# US 10,767,610 B2 · Liquid fuel injector having dual nozzle outlet sets, fuel system, and method

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- Number: US 10,767,610 B2
- Document ID: US10767610B2
- Status: Granted
- Kind: B2
- Application number: 16/107,199
- Filed: 2018-08-21
- Published: 2020-02-27
- Granted: 2020-09-08
- Earliest claimed: 2018-08-21
- Assignees: Caterpillar Inc.
- Applicants: Caterpillar Inc.
- Inventors: Jonathan W Anders; Bobby John; Robert Campion
- Web page: https://patentgrep.com/patent/US10767610B2

## CPC

- F02M 45/086: {Having more than one injection-valve controlling discharge orifices}
- F02D 41/3011: {according to or using specific or several modes of combustion}
- F02M 47/027: {Electrically actuated valves draining the chamber to release the closing pressure}
- F02M 57/025: {hydraulic, e.g. with pressure amplification}
- F02M 61/1806: {characterised by the arrangement of discharge orifices, e.g. orientation or size}
- F02M 61/182: {Discharge orifices being situated in different transversal planes with respect to valve member direction of movement}
- F02M 61/1826: {Discharge orifices having different sizes}
- F02M 61/1846: {Dimensional characteristics of discharge orifices}
- F02M 63/0225: {Fuel-injection apparatus having a common rail feeding several injectors (F02M63/0003 takes precedence); Means for varying pressure in common rails; Pumps feeding common rails}
- F02D 41/401: {Controlling injection timing (F02D41/402 takes precedence)}
- F02M 2200/44: Valves, e.g. injectors, with valve bodies arranged side-by-side
- F02M 2200/46: Valves, e.g. injectors, with concentric valve bodies
- F02M: SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02D: CONTROLLING COMBUSTION ENGINES (vehicle fittings, acting on a single sub-unit only, for automatically controlling vehicle speed B60K31/00; conjoint control of vehicle sub-units of different type or different function, road vehicle drive control systems for purposes other than the control of a single sub-unit B60W)

## Abstract

A liquid fuel injector for a fuel system in an internal combustion engine includes two injection control valves for controlling two outlet checks. A common nozzle supply cavity is fluidly connected to an inlet passage and supplies each of the two sets of nozzle outlets opened and closed by the outlet checks. A first nozzle outlet set forms a narrower spray angle and has a first combination of outlet number and outlet size, and a second nozzle outlet set forms a wider spray angle and has a second combination of outlet number and outlet size. The first nozzle outlet set has a greater steady flow than the second nozzle outlet set.

## Claims

### Claim 1

A liquid fuel injector for an internal combustion engine comprising:
an injector body defining an inlet passage, a first set of nozzle outlets, a second set of nozzle outlets, a first control chamber and a second control chamber each in fluid communication with the inlet passage, and a low pressure space;
a first outlet check having a closing hydraulic surface exposed to a fluid pressure of the first control chamber and movable between a closed position blocking the first set of nozzle outlets, and an open position;
a second outlet check having a closing hydraulic surface exposed to a fluid pressure of the second control chamber and movable between a closed position blocking the second set of nozzle outlets, and an open position;
a first injection control valve positioned fluidly between the first control chamber and the low pressure space;
a second injection control valve positioned fluidly between the second control chamber and the low pressure space;
the first set of nozzle outlets forming a narrower spray angle, from about 130 degrees to about 140 degrees, and having a first combination of outlet number and outlet size, such that the first set of nozzle outlets produces a relatively greater steady flow of fuel for injection;
the second set of nozzle outlets forming a wider spray angle, from about 140 degrees to about 150 degrees, and having a second combination of outlet number and outlet size different from the first combination, such that the second set of nozzle outlets produces a relatively lesser steady flow of fuel for injection; and
the injector body further defining a common nozzle supply cavity in fluid communication with the inlet passage, and the first set of nozzle outlets and the second set of nozzle outlets being in fluid communication with the common nozzle supply cavity at the open positions of the first outlet check and the second outlet check, respectively.

### Claim 2 (depends on 1)

The liquid fuel injector of claim 1 wherein each of the first injection control valve and the second injection control valve includes a two-way valve.

### Claim 3 (depends on 1)

The liquid fuel injector of claim 1 wherein the first combination of outlet number and outlet size includes a first outlet number and a first outlet size, and the second combination of outlet number and outlet size includes a second outlet number and a second outlet size that are different from the first outlet number and the first outlet size.

### Claim 4 (depends on 3)

The liquid fuel injector of claim 3 wherein:
the first set of nozzle outlets has an outlet number from 6 to 8 and the second set of nozzle outlets has an outlet number from 4 to 6;
the first set of nozzle outlets has an outlet size that includes a first hole diameter and the second set of nozzle outlets has an outlet size that includes a second hole diameter; and
the second hole diameter is from about 25% to about 50% of the first hole diameter.

### Claim 5 (depends on 4)

The liquid fuel injector of claim 4 wherein the first hole diameter is about 0.0030 millimeters, and the second hole diameter is about 0.0015 millimeters.

### Claim 6 (depends on 1)

The liquid fuel injector of claim 1 wherein the injector body defines a first set of orifices arranged in an A-F-Z pattern among the inlet passage, the low pressure space, and the first control chamber, and a second set of orifices arranged in an A-F-Z pattern among the inlet passage, the low pressure space, and the second control chamber.

### Claim 7 (depends on 6)

The liquid fuel injector of claim 6 wherein the injector body includes a casing and a stack positioned within the casing, and wherein the common nozzle supply cavity is formed within the stack and each of the first outlet check and the second outlet check extends through the common nozzle supply cavity.

