INJECTOR CUP FOR ENGINES APPARATUS AND METHODS OF USE

Abstract

An improved injector cup may be used in diesel engines that fits more securely into the engine's cylinder heads to better prevent engine coolant from leaking into the fuel and/or fuel leaking into the coolant. An improved injector cup may be designed to accommodate specific engine types and sizes in order to prevent engine coolant from leaking into the fuel and/or fuel leaking into the coolant.

Claims

1-19. (canceled)

20. A method for preventing leakage of coolant in a diesel engine, comprising: providing an injector cup comprising threads at a distal end and at least two O-rings near a proximal end; inserting the injector cup into an injector cavity bore of a cylinder head, wherein the cylinder head comprises insertion threads at the bottom of the cylinder head; and tightening the injector cup into the injector cavity bore via engagement between the insertion threads and the threads of the injector cup in a manner that prevents floating of the injector cup within the cylinder head and in a manner that enables the O-rings to engage an injector cavity wall.

21. The method of claim 20 further comprising: creating a seal between the injector cavity bore and a coolant chamber, wherein the seal is created by the engagement of the O-rings with the injector cavity wall and the seal prevents leakage of coolant into the fuel and prevents leakage of fuel into the coolant.

22. The method of claim 21, wherein the injector cup further comprises a recession.

23. The method of claim 20, wherein the injector cup further comprises a plurality of cavities near the proximal end and the tightening is performed using a torque tool comprising a plurality of prongs that engage the plurality of cavities.

24. The method of claim 23, wherein the injector cup further comprises a recession for engagement with a plug.

25. The method of claim 23, wherein the injector cup further comprises a conical portion near the distal end of the injector cup.

26. The method of claim 25, wherein the injector cup has a barrel that has a length that places all O-rings above the coolant chamber and within the injector cavity bore such that the O-ring nearest the coolant chamber is at least 0.05 inches above the coolant chamber.

27. The method of claim 23, wherein the tightening of the injector cup is done to achieve at least sixty-five (65) foot-pounds of torque.

28. The method of claim 20, wherein the injector cup is comprised of stainless steel.

29. The method of claim 26, wherein the O-rings can withstand a temperature of at least 450° F.

30. A method for installing an injector cup into a diesel engine, comprising: providing an injector cup, wherein the injector cup comprises threads at a distal end, at least two O-rings near a proximal end, and a conical portion near the distal end of the injector cup; inserting the injector cup into an injector cavity bore of a cylinder head, wherein the cylinder head comprises insertion threads at the bottom of the cylinder head; tightening the injector cup into the injector cavity bore via engagement between the insertion threads and the threads of the injector cup in a manner that prevents floating of the injector cup within the cylinder head and in a manner that enables the O-rings to engage an injector cavity wall; and creating a seal between the injector cavity bore and a coolant chamber, wherein the seal is created by the engagement of the O-rings with the injector cavity wall and the seal prevents leakage of coolant in the fuel of the diesel engine and prevents leakage of fuel into the coolant of the diesel engine.

31. The method of claim 30, further comprising: cutting a recession into the injector cup.

32. The method of claim 30, wherein the injector cup further comprises a plurality of cavities near the proximal end and the tightening is accomplished using a torque tool comprising a plurality of prongs that engage the plurality of cavities.

33. The method of claim 30, wherein the O-rings can withstand a temperature of at least 450° F.

34. The method of claim 32, wherein the tightening of the injector cup is done to achieve approximately sixty-five (65) foot-pounds of torque.

35. The method of claim 31, wherein the injector cup is comprised of stainless steel.

36. A method for preventing leakage past an injector cup of a diesel engine, comprising: providing an injector cup, wherein the injector cup comprises threads at a distal end, at least two O-rings near a proximal end, and a plurality of cavities near the proximal end of the injector cup; inserting the injector cup into an injector cavity bore of a cylinder head, wherein the cylinder head comprises insertion threads in a fire deck side of the cylinder head; providing a torque tool having a plurality of prongs at one end, wherein the plurality of prongs are configured to engage the plurality of cavities in the injector cup; inserting the plurality of prongs into the plurality of cavities; engaging, properly, the threads of the injector cup with the insertion threads; tightening the injector cup into the fire deck side of the cylinder head via the engagement between the insertion threads and the threads of the injector cup in a manner that prevents floating of the injector cup within the cylinder head and in a manner that enables the O-rings to engage an injector cavity wall.

