Information
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Patent Grant
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6405711
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Patent Number
6,405,711
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Date Filed
Thursday, July 27, 200024 years ago
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Date Issued
Tuesday, June 18, 200222 years ago
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Inventors
-
Original Assignees
-
Examiners
Agents
-
CPC
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US Classifications
Field of Search
US
- 123 456
- 123 468
- 123 469
- 123 470
- 123 508
- 123 509
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International Classifications
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Abstract
An integrated fuel delivery module for a fuel injected engine includes a fuel rail having a fuel distribution channel and a plurality of spaced-apart fuel injector sockets connected with the fuel distribution channel. A high-pressure fuel pump has a high-pressure chamber connected internally to the fuel distribution channel without external high-pressure fuel lines.
Description
TECHNICAL FIELD
This invention relates to a fuel pump and fuel delivery module arrangement for fuel injected internal combustion engines.
BACKGROUND OF THE INVENTION
Various fuel injection systems for internal combustion engines have been developed. One type of system includes a plurality of fuel injection nozzles that inject fuel into the intake passageways leading to the combustion chamber. Alternately, fuel may be directly injected into the engine combustion chambers. In such direct injection (DI) systems, high fuel pressures are required to overcome compression pressures in the chamber and to generate very fine fuel atomization. Required fuel pressures for direct injection gasoline engines are on the order of 10 MPa (about 1500 PSI). Further, diesel engines may require much higher fuel pressures, on the order of 67 MPa (about 10,000 PSI). in contrast, fuel injection systems having fuel injected into the intake runner (upstream of the intake valve) operate at relatively low fuel pressures, on the order of 0.3 MPa (about 40 PSI).
Existing direct injection systems generally include a fuel rail having a plurality of fuel injector sockets supplying fuel to the fuel injectors. A high-pressure fuel pump supplies fuel to the fuel rail through a high-pressure fuel line that is connected to the rail and the fuel pump by high-pressure fittings. However, various problems may be encountered with such an arrangement. For example, fuel leakage at the fittings and the like may occur with such systems. Further, the fuel line and fittings require fabrication and installation/assembly, thus adding to the cost and complexity of the vehicle.
SUMMARY OF THE INVENTION
One aspect of the present invention is an integrated high-pressure fuel pump and fuel delivery module for fuel injected internal combustion engines. A fuel delivery module includes a fuel rail having a fuel distribution channel and a plurality of spaced-apart fuel injector sockets connected with the fuel distribution channel. A high-pressure fuel pump has a high-pressure chamber connected internally to the fuel distribution channel without external high-pressure fuel lines.
Another aspect of the present invention is an internal combustion engine of the type having a plurality of combustion chambers and an intake system supplying air to the combustion chambers. The intake system includes an intake manifold having a plurality of intake ports configured to supply air to the combustion chambers. A plurality of fuel injectors supply fuel to a selected one of the intake ports and the combustion chambers. A fuel rail extends along the intake manifold, and includes a fuel distribution channel supplying fuel to the fuel injectors. A fuel pump is mounted on the fuel rail, and has a high-pressure chamber connected internally to the fuel distribution channel without external fuel lines.
Yet another aspect of the present invention is an integrated fuel pump and fuel rail for fuel injected internal combustion engines. A fuel rail has an elongated fuel distribution channel and a plurality of spaced-apart fuel injection sockets connected to the fuel distribution channels. A fuel pump has a high-pressure chamber connected internally to the fuel distribution channel. The fuel pump includes a housing, at least a portion of which is integrally formed with the fuel rail.
These and other features, advantages and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1
is a partially schematic, perspective view of an internal combustion engine including an integrated high-pressure fuel pump and fuel delivery module embodying the present invention;
FIG. 2
is a partially fragmentary, perspective view of an integrated high-pressure fuel pump and fuel delivery module according to one aspect of the present invention;
FIG. 3
is a partially fragmentary, perspective view of an integrated high-pressure fuel pump and fuel delivery module according to one aspect of the present invention;
FIG. 4
is a partially schematic view of the integrated high-pressure fuel pump and fuel delivery module of
FIG. 1
taken along the axis of the cam;
FIG. 5
is a fragmentary, perspective view of the high-pressure fuel pump and delivery module of
FIG. 1
illustrating the integral fuel rail and pump housing; and
FIG. 6
is a cross-sectional view of a diaphragm type pump suitable for use with the integrated fuel pump housing and rail of FIGS.
