Fuel injector having dual mode capabilities and engine using same

Abstract

A solitary fuel injector for a diesel engine that is capable of injecting fuel for a homogeneous charge compression ignition injection event, a conventional injection event. The solitary fuel injector also has a mixed mode that includes a homogeneous charge compression ignition injection and a conventional injection in a single compression stroke for the engine.

1. A nozzle assembly comprising:
 a plurality of assembled components having a centerline and defining a plurality of nozzle outlets; 
 a homogenous charge compression ignition portion of said plurality of nozzle outlets including at least one nozzle outlet oriented at a first angle with respect to said centerline; 
 a conventional portion of said plurality of nozzle outlets including at least one nozzle outlet oriented at a second angle with respect to said centerline; 
 said assembled components including a needle valve being positioned to move between positions that open and close said plurality of nuzzle outlets, and being moveable between a first position in which said first portion are open but said second portion are closed, and a second position in which said second portion are open but said first portion are closed; and 
 at least one electrical actuator operably coupled to said needle valve 
 said needle valve including a first needle valve member with a first closing hydraulic surface and a second needle valve member with a second closing hydraulic surface; and 
 said first closing hydraulic surface is exposed to fluid pressure in a first needle control chamber and said second closing hydraulic surface is exposed to fluid pressure in a second needle control chamber 
 said first needle control chamber contains a first fluid and said second needle control chamber contains a second fluid that is different from said first fluid. 
 
     
     
       2. The nozzle assembly of  claim 1  wherein said first angle is relatively small and said second angle is relatively large. 
     
     
       3. The nozzle assembly of  claim 2  wherein said first angle is less than or equal to 30 degrees; and
 said second angle is greater than or equal to 60 degrees. 
 
     
     
       4. The nozzle assembly of  claim 1  wherein said second needle valve member is at least partially positioned within said first needle valve member. 
     
     
       5. The nozzle assembly of  claim 4  wherein said first needle valve member includes a valve seat and said second needle valve member includes a valve surface;
 a nozzle supply passage being blocked when said valve surface is in contact with said valve seat; and 
 said nozzle supply passage being open when said valve surface is out of contact with said valve seat. 
 
     
     
       6. The nozzle assembly of  claim 1  wherein a nozzle body includes a first valve seat and a second valve seat; and
 a number of said plurality of nozzle outlets are located between said first valve seat and said second valve seat. 
 
     
     
       7. The nozzle assembly of  claim 1  wherein said needle valve includes a solitary needle valve member; and
 said needle valve member defines a portion of at least one nozzle supply passage. 
 
     
     
       8. The nozzle assembly of  claim 7  wherein said needle valve is movable to a first position in which said first portion of said plurality of nozzle outlets and said second portion of said plurality of nozzle outlets are blocked;
 said needle valve is movable to a second position in which said first portion of said plurality of nozzle outlets is open; and 
 said needle valve being movable to a third position in which said second portion of said plurality of nozzle outlets is open. 
 
     
     
       9. The nozzle assembly of  claim 1  wherein said homogenous charge portion and said conventional portion are mutually exclusive. 
     
     
       10. An engine having at least two modes of operation comprising:
 an engine housing defining a plurality of cylinders; 
 a solitary fuel injector for each of said plurality of cylinders, each said fuel injector having at least one electrical actuator and including a tip at least partially positioned in one of said plurality of cylinders; 
 each said fuel injector having a first configuration for a homogeneous charge compression ignition mode of operation in which fuel is injected relatively early in a compression stroke when a piston is nearer a bottom dead center position than a top dead center position in a first spray pattern with a relatively small average angle to an injector centerline; and 
 each said fuel injector having a second configuration for a conventional mode of operation in which fuel is injected relatively late in a compression stroke when said piston is nearer said top dead center position than said bottom dead center position in a second spray pattern with a relatively large average angle to said injector centerline. 
 
     
     
       11. The engine of  claim 10  wherein each said fuel injector includes a plurality of nozzle outlets disposed therein;
 a first portion of said plurality of nozzle outlets being open when said fuel injector is in said first configuration; and 
 a second portion of said plurality of nozzle outlets being open when said fuel injector is in said second configuration. 
 
