control the position of the valve needle 5 with good accuracy by an electronic control unit in real time. Consequently, the mass flow of fluid and the achievement of very low fuel quantities poses problems especially in the ballistic operating range. The ballistic operating range may indicate the range in which the valve needle 5 is not in contact with the valve seat 13 and/or the stop face 8 of the pole piece 1. The mentioned problems may, particularly, overcome by the teachings of the present disclosure, particularly by the provision of the mentioned damping element 7. Moreover the disclosed embodiments provide for a cost-efficient damping solution. Thereby, expensive damping solutions, such as dynamic pressure drop fixture, wherein slots or holes are provided in the armature, can be avoided.

(31) As mentioned above, when the electromagnetic actuator assembly is activated or energized, the armature 2 is axially movable for an initial idle stroke until it contacts the armature retainer 15 of the valve needle 5 to generate the momentum and the above mentioned kick on the valve needle 5. Then, the armature 2 takes the valve needle 5 for about 80 to 90 m with it on its travel towards the pole piece 1 (opening of the valve or so-called working stroke) such that the total movable distance of the armature 2 may relate to about 120 m or 130 m. The overall force F.sub.tot of the armature effected by the electromagnetic actuator assembly provides the momentum for the opening of the valve needle (cf. kick of the valve needle as described above). The momentum is given by the following equation:
.sub.0.sup.TF.sub.tot(t)dt=m.sub.A*v.sub.T,
wherein m.sub.A is the armature mass and v.sub.T is the speed of the valve needle 5 at the event T of the contact of the valve needle 5 and the armature 2. The damping effect generated by the damping element to reduce the speed of the valve needle and to improve the controllability of the position and consequently the minimum flow rate is described by the following damping equations:
F(t)=m.sub.N{umlaut over (z)}+D+kz,
z(t=T).sub.0.sup.TF.sub.tot(t)dt,
wherein m.sub.N is the needle mass, D is the introduced damping constant of the damping element 7 and k is the spring constant of the spring element 12.

(32) The scope of protection is not limited to the examples given herein above. The invention is embodied in each novel characteristic and each combination of characteristics, which particularly includes every combination of any features which are stated in the claims, even if this feature or this combination of features is not explicitly stated in the claims or in the examples.