Shrouds for low pressure fuel injectors are provided, and in particular, devices, systems, and methods are provided for directing gaseous fuel flow into a combustion chamber.
Current direct inject fuel gas injector systems can generally be categorized as low pressure systems or high pressure systems. Compared to low pressure systems, high pressure systems can provide better fuel penetration and improved homogeneity of a fuel/air mixture. However, high pressure systems can be much more expensive to purchase and maintain than low pressure systems. Converting a low pressure system to a high pressure system can also require expensive system level upgrades in applications such as, e.g., pipeline gas compression. In other applications, it may not be possible to use a high pressure system due to lack of a high pressure gas source.
Shrouds for use with lower pressure fuel injectors, low pressure fuel injectors assemblies, and methods for directing gaseous fuel flow into a combustion chamber are provided. In one embodiment, a shroud for a gas fuel injector is provided that can include a body having an open proximal end configured to receive fuel from a fuel injector and a distal end configured to deliver the fuel to a combustion chamber of an engine. The distal end can have a primary opening extending therethrough. The primary opening can be configured to be sealed by a valve during injection of a fuel. The distal end can include at least one secondary opening extending therethrough and positioned radially outward of the primary opening. The at least one secondary opening can be configured to pass fuel therethrough when the primary opening is sealed by a valve.
The shroud can vary in a number of ways. For example, the at least one secondary opening can be configured to direct fuel radially outward from the at least one secondary opening. As another example, the body of the shroud can have a substantially cylindrical geometry. As another example, the distal end of the body of the shroud can be configured to couple with a cylinder head of an engine, adjacent to a fuel intake port. As yet another example, a portion of the body of the shroud can configured to be received within a fuel intake port of an engine.
In some implementations, the at least one secondary opening can have a longitudinal axis that can be angled radially outward from a central axis of the primary opening. In other implementations the at least one secondary opening can be a longitudinal slot that extends through the body of the shroud. As another example, the at least one secondary opening can comprise a plurality of openings positioned radially around the primary opening.
In another embodiment, a fuel injector is provided that can include a housing defining a first passage configured to allow fuel to flow therethrough. The housing can include a sealing element. The fuel injector can also include a valve that can be movable between a first position in which the valve forms a seal with the sealing element and a second position. The fuel injector can further include a shroud that can have a proximal end coupled to the housing. The shroud can have a central passage configured to be substantially sealed by the valve when the valve is in the second position, and at least one fuel passage configured to allow fuel to flow therethrough when the central passage is sealed by the valve.
The fuel injector can vary in a number of ways. For example, the at least one fuel passage can be configured to direct fuel radially outward from the at least one fuel passage. As another example, the body of the shroud can have a substantially cylindrical geometry. In some implementations, the at least one fuel passage can be angled radially outward from a central axis of the primary passage. In other implementations the at least one fuel passage can be in the form of at least one longitudinal slot that extends through the body of the shroud. As another example, the at least one fuel passage can be in the form of a plurality of passages positioned radially around the central passage.
In another aspect, a method for injecting fuel into an engine is provided. The method can include delivering a gaseous fuel to a fuel inlet passage of a fuel injector, moving a sealing member from a first position to a second position to thereby open the fuel inlet passage and to seal a first passage of a shroud. The gaseous fuel can flow from the fuel inlet passage through at least one secondary passage in the shroud such that the fuel flows into a combustion chamber. The method can further include moving the sealing member from the second position to the first position, thereby closing the fuel inlet passage, and igniting the fuel to cause combustion.
The method can vary in a number of ways. For example, the sealing member can move away from a sealing element to open the fuel passage when it is moved from the first position to the second position. In some implementations, the fuel can be directed radially outward from a central axis of the first passage as it flows into the combustion chamber. In other implementations, a flame front from the combustion chamber can enter the first passage of the shroud. The flame font can burn fuel within the shroud.