1
-
5
.
DESCRIPTION OF THE PREFERRED EMBODIMENT
For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front, ” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in FIG.
1
. However, it is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.
The reference numeral
1
(
FIG. 1
) generally designates an integrated high-pressure fuel pump and fuel delivery module for a fuel injected internal combustion engine
2
. In the illustrated example, the integrated high-pressure fuel pump and fuel delivery module
1
includes a fuel delivery module
3
having a fuel rail
4
forming a fuel distribution channel
5
and including a plurality of spaced-apart fuel injector sockets
6
(see also
FIG. 2
) connected with the fuel distribution channel to supply fuel to a plurality of fuel injector nozzles
7
. A high-pressure fuel pump
10
includes a high-pressure chamber
11
(
FIG. 5
) connected internally to the fuel distribution channel
5
without external high-pressure fuel lines.
Internal combustion engine
2
includes an intake manifold
12
having a plurality of intake runners or passageways
13
that connect with the ports
14
(
FIG. 3
) of a second intake manifold part
15
. A mechanical linkage
16
operates conventional throttle valves
17
located within each port
14
. A conventional electrical actuator
18
includes an electrical connector
19
for receiving signals from the engine control unit (ECU) (not shown) to control the linkage
16
and throttle valves
17
. Throttle valves
17
are of a conventional “flow control” or “port throttle” valve design. A fuel pressure sensor
20
is positioned at one end of the fuel rail to provide a signal to the ECU corresponding to the fuel pressure within the fuel distribution channel
5
of fuel rail
4
. The fuel injector nozzles
7
are direct injection type injectors, wherein the fuel is injected directly into the combustion chamber
21
of engine cylinder head
22
(see also FIG.
4
).
Fuel rail
4
includes a tubular main section
23
forming fuel distribution channel
5
therein. Fuel injector sockets
6
are also generally tubular, and extend transversely from the tubular main portion
23
of rail
4
. Sockets
6
include a conventional connector
24
to distribute the fuel to the fuel injector nozzles
7
. A plurality of reinforcing ribs
25
(
FIG. 2
) extend parallel to the fuel injector sockets
6
, and rigidly interconnect the second intake manifold part
15
with the tubular main portion
23
of fuel rail
4
. Significantly, fuel rail
4
, fuel injector sockets
6
, second intake manifold part
15
, and ribs
25
may all be integrally cast as a one piece unit that can be readily assembled to the cylinder head
22
of internal combustion engine
2
.
High-pressure fuel pump
10
includes a housing
26
having a first portion
27
, and a second portion
28
that is formed integrally with the fuel rail
4
(see also FIG.
5
). Opening
43
directly connects high-pressure chamber
11
of pump
10
with channel
5
of rail
4
without fittings. Alternately, the fuel pump
10
could be connected to the fuel rail
4
by a high-pressure fitting without use of an external fuel line. However, in a preferred construction second housing portion
28
is integrally cast with rail
4
to completely eliminate external fittings and fuel lines between pump
10
and rail
4
. A preferred material for rail
4
and integral fuel pump housing
28
is a “high density” cast aluminum. In the illustrated example, internal combustion engine
2
includes overhead cams
29
and
30
(FIG.
