The field of the present invention is fuel delivery systems. More particularly, the present invention relates to an injector cup for use in fuel delivery systems, such as, for example, gasoline direct injection systems, and a method of manufacturing the same.
Fuel delivery systems for direct injection and port injection applications, such as, for example, fuel-injected engines used in various types of on-road and off-road vehicles, typically include one or more fuel rails having a plurality of fuel injectors associated therewith. In such applications, the fuel rails include a plurality of outlet openings in which injector sockets or cups are affixed. The fuel injectors are inserted into and coupled with the injector cups so as to allow for the fuel flowing in the fuel rail to be communicated to the fuel injectors. The fuel communicated from the fuel rail to the fuel injectors is then communicated to the combustion chamber of the engine. Accordingly, in these arrangements the fuel injectors are sandwiched between the fuel rail and a corresponding cylinder head of the engine.
Conventional fuel injector cups generally take one of two forms. The first is normally used in low-pressure port fuel injection applications. This type of injector cup is typically stamped and includes a flange or ears that act as an attachment for retention clips that are used to retain the fuel injector within the fuel injector cup. The second is normally used in high-pressure direct injection applications. This type of injector cup is typically cast or forged and then subjected to secondary machining processes to create precise sealing surfaces for injector o-rings, as well as internal and/or external features for mating with the injector clip, for example.
Cast or forged cups, as opposed to stamped cups, are utilized in direct injection applications due to the force generated by the relatively high amount of pressure (i.e., on the order of 10-20 MPa or more) that is applied to the injector/injector clip/fuel injector cup interface in such systems. One drawback of cast/forged cups is that secondary machining processes or operations have to be performed on the cup to create the necessary surfaces and/or features required to allow for the sealing of the system and the retention of the injector within the cup. This secondary machining results in additional manufacturing steps, and therefore, complexity and cost, being added to the manufacturing process.
Therefore, there is a need for a fuel delivery system that will minimize and/or eliminate one or more of the above-identified deficiencies.
The present invention is directed to a fuel delivery system. The fuel delivery system comprises a fuel rail having an outlet, and a fuel injector cup associated therewith. The fuel injector cup includes a first portion and a ring portion.
The first portion of the fuel injector cup comprises a body. The body includes a first end, a second end, and a cavity therein between the first and second ends. The cavity of the body is configured to receive a fuel injector, and the first end of the body is configured to be associated with the outlet of the fuel rail.
The ring portion of the fuel injector cup is configured to be affixed to the first portion, and the second end thereof, in particular. The ring portion is further configured to reinforce the second end of the first portion.
Further features and advantages of the present invention, including the constituent components and methods of manufacturing the same, will become more apparent to those skilled in the art after a review of the invention as it is shown in the accompanying drawings and detailed description.
a and 2b are exaggerated cross-sectional views of an exemplary embodiment of the fuel injector cup illustrated in
a and 4b are exaggerated partial cross-sectional views of another exemplary embodiment of the fuel injector cup illustrated in
a and 5b are exaggerated partial cross-sectional views of an alternate exemplary embodiment of the fuel injector cups illustrated in
a and 6b are exaggerated partial cross-sectional views of an alternate exemplary embodiment of the fuel injector cups illustrated in
The present invention is directed, at least in part, to a fuel delivery system having a fuel injector cup comprising a stamped cup portion that is augmented with a ring portion to provide the stamped cup the strength and structural integrity typically found in cast or forged fuel injector cups to withstand the forces generated by the fuel delivery system having a system pressure on the order of 10-20 MPa or more. Accordingly, referring now to the drawings wherein like reference numerals are used to identify identical components in the various views,
With continued reference to
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As illustrated in
Turning now ring portion 28 of injector cup 16, ring portion 28 (also referred to herein as ring 28) is configured to be affixed to cup portion 26, and second end 34 thereof, in particular. When affixed to cup portion 26, ring portion 28 is operative to, at least in part, reinforce second end 34 of cup portion 26 to avoid damage or destruction thereto caused by the force applied to injector 14 and cup 16 as a result of the pressure attendant in the system, which can be on the order of 10-20 MPa or more. More particularly, the pressure in fuel delivery system 10 generates a force that is applied to the fuel injector causing the injector to want to “pop” out of the injector cup. A fuel injector clip is coupled to or mated with both the fuel injector and the injector cup to retain the fuel injector in the injector cup and to counteract the force. Accordingly, the force applied to the injector is transferred to the clip, and from the clip to the cup to which the clip is coupled/mated. As a result, the portion of the cup mated or coupled with the injector clip (i.e., second end 34) must have sufficient strength and structural integrity to bear this force. Ring portion 28 provides this added strength and structural integrity to cup portion 26.
