TECHNICAL FIELD
[0001] The present subject matter described herein, relates to a profile of a
nozzle plate to arrest fuel impurities accumulation in the flow path. More
particularly, to a profile of a nozzle plate for eliminating chances of fuel
impurities accumulation in the flow path.
BACKGROUND
[0002] Background description includes information that may be useful in
understanding the present invention. It is not an admission that any of the
10 information provided herein is prior art or relevant to the presently claimed
invention, or that any publication specifically or implicitly referenced is prior art.
[0003] Generally, nozzle plates are provided at the extreme end of the fuel
injectors with at least one hole for spraying the fuel into a cylinder bore or an
intake manifold. The spray from the nozzle plates takes different patterns
15 depending on the shape of the hole of the nozzle plates, shape of the chamber of
the fuel injector and pressure from the plunger of the fuel injector. Further, the
spray from the nozzle plates happens at a spray angle due to air resistance and due
to gravity.
[0004] Technical Problem: As shown in the fig 1(a), 1(b), 1(c), 1(d) and
20 1(e), a nozzle plate 200 of a fuel injector 300 is provided with a plurality of ports
202 therein. The nozzle plate 200 is a precision component with thickness in
millimeters and the diameter of the plurality of ports 202 in microns. Typically,
the plurality of ports 202 are cylindrical in shape and the height of the wall 202(a)
of the plurality of ports 202 is equal to the thickness of the nozzle plate 200. Over
25 a period of operation of the fuel injector 300, there are chances of fuel impurities
100 being deposited on the wall 202(a) of the plurality of ports 202 resulting in
the creation of obstruction to the free flow of the fuel in the direction of G, which
ultimately results in the change of specified spray pattern and amount. The risk of
film deposition of fuel impurities 100 on the wall 202(a) and the opening of the
3
plurality of ports 202 increases at times of stoppage of application of pressure
from the plunger of the fuel injector.
[0005] One solution for the above mentioned technical problem disclosed in
prior patent application publication JP2002206469A is to provide a circular
groove on the surface of the nozzle plate concentric to the hole of the nozzle plat5 e
leaving a flat surface in between therein. The impurities in the fuel slowly
accumulates on the flat surface and the circular groove of the nozzle plate instead
of accumulating in the hole of the nozzle plate.
[0006] Another solution for the above mentioned technical problem disclosed
10 in prior patent application publication JP2008291738A is to provide a groove
adjacent to the hole of the nozzle plate leaving a flat surface in between therein.
The hole of the nozzle plate is provided at an inclined angle forming an elliptical
shape to eliminate any chances of film deposition of fuel impurities in the hole.
Any traces of the fuel impurities left in the hole of the nozzle plate slowly moves
15 along the wall surface of the hole of the nozzle plate and will reach the edge of the
hole of the nozzle plate facing the cylinder bore because of the slope provided in
the wall surface of the nozzle plate. The groove of predefined depth having an
inclined wall surface adjoining the flat surface of the nozzle plate is provided.
[0007] Existing solutions or grooves provide information on currently
20 available solutions for shifting the location of accumulation of fuel impurities
from the wall surface of the port of the nozzle plate to an adjacent groove
provided therein, but each has its own drawbacks and limitations. These known
systems do not provide solution to accumulation of fuel impurities slowly on the
wall surface of the port of the nozzle plate once the groove and the adjoining flat
25 surface on the nozzle plate got filled up by the fuel impurities.
[0008] Therefore, a simple and in-expensive solution is required which
eliminate the chances of accumulation of fuel impurities in the port of the nozzle
plate.
4
OBJECTS OF THE DISCLOSURE
[0009] Some of the objects of the present disclosure, which at least one
embodiment herein satisfy, are listed herein below.
[0010] The principal object of the present invention is to eliminate chances of
deposition of fuel impurities in the port of a nozzle plate of a fuel injec5 tor.
[0011] Another object of the present invention is to eliminate chances of
traces of fuel being left in the port of a nozzle plate of a fuel injector.