4
). Cam
30
includes a cam lobe
31
, and pump
10
includes a cam follower
32
that engages lobe
31
to actuate pump
10
. Alternately, pump
10
could be mechanically driven by other known arrangements, or, pump
10
could be an electrical pump. Pump
10
includes a low-pressure fuel supply port
33
that is connected to a low-pressure fuel supply line
35
via a conventional threaded connectors. Pump
10
further includes a low-pressure fuel return port
34
connected to a low-pressure fuel return line
36
, also via conventional threaded connectors. Pump
10
includes an electrical connector
37
for receiving/sending electrical signals to the ECU. Electrical connector
37
is connected to a fuel pressure sensor and regulator assembly
38
that senses the pressure of the fuel within chamber
11
, and returns fuel to the fuel tank (not shown) of the vehicle through the low-pressure return line
36
. The regulator assembly
38
includes a sensor
39
extending into chamber
11
to sense the fuel pressure within chamber
11
. Housing
28
of fuel pump
10
is integrally formed with fuel rail
4
, such that the fuel return line
36
can be routed directly from the fuel pump
10
to the fuel tank, rather than from the fuel rail
4
.
Pump
10
could have various internal mechanical or electrical pump configurations.
FIG. 6
illustrates an existing diaphragm fuel pump
40
having a pump design usable with the integrated fuel rail and housing of the present invention. The pump
40
of
FIG. 6
is described in detail in U.S. patent application No. 09/027,121, filed Feb. 20, 1998, entitled HYDRAULIC DIAPHRAGM PUMP, the entire contents of which are hereby incorporated herein by reference. Although the various internal components of pump
40
would be rearranged somewhat to fit within the housing
26
of the present fuel pump
10
, the operation of the internal components is substantially the same as illustrated in FIG.
6
. Inlet port
41
and outlet port
42
correspond to the supply port
33
and opening
43
, respectively, of pump
10
of the present invention (FIG.
5
). Accordingly, the routing of ports
41
and
42
would be changed to match ports
41
and
42
. Although the housing
27
of the present pump
10
is illustrated with a relatively thin sidewall in
FIG. 5
, the actual internal dimensions of housing
27
would be substantially the same as housing
44
of pump
40
illustrated in
FIG. 6
, such that housing
27
would accommodate the follower
32
and internal pump components
45
. The pump
40
of
FIG. 6
includes housing portions
49
,
50
, and
51
, as well as inlet and outlet valve assemblies
46
and
47
that route the fuel through the internal passageways
51
of pump
40
. Pump
10
of the present invention could utilize substantially the same valve assemblies
46
and
47
, as well as the various other internal passageways
51
and related components. However, housing portion
28
would have an internal configuration providing for internal passageways
51
, valves
46
and
47
, and other internal components configured to-pump fuel from the supply port
33
to the opening
43
into fuel distribution channel
5
. Numerous mechanical or electrical pump designs could be utilized with the integral fuel pump housing and fuel rail of the present invention, such that pump
40
merely illustrates one example of a cam-driven mechanical pump suitable for use with the present integrated fuel pump housing and delivery module. Clearly, electrical fuel pumps that are not cam-driven could also be utilized.
The integrated fuel pump and fuel delivery module of the present invention eliminates external high-pressure connections and lines, thus improving reliability while reducing the possibility of leakage. Further, elimination of the high-pressure external fittings and lines reduces the complexity and attending cost associated with conventional arrangements. In the illustrated example, internal combustion engine
2
is a direct injection gasoline engine. However, the integrated high-pressure fuel pump and fuel delivery rail and module of the present invention may also be utilized with high-pressure diesel engines, or low-pressure gasoline fuel injection systems wherein fuel is injected upstream of the intake valves.
It will be understood by those who practice the invention and those skilled in the art, that various modifications and improvements may be made to the invention without departing from the spirit of the disclosed concept. The scope of protection afforded is to be determined by the claims and by the breadth of interpretation allowed by law.
Claims
- 1. An integrated high-pressure fuel delivery module, comprising:a one piece integral unit including an intake manifold part having a plurality of intake ports configured to flow air to a cylinder head, and a fuel rail having a fuel distribution channel and a plurality of space-apart fuel injector sockets connected with said fuel distribution channel; said one piece integral unit further including a pump housing and a high-pressure fuel pump having a high-pressure chamber connected internally to said fuel distribution channel without external high-pressure fuel lines.
