Method and apparatus for attenuating fuel pump noise in a direct injection internal combustion chamber

Abstract

A method and apparatus for attenuating fuel pump noise in a direct injection internal combustion engine. In one proposal, the direct injection fuel nozzle is suspended from a fuel rail in a fashion that avoids direct metal-to-metal contact between the injector and the engine block. The direct injection nozzle may also be connected to the fuel rail by a pair of spaced-apart seals which equalize the longitudinal pressure on the nozzle during operation. Enlarged diameter fuel reservoirs and/or a restricted orifice may be provided fluidly in series between the fuel pump and the direct injection nozzle in order to attenuate noise resulting from fuel pump pulsation.

1. For use in conjunction with a direct injection internal combustion engine having at least one fuel rail, an engine block, a combustion chamber in the engine block and a passageway in the engine block to the combustion chamber, a direct injection nozzle assembly comprising:
 a direct injection fuel nozzle injector having a main body with a fuel inlet and a nozzle tip with a fuel outlet, 
 an injector cup secured to the fuel rail, said injector cup having an open end cavity in fluid communication with the fuel rail and dimensioned to receive a portion of said main body of said fuel injector, and 
 an injector holder assembly which secures said direct injection fuel injector to the injector cup so that said nozzle tip of said fuel injector is positioned within but the engine block passageway, and said nozzle tip and said main body are spaced from the engine block passageway, 
 wherein said injector holder assembly comprises a clip holder attached to said injector cup and a clip plate attached to said clip holder, said clip plate having a portion in abutment with an abutment surface on said fuel injector main body so that said clip plate supports said direct injection fuel injector against movement towards the engine block, 
 wherein said abutment surface on said fuel injector main body extends laterally outwardly from the fuel injector main body and tapers curvilinearly upwardly away from said fuel injector tip. 
 
     
     
       2. The invention as defined in  claim 1  wherein said injector cup comprises at least two circumferentially spaced and outwardly extending tabs, and wherein said clip holder includes at least two openings which receive said tabs. 
     
     
       3. The invention as defined in  claim 1  wherein said injector cup comprises at least three circumferentially spaced and outwardly extending tabs, and wherein said clip holder includes at least three openings which register with and receive said tabs. 
     
     
       4. The invention as defined in  claim 2  wherein said injector clip comprises at least two protrusions, one protrusion being positioned in each of said at least two clip holder openings. 
     
     
       5. The invention as defined in  claim 1  and comprising a tip seal disposed around said nozzle tip of said fuel injector so that an outer surface of said tip seal is in abutment with the engine block. 
     
     
       6. The invention as defined in  claim 5  wherein said tip seal is constructed of a non-metallic material. 
     
     
       7. The invention as defined in  claim 1  wherein said abutment surface on said fuel injector main body extends laterally outwardly from the fuel injector main body and tapers upwardly away from said fuel injector tip includes a downwardly tapered surface opposed to and facing said abutment surface. 
     
     
       8. The invention as defined in  claim 1  and comprising a seal disposed around said main body of said fuel injector within said injector cup cavity, said seal having an outer surface in sealing contact with said injector cup. 
     
     
       9. The invention as defined in  claim 1  and comprising a pair of spaced seals disposed around said main body of said fuel injector within said injector cup cavity, said seals each having an outer surface in sealing contact with said injector cup and wherein said seals form an annular fluid chamber between said injector cup and said direct injection fuel injector, said injector fuel inlet being open to said annular fluid chamber. 
     
     
       10. A method of dampening transmission of fuel pump vibration to an engine block in a direct injection internal combustion engine having a fuel rail connected to the fuel pump and at least one direct injection fuel nozzle injector having a main body comprising the steps of:
 suspending the direct injection nozzle fuel injector from the fuel rail so that a portion of the direct injection nozzle fuel injector is positioned within an engine block passageway without direct contact with the engine block, and 
 fluidly sealing the direct injection nozzle fuel injector to the engine block with a seal, 
 wherein the direct injection nozzle fuel injector includes a fuel inlet, and further comprising the steps of: 
 providing a pair of axially spaced apart O-rings around the main body of the direct injection fuel nozzle so that the O-rings form an annular fluid chamber around the main body of the direct injection nozzle, the fuel inlet of the nozzle direct injection fuel injector being in direct fluid communication with the annular fluid chamber, and 
 directly fluidly connecting the annular fluid chamber with the fuel rail. 
 
     
     
       11. The invention as defined in  claim 10  wherein said suspending step further comprises the step of pivotally suspending the direct injection nozzle fuel injector to the fuel rail. 
     