Certain exemplary embodiments will now be described to provide an overall understanding of the principles of the structure, function, manufacture, and use of the systems, devices, and methods disclosed herein. One or more examples of these embodiments are illustrated in the accompanying drawings. Those skilled in the art will understand that the systems, devices, and methods specifically described herein and illustrated in the accompanying drawings are non-limiting exemplary embodiments and that the scope of the present invention is defined solely by the claims. The features illustrated or described in connection with one exemplary embodiment may be combined with the features of other embodiments. Such modifications and variations are intended to be included within the scope of the present invention. Further, in the present disclosure, like-named components of the embodiments generally have similar features, and thus within a particular embodiment each feature of each like-named component is not necessarily fully elaborated upon.
Some gas fired internal combustion engines utilize direct inject fuel gas injector systems to inject fuel into a combustion chamber of the engine. The fuel within the combustion chamber can be ignited to cause combustion, which can displace a piston. The motion of the piston creates mechanical energy that can be harnessed. Direct inject fuel gas injector systems can generally be categorized as low pressure systems, which can deliver fuel at approximately ˜30-60 psig, or high pressure systems, which can deliver fuel at approximately ˜100-500 psig. In some circumstances, low pressure systems can provide relatively low fuel penetration, and poor fuel/air mixing, in the combustion chamber, which can result in inefficient combustion and increased emissions. One way to correct this is to use a shroud, or cap, to direct flow from the injector into the combustion chamber. The shroud can maximize fuel penetration, improve free jet mixing of a gas stream, and create a more homogeneous fuel/air mixture in the combustion chamber by optimizing the injection direction and spread of gas into the chamber. This can allow for better fuel distribution as compared to other, similar low pressure injectors. The improved fuel distribution can result in more efficient combustion and reduced emissions.
The fuel injector 112 can have a variety of configurations and any fuel injector known in the art can be used with the shrouds disclosed herein. As shown in
In operation, with reference to
As indicated above, the shroud 250 can couple between the fuel injector 112 and the combustion chamber 114 for delivering fuel from the fuel injector 112 to the combustion chamber 114. The shroud 250 can have various configurations. In the illustrated embodiment, as shown in more detail in
In an exemplary embodiment, the shroud 250 is configured to direct fuel in a controlled manner from the fuel injector 112 into the combustion chamber 114. While various techniques can be used to control fuel flow, in one embodiment as shown the shroud 250 can include a central primary passage 254 and at least one secondary passage 256, which can be referred to as a fuel passage, disposed adjacent to the central passage 254. In the illustrated embodiment, the shroud 250 includes four secondary passages 256 disposed radially outward of and around the central passage 254. However, the shroud 250 can include one or more secondary passages 256.
The central and secondary passages 254, 256 can have any geometry that suits the described purpose. For example, the central passage 254 can be circular as shown, or it can be another shape, such as oval, square, rectangular, etc. The secondary passages 256 can also have various shapes. In an exemplary embodiment, the secondary passages 256 can each be in the form of an elongate slot.
As shown in
Although the shroud 250 and fuel injector 112 are described as independent components, in some embodiments, the shroud 250 can be integral with the housing 116 of the fuel injector 116. Therefore, the fuel injector can include the central passage 254 and the secondary passages 256 as described above with regard to the shroud 250.
In use, the configurations of the passages in the shroud 250 can function to direct a flow of fuel from the fuel injector 112 into the combustion chamber 114 during fuel injection. Directed fuel flow can create more air entrainment and can result in improved mixing and homogeneity of a fuel/air mixture in the combustion chamber 114. In other words, a larger portion of the fuel/air mixture can be at a desired equivalence ratio, and the equivalence ratio can have a smaller standard deviation.
Prior to combustion, or during an initial phase of combustion, the valve member 120 can move back to the first position, thereby uncovering the central passage 254 and forming a seal with the sealing element 118. In order to ensure that any fuel that can remain in the shroud 250 can be burned during combustion, the central passage 254, or cleanout hole, can function to allow a flame front and charge motion from combustion to burn, or sweep out, an enclosed volume of the shroud 250. This can prevent unburned hydrocarbons from collecting within the shroud 250, and can help reduce emissions by ensuring a complete combustion.