37. The method of claim 36, further comprising: creating a seal between the injector cavity bore and a coolant chamber, wherein the seal is created by the engagement of the O-rings with the injector cavity wall; and cutting a recession into the injector cup.

38. The method of claim 36, wherein the tightening of the injector cup is done to achieve approximately sixty-five (65) foot-pounds of torque.

39. The method of claim 38, wherein the injector cup has a barrel that has a length that places all O-rings above the coolant chamber and within the injector cavity bore such that the O-ring nearest the coolant chamber is at least 0.05 inches above the coolant chamber.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The foregoing features of the present invention will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only typical embodiments of the invention and are, therefore, not to be considered limiting of its scope, the invention will be described with additional specificity and detail through use of the accompanying drawings in which:

[0023] FIG. 1 is a perspective view of one embodiment of an injector cup;

[0024] FIG. 2A is a side view of one embodiment of an injector cup;

[0025] FIG. 2B is a cut-away side view of one embodiment of an injector cup;

[0026] FIG. 3A is a top plan view of one embodiment of an injector cup;

[0027] FIG. 3B is a bottom plan view of one embodiment of an injector cup;

[0028] FIG. 4 is a perspective view of one embodiment of an injector cup as installed in a cylinder head;

[0029] FIG. 5 is a perspective view of another embodiment of an injector cup;

[0030] FIG. 6A is a side view of another embodiment of an injector cup;

[0031] FIG. 6B is a cut-away side view of another embodiment of an injector cup;

[0032] FIG. 7A is a top plan view of another embodiment of an injector cup;

[0033] FIG. 7B is a bottom plan view of another embodiment of an injector cup;

[0034] FIG. 8 is a perspective view of another embodiment of an injector cup as installed in a cylinder head;

[0035] FIG. 9A is a perspective view of a torque tool; and

[0036] FIG. 9B is a side view of a torque tool.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0037] It will be readily understood that the components of the present invention, as generally described herein, could be arranged and designed in a wide variety of different configurations or formulations. Thus, the following more detailed description of the embodiments of the system, products and methods of use of the present invention, are not intended to limit the scope of the invention, as claimed, but is merely representative of various embodiments of the invention.

[0038] An improved injector cup component or product may be used to seat a cylinder head in a manner that better prevents coolant from leaking into an engine's cylinder and/or fuel system. Such an injector cup component replaces a similar device, but the new, improved injector may be designed and installed to have improved seal and retention.

[0039] Referring to FIGS. 1-3, and notably FIG. 1, an improved injector cup 10 may be designed more particularly for use in a DOHC engine. An improved injector cup 10 may include a barrel 12, a tapered surface 20, a pipe 22 (or pipe surface 22), a conical portion 24 (or conical surface 24), and threads 26. An improved injector cup 10 may be described as having a proximal end and a distal end. The proximal end may include a rim 28, which rim 28 defines a proximal aperture 14. The distal end may include threads 26, which threads 26 define a distal aperture 16. An O-ring groove 18 may be included along the outside of the barrel 12 near the proximal end of the injector cup 10. More likely, two or more O-ring grooves 18 may be included along the outside of the barrel 12 near the proximal end of the injector cup 10.

[0040] Generally, an improved injector cup 10 may be made of stainless steel, but any suitable material may be used to form the injector cup 10. An O-ring may be a dual silicone O-ring, but any suitable material may be used to form an O-ring. An O-ring may be comprised of a material that can withstand temperatures of at least 450° F. Upon installation of an injector cup 10, each O-ring groove 18 that is on the barrel 12 will include a suitable O-ring within the O-ring groove 18.

