Fuel injector actuator assemblies and associated methods of use and manufacture

• US 8,997,718 B2
• Filed: 12/09/2011
• Issued: 04/07/2015
• Est. Priority Date: 01/07/2008
• Status: Active Grant

• Current Assignee: Advanced Green Innovations, LLC
• Original Assignee: McAlister Technologies, LLC
• Inventors: McAlister, Roy Edward
• Primary Examiner(s): Gimie, Mahmoud
• Application Number:
  US13/316,412
• Publication Number:
  US 20120145125A1
• Time in Patent Office: 1,215 Days
• Field of Search: 123/490, 123/499, 123/498, 123/467, 123/468, 123/469, 123/470, 123/472, 123/480, 2395851-5855, 239/102.2, 239/533.2, 239/533.9, 251/129.15
• US Class Current: 123/490
• 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 21/0254 Electric actuators, e.g. solenoid or piezoelectric
• CPC Class Codes: F02M 21/0266 Hollow stem valves; Piston valves; Stems having a spherical tip
• 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: H01M 8/04089 of gaseous reactants
• CPC Class Codes: H01M 8/04186 of liquid-charged or electrolyte-charged reactants
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y02T 10/30 Use of alternative fuels, e.g. biofuels

Abstract

The present disclosure is directed to integrated injector/igniters providing efficient injection, ignition, and complete combustion of various types of fuels. One such injector/igniter can include a body having a base portion opposite a nozzle portion. The base portion receives fuel into the body and the nozzle portion can be positioned adjacent the combustion chamber. The injector further includes a valve carried by the nozzle portion that is movable between a closed position and an open position to inject the fuel into the combustion chamber. An actuator is coupled to the valve and extends longitudinally through the body towards the base portion, and a driver is carried by the body and is movable between a first position and a second position. In the first position the driver does not move the actuator and in the second position the driver moves the actuator to move the valve to the open position.

Claims

1. A fuel injector for delivering fuel to an engine, the fuel injector comprising:

a body having a fuel conduit for receiving the fuel from a fuel source and a fuel exit passage for delivering the fuel to a combustion chamber of the engine;

an actuator having a valve and a stop, wherein the stop is configured to move from a first position to a second position to move the valve from a closed position to an open position; and

a driver positioned proximate to the actuator and extending from a first end to a second end, wherein the driver is configured to travel longitudinally within the body to impact the stop to move the stop from the first position to the second position, and wherein travel of the driver includes travel of the first end and travel of the second end.

2. The fuel injector of claim 1, further comprising a force generator positioned concentrically around the driver, wherein the driver is further positioned between the stop and the valve, wherein the force generator is configured to move the driver from the first position to the second position, wherein the first position includes the first end of the driver spaced apart from the stop and the second end of the driver in contact with the valve, and wherein the second position includes the first end of the driver in contact with the stop and the second end of the driver spaced apart from the valve.

3. The fuel injector of claim 1 wherein the driver includes an actuator cavity, wherein the actuator is positioned within the actuator cavity, and wherein the driver is further configured to travel longitudinally to move the valve to the closed position.

4. The fuel injector of claim 1, further comprising a spring positioned in the body, wherein the driver includes a first biasing surface, wherein the body further includes a second biasing surface, wherein the travel of the driver to impact the stop is in a first direction, and wherein the spring is positioned to contact the first surface and the second surface to bias the driver in a second direction, opposite to the first direction.

5. The fuel injector of claim 4 wherein biasing of the driver in the second direction urges the second end of the driver against the valve and at least partially maintains the valve in the closed position.

6. The fuel injector of claim 1, further comprising:

a force generator positioned within the body and configured to move the driver to impact the stop; and

a fuel passage at least partially surrounding the force generator and configured to cool the force generator as the fuel flows through the fuel passage.

7. A fuel injector for delivering fuel to an engine, the fuel injector comprising:

a body having a fuel conduit for receiving the fuel from a fuel source and a fuel exit passage for delivering the fuel to a combustion chamber of the engine;

an actuator having a valve and a stop, wherein the stop is configured to move from a first position to a second position to move the valve from a closed position to an open position;

a driver positioned proximate to the actuator and configured to travel longitudinally within the body to impact the stop to move the stop from the first position to the second position; and

a magnet positioned in the body, wherein the travel of the driver to impact the stop is in a first direction, wherein the magnet is configured to bias the driver in a second direction, opposite to the first direction, and wherein biasing of the driver in the second direction at least partially maintains the valve in the closed position.