[0012] One more object of the present invention is to ensure all the fuel in the
chamber of the fuel injector to drop into a cylinder bore of an engine.
10 [0013] Still another object of the present invention is to transfer the location
of deposition of fuel impurities from the port of a nozzle plate of a fuel injector.
[0014] Further one more object of the present invention is to provide an
effective nozzle plate of a fuel injector.
[0015] Yet another object of the present invention is to provide a nozzle plate
15 of a fuel injector requiring no frequent maintenance.
[0016] Still one more object of the present invention is to improve the life of a
nozzle plate of a fuel injector.
[0017] These and other objects and advantages will become more apparent
when reference is made to the following description and accompanying drawings.
20
SUMMARY
[0018] This summary is provided to introduce concepts related to a profile of
a nozzle plate of a fuel injector to avoid fuel impurities in the flow path. The
concepts are further described below in the detailed description. This summary is
25 not intended to identify key features or essential features of the claimed subject
matter, nor is it intended to be used to limit the scope of the claimed subject
matter.
5
[0019] In an embodiment, the present disclosure relates to a plurality of
protrusions formed on a nozzle plate surrounding a plurality of ports formed in the
nozzle plate thereby creating a sliding contact or point of contact for droplets of
fuel impurities to fall into a cylinder bore or an intake manifold of an engine
without being accumulated on the wall surface and the opening of the plurality 5 of
ports of the nozzle plate.
[0020] Various objects, features, aspects, and advantages of the inventive
subject matter will become more apparent from the following detailed description
of preferred embodiments, along with the accompanying drawing figures in which
10 like numerals represent like components.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The illustrated embodiments of the subject matter will be best
understood by reference to the drawings, wherein like parts are designated by like
15 numerals throughout. The following description is intended only by way of
example, and simply illustrates certain selected embodiments of devices, systems,
and methods that are consistent with the subject matter as claimed herein,
wherein:
[0022] Figure 1(a) illustrates a front view of a fuel injector according to the
20 prior art;
[0023] Figure 1(b) illustrates a bottom view of a fuel injector of figure 1(a);
[0024] Figure 1(c) illustrates an enlarged view of portion D of a nozzle plate
of figure 1(b);
[0025] Figure 1(d) illustrates a cross-sectional view along A-A of a fuel
25 injector of figure 1(a);
[0026] Figure 1(e) illustrates an enlarged view of portion X of a nozzle plate
of figure 1(d);
6
[0027] Figure 2(a) illustrates a front view of a fuel injector, in accordance
with first embodiment of the present disclosure;
[0028] Figure 2(b) illustrates a bottom view of a fuel injector of figure 2(a);
[0029] Figure 2(c) illustrates an enlarged view of portion E of a nozzle plate
5 of figure 2(b);
[0030] Figure 2(d) illustrates a cross-sectional view along B-B of a fuel
injector of figure 2(a);
[0031] Figure 2(e) illustrates an enlarged view of portion Y of a nozzle plate
of figure 2(d);
10 [0032] Figure 3(a) illustrates a front view of a fuel injector, in accordance
with second embodiment of the present disclosure;
[0033] Figure 3(b) illustrates a bottom view of a fuel injector of figure 3(a);
[0034] Figure 3(c) illustrates an enlarged view of portion F of a nozzle plate
of figure 3(b);
15 [0035] Figure 3(d) illustrates a cross-sectional view along C-C of a fuel
injector of figure 3(a); and
[0036] Figure 3(e) illustrates an enlarged view of portion Z of a nozzle plate
of figure 3(d).
[0037] The figures depict embodiments of the present subject matter for the
20 purposes of illustration only. A person skilled in the art will easily recognize from
the following description that alternative embodiments of the structures and
methods illustrated herein may be employed without departing from the principles
of the disclosure described herein.
