Integrated fuel injectors and igniters and associated methods of use and manufacture

• US 9,581,116 B2
• Filed: 01/22/2014
• Issued: 02/28/2017
• 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:
  US14/161,373
• Publication Number:
  US 20140345563A1
• Time in Patent Office: 1,133 Days
• Field of Search: 123/297, 123/299, 123/300, 123/304, 123/472, 123/478, 123/494, 701102-104, 701/105
• US Class Current: 1/1
• 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: F02D 19/027 Determining the fuel pressure, temperature or volume flow, the fuel tank fill level or a valve position
• CPC Class Codes: F02D 41/36 with means for controlling distribution
• CPC Class Codes: F02D 41/40 with means for controlling injection timing or duration
• CPC Class Codes: F02D 41/401 Controlling injection timing F02D41/402 takes precedence
• CPC Class Codes: F02D 41/406 Electrically controlling a diesel injection pump F02D41/401 takes precedence
• CPC Class Codes: F02M 21/0206 Non-hydrocarbon fuels, e.g. hydrogen, ammonia or carbon monoxide
• CPC Class Codes: F02M 21/0227 Means to treat or clean gaseous fuels or fuel systems, e.g. removal of tar, cracking, reforming or enriching
• 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 2200/26 Fuel-injection apparatus with elastically deformable elements other than coil springs
• CPC Class Codes: F02M 45/086 Having more than one injection-valve controlling discharge orifices
• CPC Class Codes: F02M 51/0625 characterised by arrangement of mobile armatures
• CPC Class Codes: F02M 51/0671 the armature having an elongated valve body attached thereto
• CPC Class Codes: F02M 57/005 the devices being sensors
• CPC Class Codes: F02M 57/06 the devices being sparking plugs
• CPC Class Codes: F02M 61/047 the valves being formed by deformable nozzle parts, e.g. flexible plates or discs with fuel discharge orifices
• 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 injectors with integrated igniters providing efficient injection, ignition, and complete combustion of various types of fuels. These integrated injectors/igniters can include, for example, insulators with adequate mechanical and dielectric strength to enable high-energy plasma generation by components that have very small dimensions, multifunction valving that is moved to injector multiple bursts of fuel and to induce plasma projection, a fuel control valve at the interface to the combustion chamber for the purpose of eliminating fuel drip at undesired times, and one or more components at the interface of the combustion chamber for the purpose of blocking transmission of combustion sourced pressure.

Claims

1. A fuel injector valve for use in a direct fuel injection engine, comprising:

a fuel injection valve fluidically connected to a fuel source and positioned adjacent to a combustion chamber to directly inject a first fuel stream per cycle into the combustion chamber;

at least one sensor configured to determine at least one engine operation parameter that affects formation of a stratified air-fuel mixture inside the combustion chamber; and

a controller configured to selectively control the fuel injection valve to use a plurality of fuel streams wherein a first fuel stream timing is set to control the injection valve to inject the first fuel stream during an intake stroke while a piston in the combustion chamber is approximately at an intake top dead center position such that a majority of the first fuel stream injected from the fuel injection valve is received inside a pocket of excess oxidant in the combustion chamber, the excess oxidant further providing thermal insulation to the combustion chamber.

2. The fuel injector of claim 1, wherein the sensor is positioned flush with a wall of the combustion chamber.

3. The fuel injector of claim 1, wherein the sensor is integral with the valve.

4. The fuel injector of claim 1, wherein the parameter is temperature.

5. The fuel injector of claim 1 further comprising an igniter integral with the fuel injection valve.

6. The fuel injection valve of claim 1 is contained within a fuel injector-igniter device, the fuel injector-igniter device includes a body having a middle portion extending between a base portion and a nozzle portion;

the nozzle portion is configured to engage a standard spark plug connection in a fuel combustion engine, the body having a channel configured to allow fluid passage extending there through;

a first and a second electrode configured to provide a ignition event, the first and the second electrode positioned at a distal end of the nozzle portion;

an actuator contained within the channel of the injector-igniter body, the actuator having a distal end and a proximal end, wherein the fuel injection valve operably connected to a distal end of the actuator;

a driver operably connected to a proximal end of the actuator; and

a controller operably connected to the driver, the controller configured to adaptively optimize the fuel injection and ignition characteristics of the injector-igniter.

7. The fuel injector-igniter of claim 6 wherein the driver is movable from a first position to a second position in response to an inducing component, wherein the movement from a first position to a second position creates a controlled pattern of fuel distribution.

8. The fuel injector-igniter of claim 7 wherein the inducing component is at least one of an acoustic component, an electromagnetic component and/or piezoelectric component.

9. The fuel injector-igniter of claim 6 wherein the actuator is a fiber optic cable, insulated transducers integrated within a rod or cable, and/or other sensor.

10. The fuel injector-igniter of claim 6 further comprising an ignition and flow adjusting device carried by the flow control device.

11. The fuel injector-igniter of claim 6 wherein the ignition and flow adjusting device protects the flow control device.

12. The fuel injector-igniter of claim 6 wherein the ignition and flow adjusting device is a sensor.

13. The fuel injector-igniter of claim 6 wherein the ignition and flow adjusting device is the first electrode and wherein the ignition and flow adjusting device is configured to affect the shape, pattern, and/or phase of an injected fuel.

14. The fuel injector-igniter of claim 6 wherein the body is made from a first and a second dielectric material suitable to enable high energy ignition to combust different multiple fuels, wherein the dielectric material provides sufficient electrical insulation of the high voltage at the electrode for the production, isolation, and/or delivery of spark or plasma for ignition.

15. The fuel injector-igniter of claim 6 wherein the body portion is constructed from a first dielectric material and the nozzle portion is constructed from a second dielectric material having a dielectric strength higher than the first dielectric material strength.

16. The fuel injector-igniter of claim 6 wherein the valve control device includes a first and a second valve.

17. The fuel injector-igniter of claim 16 wherein the first valve is a check valve operably connected to the second valve.

18. The fuel injector-igniter of claim 16 wherein the first valve is a pressure valve mechanically and electronically decoupled from the actuator.

19. The fuel injector-igniter of claim 18 wherein the electrode has a plurality of enhanced surfaces designed to increase gasification of injected fuels and provide extended electrode life.

20. The fuel injector-igniter of claim 6 wherein the driver is mechanically coupled to the valve control device and electrically separated from the valve control device.

21. A method for injection fuel in a direct fuel injection engine, comprising:

determining at least one engine operation parameter that affects formation of a stratified air-fuel mixture inside a combustion chamber;

determining whether to inject multiple fuel bursts based on the a determination of the engine operation parameter; and

injecting the plurality of fuel bursts based on the determination of the engine operation parameter, wherein a first fuel stream is injected while a piston is approximately at an intake top dead center position, and wherein a majority of the first fuel stream is received inside a pocket of excess oxidant in the combustion chamber, the pocket of excess oxidant further providing thermal insulation to the combustion chamber.