[0041] Referring to FIGS. 1-3, and notably FIG. 2A, the barrel 12 and/or pipe portion 22 of an injector cup 10 may be any suitable length. An overall length of the injector cup 10 should allow for all O-rings to connect with and seal against the bore of an injector cavity 52, or against the injector cavity wall 54, of the cylinder head 50 in which the injector cup 10 is installed. An example of an overall length of the injector cup 10 would be 2.05 inches. An example of the length of the barrel 12 would be 0.68 inches. The injector cup 10 may have a barrel 12 that has a length that places all O-rings above the coolant chamber 56 and within the injector cavity bore 52 such that the O-ring nearest the coolant chamber 56 is at least 0.05 inches above the coolant chamber 56. An example of the outer diameter of the barrel 12, and ring 28, would be 1.38 inches. An example of the diameter of the proximal aperture 14 would be 1.27 inches. An example of the diameter of the distal aperture 16 would be 0.57 inches.

[0042] Referring to FIGS. 1-3, and notably FIG. 3A, an improved injector cup 10 may include an inner annulus 32 inside the barrel 12 portion of the injector cup 10. The inner annulus 32 may include multiple cavities 34, or a plurality of cavities 34. The cavities 34 may be configured to receive prongs 78 from a torque tool 70. The cavities 34 may be arranged in any suitable configuration around the inner annulus 32 to enable engagement with a suitable torque tool 70. An example of the inner diameter of the inner annulus 32 would be 1.11 inches.

[0043] Referring to FIG. 4, an improved injector cup 10 may be installed into a bore of an injector cavity 52 of a cylinder head 50, or engine 50. The injector cup 10 may secured to the bottom of the cylinder 62, or the cup seat 62, via the threads 26. The bottom of the cylinder head 62, or cup seat 62, may need to be tapped, or have an internal screw thread cut therein, to engage with the threads 26. Installation of the improved injector cup 10 may be accomplished using a torque tool 70 where the body 72 of the torque tool 70, and the tube 76 of the torque tool 70, may extend into the bore of an injector cavity 52 to allow the prongs 78 of the torque tool 70 to engage the cavities 34 of the injector cup 10. Once the prongs 78 are engaged with the cavities 34, the torque tool 70 can be used to tighten the injector cup 10 into place within the cylinder head 52.

[0044] Once the injector cup 10 is secured into place, O-rings positioned in O-ring grooves 18 will engage or contact the injector cavity wall 54. This will effectively seal the fuel side 60 of the configuration from the coolant side 58. Coolant in the coolant chamber 56 will be prevented from leaking into the fuel and/or fuel will be prevented from leaking into the coolant chamber 56.

[0045] Referring to FIGS. 5-7, and notably FIG. 5, an improved injector cup 10 may be designed more particularly for use in a SOHC engine. An improved injector cup 10 may include a barrel 12, and threads 26. An improved injector cup 10 may be described as having a proximal end and a distal end. The proximal end may include a rim 28, which rim 28 defines a proximal aperture 14. The distal end may include threads 26, which threads 26 define a distal aperture 16. An O-ring groove 18 may be included along the outside of the barrel 12 near the proximal end of the injector cup 10. More likely, two or more O-ring grooves 18 may be included along the outside of the barrel 12 near the proximal end of the injector cup 10.

[0046] Generally, an improved injector cup 10 may be made of stainless steel, but any suitable material may be used to form the injector cup 10. An O-ring may be a dual silicone O-ring, but any suitable material may be used to form an O-ring. An O-ring may be comprised of a material that can withstand temperatures of at least 450° F. Upon installation of an injector cup 10, each O-ring groove 18 that is on the barrel 12 will include a suitable O-ring within the O-ring groove 18.

[0047] Referring to FIGS. 5-7, and notably FIG. 6A, the barrel 12 of an injector cup 10 may be any suitable length. An overall length of the injector cup 10 should allow for all O-rings to connect with and seal with the bore of an injector cavity 52, or the injector cavity wall 54, in which the injector cup 10 is installed. An example of an overall length of the injector cup 10 would be 1.65 inches. An example of the length of the barrel 12 would be 0.97 inches. The injector cup 10 may have a barrel 12 that has a length that places all O-rings above the coolant chamber 56 and within the injector cavity bore 52 such that the O-ring nearest the coolant chamber 56 is at least 0.05 inches above the coolant chamber 56. An example of the outer diameter of the barrel 12, and rim 28, would be 1.38 inches. An example of the diameter of the proximal aperture 14 would be 1.06 inches. An example of the diameter of the distal aperture 16 would be 0.93 inches.