25 DETAILED DESCRIPTION
[0038] The detailed description of various exemplary embodiments of the
disclosure is described herein with reference to the accompanying drawings. It
7
should be noted that the embodiments are described herein in such details as to
clearly communicate the disclosure. However, the amount of details provided
herein is not intended to limit the anticipated variations of embodiments; on the
contrary, the intention is to cover all modifications, equivalents, and alternatives
falling within the scope of the present disclosure as defined by the appende5 d
claims.
[0039] It is also to be understood that various arrangements may be devised
that, although not explicitly described or shown herein, embody the principles of
the present disclosure. Moreover, all statements herein reciting principles, aspects,
10 and embodiments of the present disclosure, as well as specific examples, are
intended to encompass equivalents thereof.
[0040] The terminology used herein is for the purpose of describing particular
embodiments only and is not intended to be limiting of example embodiments. As
used herein, the singular forms “a",” “an” and “the” are intended to include the
15 plural forms as well, unless the context clearly indicates otherwise. It will be
further understood that the terms “comprises,” “comprising,” “includes” and/or
“including,” when used herein, specify the presence of stated features, integers,
steps, operations, elements and/or components, but do not preclude the presence
or addition of one or more other features, integers, steps, operations, elements,
20 components and/or groups thereof.
[0041] It should also be noted that in some alternative implementations, the
functions/acts noted may occur out of the order noted in the figures. For example,
two figures shown in succession may, in fact, be executed concurrently or may
sometimes be executed in the reverse order, depending upon the functionality/acts
25 involved.
[0042] In addition, the descriptions of "first", "second", and the like in the
present invention are used for the purpose of description only, and are not to be
construed as indicating or implying their relative importance or implicitly
indicating the number of technical features indicated. Thus, features defining
8
"first" and "second" may include at least one of the features, either explicitly or
implicitly.
[0043] Unless otherwise defined, all terms (including technical and scientific
terms) used herein have the same meaning as commonly understood by one of
ordinary skill in the art to which example embodiments belong. It will be f5 urther
understood that terms, e.g., those defined in commonly used dictionaries, should
be interpreted as having a meaning that is consistent with their meaning in the
context of the relevant art and will not be interpreted in an idealized or overly
formal sense unless expressly so defined herein.
10 [0044] These and other advantages of the present subject matter would be
described in greater detail with reference to the following figures. It should be
noted that the description merely illustrates the principles of the present subject
matter. It will thus be appreciated that those skilled in the art will be able to devise
various arrangements that, although not explicitly described herein, embody the
15 principles of the present subject matter and are included within its scope.
[0045] As shown in figure 2(a), 2(b), 2(c), 2(d) and 2(e), there is provided a
nozzle plate 400 of a fuel injector 300 comprising a plurality of ports 402 and a
plurality of protrusions 404 surrounding the plurality of ports 402 thereon. The
plurality of ports 402 sprays fuel into a cylinder bore or an intake manifold of an
20 engine.
[0046] Referring to fig. 2(e), the wall surface 402(a) of the plurality of ports
402 is cylindrical. The plurality of protrusions 404 comprises a conical surface
404(a) seamlessly formed on the nozzle plate 400 adjoining the open edge 402(b)
of the plurality of ports 402 and a slant surface 404(b) formed on the nozzle plate
25 400 to adapt to mate the conical surface 404(a) seamlessly at its free end. The
mating location of the conical surface 404(a) with the slant surface 404(b) forms a
circular line 404(c) therein.
9
[0047] In an aspect, the conical surface 404(a) is provided at a predefined
angle with respect to the wall surface 402(a) of the plurality of ports 402 to ensure
free flow of fuel impurities up to the circular line 404(c).
[0048] In an aspect, the predefined angle of the conical surface 404(a) ranges
between 5 degrees to 60 degrees5 .
[0049] In an aspect, the slant surface 404(b) facilitates the room for
accumulation of fuel impurities left by any chance without being dropped into a
cylinder bore or an intake manifold of an engine.