In addition to providing reinforcement to cup portion 26, in an exemplary embodiment illustrated, for example, in
With reference to
With reference to
With reference to
In an exemplary embodiment, cup portion 26 and/or ring portion 28 include a plurality of notches 50 therein.
a and 6b illustrate an alternate exemplary embodiment wherein ring portion 28′ includes a plurality of notches 50 disposed therein.
The foregoing having described exemplary embodiments of fuel system 10 and fuel injector cup 16, in particular, an exemplary method of manufacturing injector cup 16 will be described with reference to
In a first step 62, cup portion 26 is formed. As set forth in greater detail above, cup portion 26 includes body 30 having first end 32, second end 34, and inner cavity 36 disposed therein between first end 32 and second end 34. In an exemplary embodiment, step 62 includes stamping cup portion 26. In such an embodiment, the stamping process includes creating sealing surfaces and retention features on or in cup portion 26. Cups typically used in high pressure applications, such as direct injection applications, are usually cast or forged to provide the cup the necessary strength and structural integrity to withstand the forces applied to the cup in the system. As such, the surfaces and features have to be machined onto injector cups in secondary post-forging/casting machining steps.
In an exemplary embodiment, forming step 62 further includes forming cup portion 26 to include at least one notch 50 in body 30 thereof. More particularly, one or more notches 50 are formed in body 30 at second end 34. Notch 50 may be formed by employing a number of processes or techniques, such as, for example, a piercing operation. Forming step 62 may further include forming cup portion 26 to include a flange 44 disposed at second end 34 thereof. In an embodiment wherein cup portion 26 includes one or more notches 50 therein and a flange 44 is desired, cup portion 26 may be formed by forming notches 50 in body 30 and then manipulating a portion of second end 34 of body 30 to create flange 44. This manipulation may include, for exemplary purposes only, rolling or folding edge 40 over to a 90 degree angle with the remainder of body 30.
In a second step 64, ring portion 28 is formed wherein ring portion 28 is configured to be affixed to cup portion 26. In an exemplary embodiment, ring portion 28 is formed to comprise an annular ring. However, in an alternate embodiment, ring portion 28 is formed to comprise a cap configured to be fitted over cup portion 26, and second end 34 thereof, in particular. In such an embodiment, ring portion 28 may be formed to include shoulder 48 on the interior surface thereof that is configured to engage and abut outer edge 40 of cup portion 26. In an exemplary embodiment, forming step 64 includes stamping ring portion 28. In other exemplary embodiments, ring portion 28 may be formed using other known processes, such as, for example, casting, forging, or other like processes. Forming step 64 may further include forming ring portion 28 to include at least one notch 50 therein. Notches 50 may be formed by employing a number of processes or techniques, such as, for example, a piercing operation.
In a third step 66, ring portion 28 is affixed to cup portion 26. In an exemplary embodiment, affixing step 66 includes positioning ring portion 28 at second end 34 of cup portion 26 such that at least part of ring portion 28 overlaps part of cup portion 26. Ring portion 28 is then affixed to cup portion 26 using any number of known processes/techniques, such as, for exemplary purposes only, welding or brazing operations. In embodiment wherein cup portion 26 includes a flange 40, affixing step 66 includes positioning ring portion 28 such that it abuts flange 44, and then affixing ring portion 28 to cup portion 26. Further, in an embodiment wherein cup portion 26 includes one or more notches 50, affixing step 66 includes positioning ring portion 28 such that it overlaps part of notches 50 and effectively closes access to notches 50, thereby creating a number of windows 56 in cup portion 26 equal to the number of notches 50. Similarly, in an embodiment wherein ring portion 28′ includes one or more notches 50, affixing step 66 includes positioning ring portion 28′ over second end 34 of cup portion 26 such that a part of each notch 50 in ring portion 28′ overlaps part of cup portion 26, effectively closing access to each notch 50, thereby creating a number of windows 56 in ring portion 28′ equal to the number of notches 50.
While the invention has been particularly shown and described with reference to the preferred embodiments thereof, it is well understood by those skilled in the art that various changes and modifications can be made in the invention without departing from the spirit and scope of the invention.
This application claims the benefit of U.S. Provisional Application Ser. No. 61/020,834 entitled “Two-Piece Injector Cup,” which was filed on Jan. 14, 2008, and which is hereby incorporated by reference in its entirety.
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Number | Date | Country | |
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Number | Date | Country | |
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61020834 | Jan 2008 | US |