[0048] Referring to FIGS. 5-7, and notably FIG. 7A, an improved injector cup 10 may include a rim 28 of the injector cup 10. The rim 28 may include multiple cavities 34, or a plurality of cavities 34. The cavities 34 may be configured to receive prongs 78 from a torque tool 70. The cavities 34 may be arranged in any suitable configuration around the rim 28 to enable engagement with a suitable torque tool 70. An example of the inner diameter of the rim 28 would be 1.06 inches.

[0049] Referring to FIG. 8, an improved injector cup 10 may be installed into a bore of an injector cavity 52 of a cylinder head 50, or engine 50. The injector cup 10 may be secured to the bottom of the cylinder head 62, or the cup seat 62, via the threads 26. The bottom of the cylinder head 62, or cup seat 62, may need to be tapped, or have an internal screw thread cut therein, to engage with the threads 26. Installation of the improved injector cup 10 may be accomplished using a torque tool 70 where the body 72 of the torque tool 70, and the tube 76 of the torque tool 70, may extend into the bore of an injector cavity 52 to allow the prongs 78 of the torque tool 70 to engage the cavities 34 of the injector cup 10. Once the prongs 78 are engaged with the cavities 34, the torque tool 70 can be used to tighten the injector cup 10 into place within the cylinder head 52.

[0050] Once the injector cup 10 is secured into place, O-rings positioned in O-ring grooves 18 will engage or contact the injector cavity wall 54. This will effectively seal the fuel side 60 of the configuration from the coolant side 58. Coolant in the coolant chamber 56 will be prevented from leaking into the fuel and/or fuel will be prevented from leaking into the coolant chamber 56.

[0051] Referring to FIG. 9, a torque tool 70 may be specially designed to engage and install an improved injector cup 10. The torque tool 70 may comprise a body 72 and a tube 76 that provide the majority of the length of the torque tool 70. One end of the torque tool 70 may include a bolt head 74 that may allow the torque tool 70 to be rotated using a wrench, a socket wrench, or similar tool. The opposite end of the torque tool 70 may include multiple prongs 78, or a plurality of prongs 78, to engage cavities 34 of the improved injector cup 10. A torque tool 70 may be configured in any suitable manner to allow use with one or more types of improved injector cups.

[0052] Generally, the torque tool 70 may be made of stainless steel, but any suitable material may be used to form the torque tool 70. The torque tool 70 may be of any suitable size and shape. An example of the overall length of the torque tool 70 would be 4.72 inches. An example of the length of the body 72 would be 3.38 inches. An example of the outside diameter of the body 72 would be 1.38 inches. An example of the length of a prong 78 would be 0.10 inches, and a cavity 34 may have a corresponding, accommodating depth.

[0053] The example dimensions included herein should be considered adjustable, and may be adjusted in a number of ways. The dimensions could be adjusted to accommodate a specific engine type and/or size. The ratio of the relative dimensions may or may not remain constant. The example dimensions may be considered as approximations to illustrate the dimensions.

[0054] An improved injector cup and associated method of installation may be utilized to address the problem of possible leakage of coolant into the fuel and/or fuel into the coolant of a diesel engine, and any similar issue with any similar engine. For example, any engine that may have an issue with coolant and/or fuel leaking past an injector cup, or similar structure, and allowing coolant into the fuel and/or fuel into the coolant may be considered a candidate for use of an improved injector cup and associated method of installation presented herein. Put another way, any engine with an injector cup that may or tends to “float” in the cylinder head during operation may benefit from the improved injector cup apparatus and installation methods described herein.

[0055] A method for installing an improved injector cup may include the following steps.