### Claim 8 (depends on 7)

The liquid fuel injector of claim 7 wherein the stack includes an orifice plate, and wherein the first set of orifices includes a first F-orifice and the second set of orifices includes a second F-orifice, and each of the first F-orifice and the second F-orifice is formed in a fluid passage in the orifice plate that opens to the common nozzle supply cavity.

### Claim 9

A fuel system for an internal combustion engine comprising:
a liquid fuel supply;
a plurality of liquid fuel injectors each defining an inlet passage, a first set of nozzle outlets, a second set of nozzle outlets, and a low pressure space;
the plurality of liquid fuel injectors each including a first direct-operated outlet check movable between a closed position blocking the first set of nozzle outlets, and an open position, and a second direct-operated outlet check movable between a closed position blocking the second set of nozzle outlets, and an open position;
the plurality of liquid fuel injectors each further including a first injection control valve coupled with the first direct-operated outlet check, and a second injection control valve coupled with the second direct-operated outlet check;
the first set of nozzle outlets in each one of the plurality of liquid fuel injectors forming a narrower spray angle, from about 130 degrees to about 140 degrees, and having a first combination of outlet number and outlet size, such that the first set of nozzle outlets produces a greater steady flow of fuel for injection; and
the second set of nozzle outlets in each one of the plurality of liquid fuel injectors forming a wider spray angle, from about 140 degrees to about 150 degrees, and having a second combination of outlet number and outlet size different from the first combination, such that the second set of nozzle outlets produces a lesser steady flow of fuel for injection.

### Claim 10 (depends on 9)

The fuel system of claim 9 wherein:
the liquid fuel supply includes a pressurized fuel reservoir, and each of the plurality of liquid fuel injectors has a common nozzle supply cavity formed therein that is in fluid communication with the pressurized fuel reservoir by way of the inlet passage; and
the common nozzle supply cavity is in fluid communication with the first and the second sets of nozzle outlets at the open positions of the corresponding first and second direct-operated outlet check.

### Claim 11 (depends on 10)

The fuel system of claim 10 wherein each of the plurality of liquid fuel injectors further defines a first control chamber and a second control chamber for the first and the second direct-operated outlet check, respectively, and defines a first set of orifices arranged in an A-F-Z pattern among the inlet passage, the low pressure space, and the first control chamber, and a second set of orifices arranged in an A-F-Z pattern among the inlet passage, the low pressure space, and the second control chamber.

### Claim 12 (depends on 9)

The fuel system of claim 9 wherein the first and the second direct-operated outlet checks are arranged side-by-side.

### Claim 13 (depends on 12)

The fuel system of claim 12 wherein the first combination of outlet number and outlet size includes a first outlet number and a first outlet size, and the second combination of outlet number and outlet size includes a second outlet number and a second outlet size.

### Claim 14 (depends on 13)

The fuel system of claim 13 wherein the first set of nozzle outlets has an outlet number from 6 to 8 and the second set of nozzle outlets has an outlet number from 4 to 6.

### Claim 15 (depends on 14)

The fuel system of claim 14 wherein the first set of nozzle outlets has an outlet size that includes a first hole diameter and the second set of nozzle outlets has an outlet size that includes a second hole diameter, and wherein the second hole diameter is from about 25% to about 50% of the first hole diameter.

### Claim 16 (depends on 15)

The fuel system of claim 15 wherein the first hole diameter is about 0.0030 millimeters, and the second hole diameter of about 0.0015 millimeters.

### Claim 17

A method of operating an engine comprising:
supplying a liquid fuel to a liquid fuel injector positioned at least partially within a cylinder in the engine;
injecting a first charge of the liquid fuel into a cylinder in the engine using a first set of nozzle outlets in a fuel injector, such that spray jets of the first charge of liquid fuel are oriented at a relatively narrower spray angle;
autoigniting the first charge of the liquid fuel such that the first charge of liquid fuel combusts by diffusion burning within the cylinder in a first engine cycle;
injecting a second charge of the liquid fuel into the cylinder using a second set of nozzle outlets in the fuel injector such that spray jets of the second charge of the liquid fuel are oriented at a relatively wider spray angle;
autoigniting the second charge of the liquid fuel such that the second charge of the liquid fuel combusts by diffusion burning within the cylinder in a second engine cycle;
transitioning operation of the engine from a relatively higher engine load in the first engine cycle to a relatively lower engine load in the second engine cycle;
decreasing fueling of the engine based on the transitioning of the operation of the engine, such that an amount of the second charge of the liquid fuel is smaller than an amount of the first charge of the liquid fuel;
targeting, based on the relatively narrower spray angle, the first charge of liquid fuel at a first target in the cylinder relative to a piston, for entrainment of relatively less air; and
targeting, based on the relatively wider spray angle, the second charge of liquid fuel at a second, different target in the cylinder relative to the piston, for entrainment of relatively more air.

### Claim 18 (depends on 17)

The method of claim 17 wherein:
the supplying of the liquid fuel further includes supplying the liquid fuel from a pressurized fuel reservoir to a common nozzle supply passage in the fuel injector; and
the injecting of the first charge of the liquid fuel and the injecting of the second charge of liquid fuel each include supplying the liquid fuel for injection to the first and the second sets of nozzle outlets from the common nozzle supply cavity.

### Claim 19 (depends on 18)

The method of claim 18 wherein the first set of nozzle outlets has a first combination of outlet number and outlet size, and the second set of nozzle outlets has a second combination of outlet number and outlet size different from the first combination.