[0050] In an aspect, the plurality of protrusions 404 are integrally formed on
10 the nozzle plate 400 through precision machining operation.
[0051] In an aspect, the plurality of protrusions 404 forms a V-shape.
[0052] In an aspect, the plurality of protrusions 404 are solid.
[0053] In another embodiment, the plurality of protrusions 404 formed around
the circumference of the plurality of ports 402 of the nozzle plate 400 has a
15 straight surface seamlessly formed adjoining the conical surface 404(a). The
mating location of the straight surface with the conical surface 404(a) forms a
sharp circular line therein.
[0054] To this as shown in figure 3(a), 3(b), 3(c), 3(d) and 3(e), there is
provided a nozzle plate 600 of a fuel injector 300 comprising a plurality of ports
20 602, a plurality of protrusions of first type 604 and a protrusion of second type
606. The plurality of protrusions of first type 604 formed on the nozzle plate 600
surrounds a major portion 602(c) of the plurality of ports 602 and a protrusion of
second type 606 formed on the nozzle plate 600 seamlessly mates with the
remaining minor portion 602(d) of the plurality of ports 602. The plurality of
25 ports 602 sprays fuel into a cylinder bore or an intake manifold of an engine.
[0055] Referring to fig. 3(c) and 3(e), the wall surface 602(a) of the plurality
of ports 602 is cylindrical. The plurality of protrusions of first type 604 comprises
a first slant surface 604(a) seamlessly formed on the nozzle plate 600 adjoining
the major portion 602(c) of the open edge 602(b) of the plurality of ports 602 and
10
a second slant surface 604(b) formed on the nozzle plate 600 to adapt to mate the
first slant surface 604(a) seamlessly at its free end. The protrusion of second type
606 is a cone seamlessly formed on the nozzle plate 600 in between the plurality
of ports 602 adjoining their remaining minor portion 602(d) of the open edge
602(b). The mating location of the first slant surface 604(a) with the second slan5 t
surface 604(b) forms a circular line 604(c) therein. The protrusion of second type
606 creates a point of contact 606(a) for droplets of fuel impurities.
[0056] In an aspect, the angle of slope of the protrusion of second type 606
depends on the distance between the plurality of ports 602.
10 [0057] In an aspect, the plurality of protrusions of first type 604 and the
protrusion of second type 606 are solid.
[0058] In an aspect, the plurality of protrusions of first type 604 and the
protrusion of second type 606 are integrally formed on the nozzle plate 600 by
precision machining operation.
15 [0059] In another embodiment, the plurality of protrusions of first type 604
formed around the major portion 602(c) of the plurality of ports 602 of the nozzle
plate 600 has a straight surface seamlessly formed adjoining the first slant surface
604(a). The mating location of the straight surface with the first slant surface
604(a) forms a sharp circular line therein.
20 [0060] The effective working of the nozzle plate 400 having a plurality of
protrusions 404 disclosed in the figure 2(e) is as follows: At times of application
of pressure on the fuel by a plunger of a fuel injector, the fuel from the plurality of
ports 402 in the direction of H directly falls in to a cylinder bore or an intake
manifold of an engine at a spray angle. But, at times of stoppage of application of
25 pressure on the fuel by the plunger of the fuel injector, the droplets of fuel
impurities stuck on the wall surface 402(a) of the plurality of ports 402 slowly
moves towards the conical surface 404(a) of the plurality of protrusions 404
because of gravity. The droplets of fuel impurities approaching the conical surface
404(a) of the plurality of protrusions 404 moves because of the predefined angle
11
provided in the conical surface 404(a) and reaches the circular line 404(c) at the
mating location of the conical surface 404(a) and the slant surface 404(b) of the
plurality of protrusions 404. As the droplets of fuel impurities comes in to contact
with the circular line 404(c), the droplets of fuel impurities falls into a cylinder
bore or an intake manifold of an engine in most of the cases. But, in some cases5 ,
there might be chances of traces of droplets of fuel impurities getting accumulated
on the slant surface 404(b) of the plurality of protrusions 404.