[0056] A first step may be to remove the factory injector cup. To perform this step, the engine may or may not have to be removed from the vehicle depending on the type of engine. For example, the engine may have to be removed to install an improved injector cup in a DOHC engine, but the engine may not have to be removed to install an improved injector cup in a SOHC engine.

[0057] A second step may be to cut threads into the bottom of the cylinder head 62, or the cup seat 62, so that an improved injector cup may be mounted in the bore of an injector cavity 52. This will allow the injector cavity 52 of the cylinder head 50 (typically made of cast iron) to glide along the outside of the improved injector cup (typically made of stainless steel).

[0058] A third step may be to lock down, or thread and tighten, an improved injector cup to the fire deck side of the cylinder. This will prevent the improved injector cup 10 from being able to “float” inside the cylinder head, in contrast to a factory injector cup. The improved injector cup may be installed in a manner that ensures that at least two O-rings at the top of the improved injector cup 10 are seated so as to seal in the portion of the injector cavity bore 52 before the injector cavity bore 52 begins to taper, or before the coolant chamber 56 begins.

[0059] Once the improved injector cup is installed in the cylinder head, a recession in the injector cup may still need to be cut. The recession allows for engagement with a plug. This may be accomplished using an Irontite™ tool, or any suitable, similar tool. A gauge may be used to measure a plug, or measure a cutter, and determine the depth of the recession needed in the improved injector cup, so that the injector will seat in the injector cup at the proper depth, or injector protrusion. The cutter tool goes into the improved injector cup and cuts the appropriate recession. The step of measuring and cutting the recession for the improved injector cup may be substantially similar to the same step for a factory injector cup.

[0060] If the head is surfaced, or serviced, the nearest portion of the improved injector cup can be surfaced, or shaved down, without diminishing the improved injector cup's ability to seal the coolant away from the fuel. However, this may not be necessary because the nearest portion of the improved injector cup will normally be approximately 50 thousandths of an inch below the surface of the head, and a normal surfacing of the head will only shave off approximately 4-10 thousandths of an inch.

[0061] It may be helpful to make any adjustments to the cylinder head while the engine is out and new, improved injector cups are being installed. This may include preventing any material or debris from getting into or staying in the cylinder head.

[0062] With certain types of engines, i.e., a SOHC engine, the installation of an improved injector cup may be accomplished while the engine is still on the vehicle, or truck. For a SOHC engine, one embodiment of an improved injector cup may be bigger and thicker because there is more room in the cylinder head. An improved injector cup may include bigger O-rings, including O-rings designed to withstand higher temperatures, i.e., 450° F.

[0063] The improved injector cups are designed to thread into the cylinder head creating a locking bond between the injector cup and the cylinder head. It is designed to address the issues arising from the fact that the factory injector cup is just a press fit into the cylinder head. The factory cup may become loose over time and can cause a coolant leak into the fuel system of the engine, or a fuel leak into the coolant system of the engine. The improved injector cups may also be engineered with a dual silicone O-ring, where each O-ring is approximately twice the size of the regular, single factory O-ring seal. This feature also allows the cylinder head to expand and contract keeping the seal between the cylinder head and injector cup intact.

[0064] In one embodiment, an improved injector cup may include threads on a distal end so as to allow more firm and secure attachment to a cylinder head. Such an improved injector cup may also include an increase in length to provide for at least one additional silicone O-ring, or an O-ring of any suitable size and material. Such an improved injector cup may be configured to be used with a DOHC engine.

[0065] In one embodiment, an improved injector cup may include threads on a distal end so as to allow more firm and secure attachment to a cylinder head. Such an improved injector cup may also include increased length and thickness to provide for at least one additional silicone O-ring, or an O-ring of any suitable size and material. Such an improved injector cup may be configured to be used with a SOHC engine.

[0066] The subject invention may be more easily comprehended by reference to the specific embodiments recited herein, which are representative of the invention. However, it must be understood that the specific embodiments are provided only for the purpose of illustration, and that the invention may be practiced in a manner separate from what is specifically illustrated without departing from its scope and spirit.