- 2. An integrated high-pressure fuel delivery module for connection to a high-pressure fuel pump having a high-pressure chamber connected internally to said fuel distribution channel without external high-pressure fuel lines for an engine,said fuel delivery module comprising a fuel rail having a fuel distribution channel and a plurality of spaced-apart fuel injector sockets connected with said fuel distribution channel; and wherein said fuel pump includes a follower adapted to connect a cam lobe to actuate said fuel pump.
- 3. The integrated fuel delivery module set forth in claim 1, wherein said fuel pump includes a low-pressure fuel supply port and a low-pressure fuel return port.
- 4. The integrated fuel delivery module set forth in claim 1, wherein said fuel delivery module includes a plurality of injectors adapted to directly inject fuel into a combustion chamber of an associated internal combustion engine.
- 5. The integrated fuel delivery module set forth in claim 4, wherein said fuel pump generates fuel pressure on the order of at least 1500 psi.
- 6. The integrated fuel delivery module set forth in claim 1, wherein:said fuel rail includes an elongated tubular portion forming said fuel distribution channel; and said fuel pump is positioned on and above said elongated tubular portion.
- 7. An internal combustion engine of the type having a plurality of combustion chambers and an intake system supplying air to said combustion chambers, said intake system comprising:an intake manifold part including a plurality of intake ports configured to supply air to the combustion chambers; a plurality of fuel injectors supplying fuel directly to said combustion chambers; a fuel rail extending along said intake manifold and formed integrally therewith, said fuel rail including a fuel distribution channel supplying fuel to said fuel injectors; and a fuel pump mounted to said fuel rail and having a fuel pump housing formed integrally with said fuel rail, said fuel pump having a high-pressure chamber connected internally to said fuel distribution channel without external fuel lines.
- 8. The internal combustion engine set forth in claim 7, wherein said fuel rail and said portion of said housing are integrally cast of a metal material.
- 9. The internal combustion engine set forth in claim 7, wherein:said internal combustion engine includes at least one camshaft configured to actuate intake valves of said engine, said camshaft including at least one pump actuation lobe; and said fuel pump includes a follower contacting said pump actuation lobe to actuate said fuel pump.
- 10. The internal combustion engine set forth in claim 9, wherein said fuel pump generates fuel pressure on the order of at least 1500 psi.
- 11. The internal combustion engine set forth in claim 10, wherein:said fuel rail includes an elongated tubular portion forming said fuel distribution channel; and said fuel pump is positioned on and above said elongated tubular portion.
- 12. An integrated fuel delivery module for a fuel injected engine, comprising:an intake manifold part having a plurality of intake ports configured to supply air to combustion chambers of an internal combustion engine; a fuel rail formed integrally with said intake manifold part and having an elongated fuel distribution channel and a plurality of spaced-apart fuel injection sockets connected to said fuel distribution channel; and a fuel pump having a high-pressure chamber connected internally to said fuel distribution channel, said fuel pump including a housing, at least a portion of which is integrally formed with said fuel rail.
- 13. An integrated fuel pump and fuel rail for a fuel injected engine, comprising:a fuel rail having an elongated fuel distribution channel and a plurality of spaced-apart fuel injection sockets connected to said fuel distribution channel; and a fuel pump having a high-pressure chamber connected internally to said fuel distribution channel, said fuel pump including a housing, at least a portion of which is integrally formed with said fuel rail, said fuel pump including a follower adapted to contact a cam lobe to actuate said fuel pump.
- 14. The integrated fuel delivery module set forth in claim 12, wherein said fuel pump includes a low-pressure fuel supply port and a low-pressure fuel return port.
- 15. The integrated fuel delivery module set forth in claim 12, wherein said fuel delivery module includes a plurality of injectors adapted to directly inject fuel into a combustion chamber of an associated internal combustion engine.
- 16. The integrated fuel delivery module set forth in claim 15, wherein said fuel pump generates fuel pressure on the order of at least 1500 psi.
- 17. The integrated fuel delivery module set forth in claim 16, wherein:said fuel rail includes an elongated tubular portion forming said fuel distribution channel; and said fuel pump is positioned on and above said elongated tubular portion.
US Referenced Citations (8)