One skilled in the art will appreciate that the valve member 120 can be moved from the first position to the second position, and vice versa, in a number of ways. For example, the valve member 120 can be coupled to a cam/lifter linkage that can be coupled to a crank shaft which can be coupled to the piston 102 by a connecting rod. As the piston 102 moves back and forth within the cylinder 104, the crank shaft can rotate which can move the cam/lifter linkage such that the valve member 120 can move between the first and second positions at appropriate times.
The fuel injector 512 can generally be similar to fuel injector 112, and can function to inject a gas such as, e.g., natural gas, into a combustion chamber 514 of the engine 500. The fuel injector 512 can include a housing 516, a sealing element 518, and a valve member 520. The valve member 520 can include a valve stem 522 and a sealing member 524. The sealing member can have a first surface 524a that can form a seal with the sealing element 518, and a second surface 524b that can seal the central passage 454.
As shown in
In the illustrated embodiment, the housing 516 of the fuel injector 512 can be releasably coupled to the cylinder head 505 at the fuel intake port 510, and the shroud 450 can be disposed over the fuel intake port 510 such that it is in the flow path of fuel traveling from the fuel injector 512 the combustion chamber 514. The fuel injector 512, including the valve member 520, can function with the shroud 450 in the same manner as that described with regard to fuel injector 112, valve member 120, and shroud 250.
Although the shrouds 250, 350, 450 have been described in the context of a two-stroke engine, the shrouds 250, 350, 450 can be used with any direct inject gas fuel injector and/or engine. In some embodiments, the shrouds 250, 350, 450 can be integral with a cylinder or a cylinder head of an engine.
As described above, the use of a shroud can help maximize fuel penetration, improve free jet mixing of a gas stream, and create a more homogeneous fuel/air mixture in the combustion chamber by optimizing the injection direction and spread of gas into a combustion chamber. This can allow for better fuel distribution as compared to other, similar low pressure injectors. The improved fuel distribution can result in more efficient combustion, and reduced emissions. For example, a more homogenous mixture of fuel and air within a combustion chamber can minimize lean and rich fuel pockets, which can reduce NOx, volatile organic compounds (VOCs), and carbon monoxide (CO), emissions.
When comparing a high pressure fuel injector and a shrouded low pressure fuel injector, preliminary analyses indicate that similar percentages of a fuel/air mixture in a combustion chamber would be at a desired equivalence ratio directly prior to combustion. Moreover, the shrouded low pressure fuel injector produced a standard deviation of the equivalence ratio that was approximately equal to that of the high pressure fuel injector, and approximately half of that of a low pressure unshrouded fuel injector.
Therefore, using a shroud with a low pressure fuel injection system can allow for comparable performance to a high pressure fuel injection system, while substantially reducing costs and maintenance associated with converting a low pressure injection system to a high pressure injection system. It can also provide a viable alternative when converting from a low pressure injection system to a high pressure injection system is not feasible.
Other embodiments are within the scope and spirit of the disclosed subject matter.
In the descriptions above and in the claims, phrases such as “at least one of” or “one or more of” may occur followed by a conjunctive list of elements or features. The term “and/or” may also occur in a list of two or more elements or features. Unless otherwise implicitly or explicitly contradicted by the context in which it is used, such a phrase is intended to mean any of the listed elements or features individually or any of the recited elements or features in combination with any of the other recited elements or features. For example, the phrases “at least one of A and B;” “one or more of A and B;” and “A and/or B” are each intended to mean “A alone, B alone, or A and B together.” A similar interpretation is also intended for lists including three or more items. For example, the phrases “at least one of A, B, and C;” “one or more of A, B, and C;” and “A, B, and/or C” are each intended to mean “A alone, B alone, C alone, A and B together, A and C together, B and C together, or A and B and C together.” In addition, use of the term “based on,” above and in the claims is intended to mean, “based at least in part on,” such that an unrecited feature or element is also permissible.
Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about” and “substantially,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and/or interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise.