Integrated fuel injector igniters suitable for large engine applications and associated methods of use and manufacture

• US 8,225,768 B2
• Filed: 10/27/2010
• Issued: 07/24/2012
• Est. Priority Date: 01/07/2008
• Status: Expired due to Fees

• Current Assignee: Advanced Green Innovations, LLC
• Original Assignee: McAlister Technologies, LLC
• Inventors: McAlister, Roy E.
• Primary Examiner(s): Solis, Erick
• Application Number:
  US12/913,744
• Publication Number:
  US 20110233308A1
• Time in Patent Office: 636 Days
• Field of Search: 123/297
• US Class Current: 123/297
• CPC Class Codes: F02B 2075/125 Direct injection in the combustion chamber for spark ignition engines, i.e. not in pre-combustion chamber
• CPC Class Codes: F02M 21/0206 Non-hydrocarbon fuels, e.g. hydrogen, ammonia or carbon monoxide
• CPC Class Codes: F02M 21/0254 Electric actuators, e.g. solenoid or piezoelectric
• CPC Class Codes: F02M 21/0269 Outwardly opening valves, e.g. poppet valves
• CPC Class Codes: F02M 21/0275 for in-cylinder direct injection, e.g. injector combined with spark plug
• CPC Class Codes: F02M 51/0671 the armature having an elongated valve body attached thereto
• CPC Class Codes: F02M 57/06 the devices being sparking plugs
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y02T 10/30 Use of alternative fuels, e.g. biofuels

Abstract

Embodiments of injectors suitable for injection ports having relatively small diameters are disclosed herein. An injector according to one embodiment includes a body having a first end portion opposite a second end portion. The second end portion is configured to be positioned adjacent to a combustion chamber and the first end portion is configured to be spaced apart from the combustion chamber. The injector also includes an ignition conductor extending through the body from the first end portion to the second end portion, and an insulator extending longitudinally along the ignition conductor and surrounding at least a portion of the ignition conductor. The injector further includes a valve extending longitudinally along the insulator from the first end portion to the second end portion. The valve includes a sealing end portion, and the valve is movable along the insulator between an open position and a closed position. The injector also includes a valve seat at or proximate to the second end portion of the body. When the valve is in the open position the sealing end portion is spaced apart from the valve seat, and when the valve is in the closed position the sealing end portion contacts at least a portion of the valve seat.

Claims

1. An injector for introducing and igniting fuel at an interface with a combustion chamber, the injector comprising:

an injector body including—

a base portion configured to receive fuel into the injector body;

a nozzle portion opposite the base portion, wherein the nozzle portion is configured to be positioned proximate to the combustion chamber for injecting fuel in the combustion chamber;

a body insulator extending through at least a portion of the body; and

a valve seat carried by the body insulator, wherein the valve seat is positioned at or proximate to the nozzle portion;

a fuel flow path extending through the body; and

a core assembly extending through the body coaxially with at least a portion of the fuel flow path, the core assembly including—

an ignition rod extending from the base portion to the nozzle portion;

an ignition insulator coaxially disposed over the ignition rod, the ignition insulator extending from the base portion at least partially into the nozzle portion; and

a valve coaxially disposed over the ignition insulator, wherein the valve includes a sealing head adjacent to the valve seat, and wherein the valve moves along the ignition insulator between an open position in which the sealing head is spaced apart from the valve seat to allow fuel to exit the fuel flow path, and a closed position in which the sealing head at least partially contacts the valve seat to close the fuel flow path.

2. The injector of claim 1 wherein the nozzle portion has a diameter of approximately 0.33 inch or less.

3. The injector of claim 1 wherein the nozzle portion has a length of approximately 12 inches or more.

4. The injector of claim 1, further comprising a valve operator assembly carried by the base portion, the valve operator assembly comprising:

a driver surrounding at least a portion of the valve and movable between a first position and a second position, wherein when the driver is in the first position the valve is retained in the closed position, and when the driver moves to the second position the driver engages and moves the valve to the open position;

a force generator configured to actuate the driver to move between the first and second positions; and

a controller configured to selectively activate the force generator.