     
       12. For use in conjunction with a direct injection internal combustion engine having at least one fuel rail, an engine block, a combustion chamber in the engine block and a passageway in the engine block to the combustion chamber, a direct injection nozzle assembly comprising:
 a direct injection fuel nozzle injector having a main body with a fuel inlet and a nozzle tip with a fuel outlet, 
 an injector cup secured to the fuel rail, said injector cup having an open end cavity in fluid communication with the fuel rail and dimensioned to receive a portion of said main body of said fuel injector, 
 an injector holder assembly which secures said direct injection fuel injector to the injector cup so that said nozzle tip of said direct injection fuel injector is positioned within but spaced from the engine block passageway, and said nozzle tip and said main body are spaced from the engine block passageway, and 
 a pair of spaced seals disposed around said main body of said fuel injector within said injector cup cavity, said seals each having an outer surface in sealing contact with said injector cup and wherein said seals form an annular fluid chamber between said injector cup and said direction injection fuel injector, said injector fuel inlet and the fuel rail both being directly fluidly connected to said annular fluid chamber. 
 
     
     
       13. The direct fuel injection assembly of claim 1, wherein said abutment surface on said main body extends laterally outwardly from the fuel injector main body and tapers curvilinearly upwardly away from said fuel injector tip. 
     
     
       14. The direct fuel injection assembly of claim 1, wherein said clip plate is supported on an opposite surface to a surface thereof in abutment with the abutment surface of said main body by said clip holder and supports the movement of said direct injection fuel injector toward the engine block. 
     
     
       15. A fuel delivery system for delivering fuel to a direct injection internal combustion engine comprising a fuel pump, a direct injection fuel injector, and a fuel rail being rigid in a construction and fluidly connected to said fuel pump and said direct injection fuel injector, said direct injection fuel injector injecting fuel from a passageway in communication with a combustion chamber in an engine block into said combustion chamber,
 wherein said direct injection fuel injector has a main body including a fuel inlet and a nozzle tip with a fuel injection port,   wherein said fuel rail has an injector cup having an end opening space fluidly connected to the fuel rail, said injector cup being dimensioned to be formed so as to receive a portion of said main body,   wherein said direct injection fuel injector is secured to said injector cup and comprises an injector holder assembly for positioning the nozzle tip in the engine block passageway, with the main body and the nozzle tip being spaced from said engine block passageway,   wherein said injector holder assembly has a clip holder attached to said injector cup and a clip plate attached to said clip holder, said clip plate being in abutment with an abutment surface of said main body so as to regulate movement of the direct injection fuel injector toward the engine block, and   wherein said abutment surface of said fuel injector main body extends laterally outwardly from the fuel injector main body and tapers curvilinearly upwardly away from said nozzle tip.   
     
     
       16. The fuel delivery system as defined in claim 15 and comprising a pipe having one end fluidly connected to said fuel pump and a second end fluidly connected with said fuel rail. 
     
     
       17. The fuel delivery system as defined in claim 15 and comprising a fuel reservoir fluidly connected in series between said fuel pump and said direct injection fuel injector. 
     
     
       18. The fuel delivery system as defined in claim 15 wherein said injector cup comprises at least two circumferentially spaced and outwardly extending tabs, and wherein said clip holder includes at least two openings which receive said tabs. 
     
     
       19. The fuel delivery system as defined in claim 15 wherein said injector cup comprises at least three circumferentially spaced and outwardly extending tabs, and wherein said clip holder includes at least three openings which register with and receive said tabs. 
     
     
       20. The fuel delivery system as defined in claim 18 wherein said injector clip comprises at least two protrusions, one protrusion being positioned in each of said at least two clip holder openings. 
     
     
       21. The fuel delivery system as defined in claim 15 and comprising a tip seal disposed around said nozzle tip so that an outer surface of said tip seal is in abutment with the engine block. 
     
     
       22. The fuel delivery system as defined in claim 21 wherein said tip seal is constructed of a non-metallic material. 
     
     
       23. The fuel delivery system as defined in claim 15 wherein said abutment surface on said main body extends laterally outwardly from the main body and tapers upwardly away from said nozzle tip. 
     
     
       24. The fuel delivery system as defined in claim 23 wherein said main body includes a downwardly tapered surface opposed to and facing said abutment surface. 
     
     
       25. The fuel delivery system as defined in claim 15 and comprising a seal disposed around said main body within said injector cup cavity, said seal having an outer surface in sealing contact with said injector cup. 
     
     
       26. The fuel delivery system as defined in claim 15 and comprising a seal disposed around said main body within said injector cup cavity, said seal having an outer surface in sealing contact with said injector cup and wherein said seals form an annular fluid chamber between said injector cup and said direct injection fuel injector, said fuel inlet being open to said annular fluid chamber. 
     
     
       27. The fuel delivery system of claim 15, wherein said clip plate is supported on an opposite surface to a surface thereof in abutment with the abutment surface of said main body by said clip holder and supports the movement of said direct injection fuel injector toward the engine block.