8. A fuel injector for delivering fuel to an engine, the fuel injector comprising:

a body having a fuel conduit for receiving the fuel from a fuel source and a fuel exit passage for delivering the fuel to a combustion chamber of the engine;

an actuator having a valve and a stop, wherein the stop is configured to move from a first position to a second position to move the valve from a closed position to an open position;

a driver positioned proximate to the actuator and configured to travel longitudinally within the body to impact the stop to move the stop from the first position to the second position; and

an electromagnetic force generator configured to generate a magnetic field to move the driver, and wherein the driver includes a slit radially extending through at least a portion of the driver, the slit configured to reduce eddy currents induced by the force generator.

9. A fuel injector for delivering fuel to a combustion chamber of an engine, the fuel injector comprising:

a body having a nozzle portion opposite a base portion, wherein the nozzle portion is configured to extend through a port to the combustion chamber, and wherein the base portion is configured to receive the fuel from a fuel source;

an actuator positioned at least partially within the body, the actuator having a valve at the nozzle portion and a stop at the base portion, wherein the valve is configured to meter the fuel delivered to the combustion chamber; and

a driver extending from a first end to a second end and encircling at least a portion of the actuator, wherein the driver is configured to move from a first position with the first end spaced apart from the stop to a second position with the first end in contact with the stop, and wherein movement of the driver from the first position to the second position includes;

movement of the first end of the driver to impact the stop to move the valve to an open position; and

movement of the second end of the driver away from the valve.

10. The fuel injector of claim 9, further comprising a biasing member configured to bias the driver toward the first position, and wherein the second end at least partially retains the valve in the closed position when the driver is in the first position.

11. The fuel injector of claim 9, further comprising:

a force generator positioned within the body and configured to move the driver from the first position to the second position; and

a fuel passage extending through the body with a portion of the fuel passage proximate to the force generator, wherein the fuel passage is configured to cool the force generator.

12. The fuel injector of claim 9, further comprising a piezoelectric force generator positioned to move the driver.

13. The fuel injector of claim 9, further comprising:

a spring positioned to bias the driver towards the first position; and

a valve seat at the nozzle portion, wherein the driver at least partially retains the valve against the valve seat when the driver is in the first position.

14. The fuel injector of claim 9, further comprising:

a force generator positioned within the body and configured to move the driver from the first position to the second position; and

a biasing member positioned within the body and configured to bias the driver towards the first position.

15. A method for injecting fuel into a combustion chamber, the method comprising:

delivering the fuel to a fuel conduit in an injector;

directing the fuel through a body of the injector;

impacting a stop with a driver to move a valve from a closed position to an open position to inject the fuel into the combustion chamber, wherein impacting the stop includes moving the driver from a first position with a first end of the driver spaced apart from the stop and a second end of the driver in contact with the valve, to a second position with the first end of the driver in contact with the stop and the second end of the driver spaced apart from the valve.

16. The method of claim 15 wherein impacting the stop with a driver includes moving the driver in a first direction, the method further comprising biasing the driver in a second direction, opposite to the first direction, to at least partially retain the valve in the closed position.

17. The method of claim 15, further comprising moving the driver with a force generator that generates a magnetic field.

18. The method of claim 17, wherein directing the fuel through the body of the injector includes directing the fuel through a fuel passage adjacent to the force generator to cool the force generator.

19. The method of claim 15 wherein moving the driver includes applying electrical current to a piezoelectric device to move the driver.

20. The method of claim 15, further comprising biasing the driver towards the first position to move the valve to the closed position.

21. A fuel injector for delivering fuel to an engine, the fuel injector comprising:

a body having a fuel conduit for receiving the fuel from a fuel source and a fuel exit passage for delivering the fuel to a combustion chamber of the engine;

an actuator having a valve and a stop, wherein the stop is configured to move from a first position to a second position to move the valve from a closed position to an open position; and

a driver positioned proximate to the actuator and configured to travel longitudinally within the body to impact the stop to move the stop from the first position to the second position, wherein the driver extends along an axis from a first end to a second end, and wherein both the first end and the second end of the driver travel longitudinally within the body.

22. The fuel injector of claim 21, further comprising a force generator positioned concentrically around the driver, wherein the driver is further positioned between the stop and the valve, and wherein the force generator is configured to move the driver from a position in contact with the valve and spaced apart from the stop to a position in contact with the stop and spaced apart from the valve.