5. The injector of claim 4, further comprising a fuel inlet fluidly coupled to the force generator to introduce fuel into the base portion via the force generator.

6. The injector of claim 1 wherein the valve includes a first end portion opposite the sealing head, and wherein the injector further comprises a driver movably positioned in the base portion between a first position and a second position, wherein when the driver is in the first position the valve is retained in the open position, and when the driver moves to the second position the driver engages the first end portion of the valve and moves the valve to the open position.

7. The injector of claim 6 wherein the first end portion of the valve includes a stop, and wherein the driver contacts the stop when the driver engages the first end portion of the valve.

8. The injector of claim 6 wherein the driver moves a predetermined distance before engaging the first end portion of the valve as the driver moves toward the second position.

9. The injector of claim 1, further comprising one or more optical fibers extending through the ignition rod, wherein the one or more optical fibers are configured to transmit combustion chamber data from the combustion chamber to a controller operably coupled to the injector.

10. The injector of claim 1, wherein the ignition rod includes one or more ignition features positioned in the nozzle portion between the sealing head of the valve and the combustion chamber, and wherein the one or more ignition features are configured to generate an ignition event to ignite fuel exiting the nozzle portion.

11. The injector of claim 10 wherein the one or more ignition features are spirally wound around at least a portion of the ignition rod.

12. The injector of claim 1 wherein the sealing head of the valve is spaced apart from the interface with the combustion chamber by a distance of at least approximately 12 inches or more.

13. The injector of claim 1 wherein the sealing head of the valve is configured to be positioned in the nozzle portion adjacent to the interface with the combustion chamber.

14. The injector of claim 1, further comprising a controller for:

selectively controlling the movement of the valve with reference to the ignition insulator; and

selectively controlling an ignition event generated by the ignition rod.

15. The injector of claim 1 wherein the valve has a first length, the ignition insulator has a second length greater than the first length, and the ignition rod has a third length greater than the second length.

16. The injector of claim 1 wherein the valve is an outwardly opening valve moving in a direction toward the combustion chamber when the valve moves from the closed position to the open position.

17. The injector of claim 1 wherein the valve is an inwardly opening valve moving in a direction away from the combustion chamber when the valve moves from the closed position to the open position.

18. The injector of claim 1, wherein the fuel flow path extends through the body between the valve and the body insulator.

19. An injector for introducing fuel into a combustion chamber, the injector comprising:

a body having a first end portion opposite a second end portion, wherein the second end portion is configured to be positioned adjacent to an interface of the combustion chamber and the first end portion is configured to be spaced apart from the combustion chamber;

an ignition conductor extending through the body from the first end portion to the second end portion, wherein the ignition conductor is configured to transmit ignition energy from the first end portion to the second end portion and generate an ignition event proximate to the interface of the combustion chamber;

an insulator extending longitudinally along the ignition conductor and surrounding at least a portion of the ignition conductor;

a valve extending longitudinally along the insulator from the first end portion to the second end portion, wherein the valve includes a sealing end portion, and wherein the valve is movable along the insulator between an open position and a closed position; and

a valve seat at or proximate to the second end portion of the body, wherein when the valve is in the open position the sealing end portion is spaced apart from the valve seat and when the valve is in the closed position the sealing end portion contacts at least a portion of the valve seat.

20. The injector of claim 19 wherein the insulator is a first insulator and wherein the injector further comprises:

a second insulator extending longitudinally along the body and spaced radially apart from the valve; and

an annular fuel flow passage extending from the first end portion to the second end portion between the second insulator and the valve.

21. The injector of claim 19, further comprising a fuel flow passage coaxially disposed around and surrounding the valve.

22. The injector of claim 19 wherein the sealing end portion of the valve comprises an enlarged end portion of the valve having a first diameter that is greater than a second diameter of the valve.

23. The injector of claim 19, further comprising one or more optical sensors extending from the first end portion to the second end portion, wherein the one or more optical fibers are configured to detect or transmit combustion chamber data from the combustion chamber.

24. The injector of claim 23 wherein the one or more optical sensors extend longitudinally through the ignition conductor.

25. The injector of claim 19 wherein the valve further comprises a base portion opposite the sealing end portion, the injector further comprising:

an actuator positioned in the first end portion, wherein the actuator is movable between a first position and a second position, wherein when the actuator moves from the first position toward the second position the actuator contacts the base portion of the valve and moves the valve from the closed position toward the open position; and

a force generator positioned in the first end portion adjacent to the actuator, wherein the force generator is configured to activate the actuator to move the actuator between the first and second positions.

26. The injector of claim 19 wherein the valve extends at least partially through the second end portion of the body, and the sealing end portion of the valve is positioned adjacent to the interface of the combustion chamber.

27. The injector of claim 19, further comprising one or more ignition features carried by the ignition conductor, wherein the one or more ignition features are positioned between the sealing end portion of the valve and the interface of the combustion chamber, and wherein the one or more ignition features are configured to generate an ignition event to ignite fuel that passes beyond the sealing end portion of the valve.

28. The injector of claim 19 wherein the second end portion of the body has a diameter of approximately 0.33 inch or less.

29. An injector for introducing fuel into a combustion chamber, the injector comprising:

a nozzle portion configured to be positioned adjacent to an interface with the combustion chamber;

a base portion opposite the nozzle portion and configured to be spaced apart from the nozzle portion;

an ignition conductor at least partially extending through the nozzle portion;

an ignition insulator coaxially disposed over at least a portion of the ignition conductor; and

a valve positioned in the nozzle portion and coaxially disposed over at least a portion of the ignition insulator and radially spaced apart from at least a portion of the ignition insulator, wherein the valve includes—

a first end portion that remains generally stationary with reference to the ignition insulator; and

a second sealing end portion positioned between the first end portion and the combustion chamber, wherein the second sealing end portion is at least partially deformable in a direction radially away from the ignition insulator to move from a closed position to an open position to inject fuel from the nozzle portion into the combustion chamber.

30. The injector of claim 29 wherein the valve is a first valve, and wherein the injector further comprises a second valve positioned in the base portion, wherein the second valve moves in a direction generally parallel to a longitudinal axis of the injector from a closed position and an open position to allow the fuel to flow from the base portion to the nozzle portion.

31. The injector of claim 30 wherein the second valve is independently movable from the first valve.

32. The injector of claim 29 further comprising a driver movably positioned in the base portion coaxially surrounding at least a portion of the second valve, wherein the driver is movable between a first position and a second position, wherein as the driver moves from the first position toward the second position the driver engages the second valve and moves the second valve from the closed position toward the open position.

33. The injector of claim 29 wherein the ignition conductor is a first ignition conductor, and wherein the injector further comprises a second ignition conductor electrically coupled to the first ignition conductor, wherein the second ignition conductor extends from the nozzle portion toward the base portion and at least partially encases a fuel flow passage extending longitudinally through the injector.

34. The injector of claim 29, further comprising an ignition terminal at the base portion, wherein the ignition terminal is configured to be operably coupled to an ignition energy source, and wherein the ignition conductor extends from the ignition terminal in the base portion to the nozzle portion.

35. The injector of claim 34 wherein the ignition insulator is coaxially disposed over the ignition conductor and extends from the base portion at least partially into the nozzle portion.

36. The injector of claim 29 wherein the ignition insulator includes an enlarged end portion positioned adjacent to the interface with the combustion chamber, and wherein the second sealing end portion of the valve is positioned adjacent to the enlarged end portion of the ignition insulator.