[0061] In an aspect, the droplets of fuel impurities coming in to contact with
the sharp circular line falls into a cylinder bore or an intake manifold of an engine
10 without any chance of being accumulated on the plurality of protrusions 404 due
to provision of the straight surface in the place of the slant surface 404(b).
[0062] The effective working of the nozzle plate 600 having a plurality of
protrusions of first type 604 and a protrusion of second type 606 disclosed in the
figure 3(c) and 3(e) is as follows: At times of application of pressure on the fuel
15 by a plunger of a fuel injector, the fuel from the plurality of ports 602 in the
direction of I directly falls in to a cylinder bore or an intake manifold of an engine
at a spray angle. But, at times of stoppage of application of pressure on the fuel by
the plunger of the fuel injector, the droplets of fuel impurities stuck on the wall
surface 602(a) at the major portion 602(c) of the plurality of ports 602 slowly
20 moves towards the first slant surface 604(a) of the plurality of protrusions of first
type 604 because of gravity. The droplets of fuel impurities approaching the first
slant surface 604(a) of the plurality of protrusions of first type 604 moves and
reaches the circular line 604(c) at the mating location of the first slant surface
604(a) and the second slant surface 604(b) of the plurality of protrusions of first
25 type 604. As the droplets of fuel impurities comes in to contact with the circular
line 604(c), the droplets of fuel impurities falls into a cylinder bore or an intake
manifold of an engine in most of the cases. But, in some cases, there might be
chances of traces of droplets of fuel impurities getting accumulated on the second
slant surface 604(b) of the plurality of protrusions of first type 604.
12
[0063] Also, at times of stoppage of application of pressure on the fuel by the
plunger of the fuel injector, the droplets of fuel impurities stuck on the wall
surface 602(a) at the remaining minor portion 602(d) of the plurality of ports 602
slowly moves towards the surface of the protrusion of second type 606 because of
gravity and finally reaches the point of contact 606(a). All the droplets of fue5 l
impurities reaching the point of contact 606(a) falls into a cylinder bore or an
intake manifold of an engine.
[0064] In an aspect, the droplets of fuel impurities coming in to contact with
the sharp circular line falls into a cylinder bore or an intake manifold of an engine
10 without any chance of being accumulated on the second slant surface 604(b) of
the plurality of protrusions of first type 604.
[0065] It will be understood by those within the art that, in general, terms used
herein, and especially in the appended claims (e.g., bodies of the appended
claims) are generally intended as “open” terms (e.g., the term “including” should
15 be interpreted as “including but not limited to,” the term “having” should be
interpreted as “having at least,” the term “includes” should be interpreted as
“includes but is not limited to,” etc.). It will be further understood by those within
the art that if a specific number of an introduced claim recitation is intended, such
an intent will be explicitly recited in the claim, and in the absence of such
20 recitation no such intent is present. For example, as an aid to understanding, the
following appended claims may contain usage of the introductory phrases “at least
one” and “one or more” to introduce claim recitations. However, the use of such
phrases should not be construed to imply that the introduction of a claim recitation
by the indefinite articles “a” or “an” limits any particular claim containing such
25 introduced claim recitation to inventions containing only one such recitation, even
when the same claim includes the introductory phrases “one or more” or “at least
one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should
typically be interpreted to mean “at least one” or “one or more”); the same holds
true for the use of definite articles used to introduce claim recitations. In addition,
30 even if a specific number of an introduced claim recitation is explicitly recited,
13
those skilled in the art will recognize that such recitation should typically be
interpreted to mean at least the recited number (e.g., the bare recitation of “two
recitations,” without other modifiers, typically means at least two recitations, or
two or more recitations). Furthermore, in those instances where a convention
analogous to “at least one of A, B, and C, etc.” is used, in general such 5 a
construction is intended in the sense one having skill in the art would understand
the convention (e.g., “a system having at least one of A, B, and C” would include
but not be limited to systems that have A alone, B alone, C alone, A and B
together, A and C together, B and C together, and/or A, B, and C together, etc.).