     
     
       12. The engine of  claim 11  wherein each said fuel injector includes a needle valve that is biased toward a first position blocking said plurality of nozzle outlets;
 said needle valve having a second position that opens said first portion of said plurality of nozzle outlets while blocking said second portion when said fuel injector is in said first configuration; and 
 said needle valve having a third position that opens said second portion of said plurality of nozzle outlets while blocking said first portion when said fuel injector is in said second configuration. 
 
     
     
       13. The engine of  claim 11  wherein each of said first portion of said plurality of nozzle outlets are oriented at first angles with respect to a centerline of said cylinder;
 each of said second portion of said plurality of nozzle outlets are oriented at a second angles with respect to said centerline; and 
 said first angles being different from said second angles. 
 
     
     
       14. The engine of  claim 13  wherein said first angle is relatively small and said second angle is relatively large. 
     
     
       15. The engine of  claim 14  wherein said first angle is less than or equal to 30 degrees; and
 said second angle is greater than or equal to 60 degrees. 
 
     
     
       16. The engine of  claim 10  wherein said needle valve includes a first needle valve member and a second needle valve member; and
 the at least one electrical actuator includes a first electrical actuator being operably coupled to said first needle valve member and a second electrical actuator being operably coupled to said second needle valve member. 
 
     
     
       17. The engine of  claim 10  wherein said fuel injector includes a first needle valve member and a second needle valve member;
 said first needle valve member includes a first closing hydraulic surface exposed to fluid pressure in a first needle control chamber; and 
 said second needle valve member includes a second closing hydraulic surface exposed to fluid pressure in a second needle control chamber. 
 
     
     
       18. The engine of  claim 17  wherein said first needle control chamber is fluidly isolated from said second needle control chamber. 
     
     
       19. The engine of  claim 10  wherein said fuel injector includes a first needle valve member and a second needle valve member; and
 said second needle valve member is at least partially positioned within said first needle valve member. 
 
     
     
       20. The engine of  claim 19  wherein said first needle valve member includes a valve seat, said second needle valve member includes a valve surface;
 a nozzle supply passage being blocked when said valve surface is in contact with said valve seat; and 
 said nozzle supply passage being open when said valve surface is out of contact with said valve seam. 
 
     
     
       21. The engine of  claim 10  wherein said needle valve includes a solitary needle valve member; and
 said needle valve member defines a portion of at least one nozzle supply passage 
 
     
     
       22. The engine of  claim 21  wherein said needle valve includes a stop component positioned in said injector body and movable between a retracted position and an advanced position;
 said needle valve member is out of contact with said stop component when said needle valve is in a first position; 
 said needle valve member being in contact with said stop component when said needle valve is in a second position; and 
 said needle valve member being in contact with said stop component when said needle valve is in a third position. 
 
     
     
       23. A method of operating an engine comprising the steps of:
 providing an engine having an engine housing defining a plurality of engine cylinders, each of said engine cylinders including a piston; 
 positioning a solitary fuel injector for each of said plurality of engine cylinders, at least in part by positioning a tip of each said fuel injector at least partially within one of said engine cylinders; 
 if said fuel injector is operating in a homogeneous charge compression ignition mode, injecting fuel in a first spray pattern from said fuel injector when said piston is nearer a bottom dead center position than a top dead center position; and 
 if said fuel injector is operating in a conventional mode, injecting fuel in a second spray pattern from said fuel injector when said piston is nearer to said top dead center position than said bottom dead center position; and 
 at least one of the injecting steps includes energizing an electrical actuator of the fuel injector. 
 
     
     
       24. The method of  claim 23  wherein said step of injecting fuel when said piston is nearer a bottom dead center position includes a step of opening a first portion of fuel injector nozzle outlets; and
 said step of injecting fuel when said piston is nearer to said top dead center position includes a step of opening a second portion of said fuel injector nozzle outlets. 
 
     
     
       25. The method of  claim 23  wherein said step of injecting fuel from said fuel injector when said piston is nearer a bottom dead center position includes a step of moving a needle valve from a first position to a second position; and
 said step of injecting fuel from said fuel injector when said piston is nearer to said top dead center position includes a step of moving said needle valve to a third position. 
 