10 In those instances where a convention analogous to “at least one of A, B, or C,
etc.” is used, in general such a construction is intended in the sense one having
skill in the art would understand the convention (e.g., “a system having at least
one of A, B, or C” would include but not be limited to systems that have A alone,
B alone, C alone, A and B together, A and C together, B and C together, and/or A,
15 B, and C together, etc.). It will be further understood by those within the art that
virtually any disjunctive word and/or phrase presenting two or more alternative
terms, whether in the description, claims, or drawings, should be understood to
contemplate the possibilities of including one of the terms, either of the terms, or
both terms. For example, the phrase “A or B” will be understood to include the
20 possibilities of “A” or “B” or “A and B.”
[0066] While the foregoing describes various embodiments of the invention,
other and further embodiments of the invention may be devised without departing
from the basic scope thereof. The scope of the invention is determined by the
claims that follow. The invention is not limited to the described embodiments,
25 versions or examples, which are included to enable a person having ordinary skill
in the art to make and use the invention when combined with information and
knowledge available to the person having ordinary skill in the art.

We claim:
1) A nozzle plate (400) of a fuel injector (300), comprising:
at least one protrusion (404) formed to surround at least one port (402)
formed therein, said protrusion (404) includes a conical surface (404(a))
seamlessly formed adjoining an open edge (402(b)) of said port (402) and a 5 slant
surface (404(b)) extending from said nozzle plate (400) to adapt to mate with said
conical surface (404(a)) seamlessly to form a circular line (404(c)) therein at the
mating location.
2) The nozzle plate (400) as claimed in claim 1, wherein a straight surface
10 formed on said nozzle plate (400) is adapted to mate with said conical surface
(404(a)) seamlessly to form a sharp circular line therein at the mating location.
3) The nozzle plate (400) as claimed in claim 1, wherein said protrusion (404) is
of ‘V’ shaped cross-section.
4) The nozzle plate (400) as claimed in claim 1, wherein said protrusion (404) is
15 solid.
5) The nozzle plate (400) as claimed in claim 1, wherein said protrusion (404) is
integrally formed on said nozzle plate (400).
6) A nozzle plate (600) of a fuel injector (300), comprising:
a plurality of protrusions of first type (604) formed to surround a major
20 portion (602(c)) of a plurality of ports (602) formed therein and a protrusion of
second type (606) formed to mate with the remaining minor portion (602(d)) of
said plurality of ports (602), wherein,
said plurality of protrusions of first type (604) includes a first slant surface
(604(a)) seamlessly formed adjoining the major portion (602(c)) of an open edge
25 (602(b)) of said plurality of ports (602) and a second slant surface (604(b))
extending from said nozzle plate (600) to adapt to mate with said first slant
surface (604(a)) seamlessly to form a circular line (604(c)) therein at the mating
location; and
15
said protrusion of second type (606) seamlessly formed on said nozzle
plate (600) in between said plurality of ports (602) adjoins the remaining minor
portion (602(d)) of said open edge (602(b)) of said plurality of ports (602) to
create a point of contact (606(a)) for droplets of fuel.
7) The nozzle plate (600) as claimed in claim 6, wherein said protrusion 5 rusion of
second type (606) is of cone shape.
8) The nozzle plate (600) as claimed in claim 6, wherein a straight surface
formed on said nozzle plate (600) is adapted to mate with said first slant
surface (604(a)) seamlessly to form a sharp circular line therein at the mating
10 location.
9) The nozzle plate (600) as claimed in claim 6, wherein said plurality of
protrusions of first type (604) and said protrusion of second type (606) are
solid.
10) The nozzle plate (600) as claimed in claim 6, wherein said plurality of
15 protrusions of first type (604) and said protrusion of second type (606) are
integrally formed on said nozzle plate (600).