     
     
       26. The method of  claim 23  wherein said step of injecting fuel when said piston is nearer a bottom dead center position includes a step of injecting fuel in a first spray pattern with respect to a centerline of said cylinder; and
 said step of injecting fuel when said piston is nearer to said top dead center position includes a step of injecting fuel in a second spray pattern with respect to said centerline. 
 
     
     
       27. The method of  claim 23  wherein said step of injecting fuel in a first spray pattern includes a step of injecting fuel at a relatively small average angle with respect to said centerline; and
 said step of injecting fuel in a second spray pattern includes a step of injecting fuel at a relatively large average angle with respect to said centerline. 
 
     
     
       28. The method of  claim 23  including a step of closing at least one fuel injector nozzle outlet at least in part by applying high pressure to a closing hydraulic surface of a needle valve member movably positioned in said fuel injector. 
     
     
       29. The method of  claim 23  including the steps of operating said fuel injector in said homogeneous charge compression ignition mode when said engine is operating in a low load condition; and
 operating said fuel injector in said conventional mode when said engine is operating in a high load condition. 
 
     
     
       30. The method of  claim 23  including the step of operating said fuel injector in a mixed mode, at least in part by injecting fuel when said piston is relatively far from its top dead center position and injecting fuel when said piston is relatively close to its top dead center position in a same piston stroke. 
     
     
       31. A fuel injector comprising:
 a plurality of assembled components having a centerline and defining a plurality of nozzle outlets; 
 a homogenous charge compression ignition portion of said plurality of nozzle outlets being oriented at a first average angle with respect to said centerline; 
 a conventional portion of said plurality of nozzle outlets being oriented at a second average angle with respect to said centerline; 
 said assembled components including at least one needle valve member being positioned adjacent said plurality of nozzle outlets; 
 said at least one needle valve member having a first position in which said homogenous charge portion is open but said conventional portion is closed, and a second position in which said conventional portion is open but said homogenous charge portion is closed; 
 said at least one needle valve member including a closing hydraulic surface exposed to fluid pressure in a needle control chamber; 
 said assembled components including at least one electrical actuator attached to said injector body; and 
 said assembled components also including a three-way needle control valve operably coupled to said electrical actuator, and being movable between a first position in which said needle control chamber is fluidly connected to a source of high pressure fluid but fluidly disconnected from a low pressure passage, and a second position in which said needle control chamber is fluidly connected to said low pressure passage but fluidly disconnected from said source of high pressure fluid. 
 
     
     
       32. The fuel injector of  claim 31  wherein said first average angle is relatively small and said second average angle is relatively large. 
     
     
       33. The fuel injector of  claim 32  wherein said first average angle is less than or equal to 30 degrees; and
 said second average angle is greater than or equal to 60 degrees. 
 
     
     
       34. The fuel injector of  claim 33  wherein said needle valve includes a first needle valve member and a second needle valve member. 
     
     
       35. The fuel injector of  claim 34  wherein said second needle valve member is at least partially positioned within said first needle valve member. 
     
     
       36. The fuel injector of  claim 35  wherein said first needle valve member includes a valve seal, said second needle valve member includes a valve surface;
 a nozzle supply passage being blocked when said valve surface is in contact with said valve seat; and 
 said nozzle supply passage being open when said valve surface is out of contact with said valve seat. 
 
     
     
       37. The fuel injector of  claim 36  wherein said first needle valve member includes a first closing hydraulic surface and said second needle valve member includes a second closing hydraulic surface; and
 said first closing hydraulic surface is exposed to fluid pressure in a first needle control chamber and said second closing hydraulic surface is exposed to fluid pressure in a second needle control chamber. 
 
     
     
       38. The fuel injector of  claim 37  wherein said first needle control chamber is fluidly isolated from said second needle control chamber. 
     
     
       39. A fuel injector comprising:
 a plurality of assembled components having a centerline and defining a plurality of nozzle outlets; 
 a homogenous charge compression ignition portion of said plurality of nozzle outlets being oriented at a first average angle with respect to said centerline; 
 a conventional portion of said plurality of nozzle outlets being oriented at a second average angle with respect to said centerline; 
 said assembled components including at least one needle valve member being positioned adjacent said plurality of nozzle outlets; 
 said at least one needle valve member having a first position in which said homogenous charge portion is open but said conventional portion is closed, and a second position in which said conventional portion is open but said homogenous charge portion is closed; 
 said at least one needle valve member including a first needle valve member with a first closing hydraulic surface exposed to fluid pressure in a first needle control chamber, and a second needle valve member with a second closing hydraulic surface exposed to fluid pressure in a second needle control chamber; 
 said first needle control chamber contains a first fluid and said second needle control chamber contains a second fluid that is different from said first fluid. 
 
     
     
       40. An engine having at least two modes of operation comprising:
 an engine housing defining a plurality of cylinders; 
 at least one common rail attached to said engine housing; 
 a solitary fuel injector for each of said plurality of cylinders, each said fuel injector having a tip at least partially positioned in one of said plurality of cylinders, and including a plunger that partially defines a fuel pressurization chamber; 
 each said fuel injector being fluidly connected to said at least one common rail; 
 each said fuel injector having a first configuration corresponding to a homogeneous charge compression ignition mode of operation in which fuel is injected in a first spray pattern with a small average angle with respect to an injector centerline relatively early in a compression stroke when a piston is nearer a bottom dead center position than a top dead center position; and 
 each said fuel injector having a second configuration corresponding to a conventional mode of operation in which fuel is injected in a second spray pattern with a large average angle with respect to said injector centerline relatively late in a compression stroke when said piston is nearer said top dead center position than said bottom dead center position. 
 
     
     
       41. The engine of  claim 40  wherein each said fuel injector includes an injector body that defines a plurality of nozzle outlets:
 a first portion of said plurality of nozzle outlets being open when said fuel injector is in said first configuration; and 
 a second portion of said plurality of nozzle outlets being open when said fuel injector is in said second configuration. 
 
     
     
       42. The engine of  claim 41  wherein each said fuel injector includes a needle valve that is biased toward a first position blocking said plurality of nozzle outlets;
 said needle valve having a second position that opens said first portion of said plurality of nozzle outlets when said fuel injector is in said first configuration; and 
 said needle valve having a third position that opens said second portion of said plurality of nozzle outlets when said fuel injector is in said second configuration. 
 
     
     
       43. The engine of  claim 42  wherein said small average angle is less than or equal to 30 degrees; and
 said large average angle is greater than or equal to 60 degrees. 
 
     
     
       44. The engine of  claim 43  wherein said needle valve includes a first needle valve member and a second needle valve member; and
 a first electrical actuator being operably coupled to said first needle valve member and a second electrical actuator being operably coupled to said second needle valve member. 
 
     
     
       45. The engine of  claim 44  wherein said first needle valve member includes a first closing hydraulic surface exposed to fluid pressure in a first needle control chamber; and
 said second needle valve member includes a second closing hydraulic surface exposed to fluid pressure in a second needle control chamber. 
 
     
     
       46. The engine of  claim 45  wherein said first needle control chamber is fluidly isolated from said second needle control chamber. 
     
     
       47. The engine of  claim 46  wherein said first needle valve member is at least partially positioned within said second needle valve member. 
     
     
       48. The engine of  claim 47  wherein said second needle valve member includes a valve scat, said first needle valve member includes a valve surface;
 a nozzle supply passage being blocked when said valve surface is in contact with said valve seat; and 
 said nozzle supply passage being open when said valve surface is out of contact with said valve seat. 
 
     
     
       49. The engine of  claim 48  wherein said at least one common rail includes an amount of oil; and
 each said fuel injector includes a fuel inlet fluidly connected to a source of fuel that is different from said oil. 
 
     
     
       50. A method of operating an engine comprising:
 providing an engine having an engine housing defining a plurality of engine cylinders, each of said engine cylinders including a piston; 
 positioning a solitary fuel injector for each of said plurality of engine cylinders, at least in part by positioning a tip of each of said solitary fuel injectors at least partially within one of said engine cylinders; 
 if said fuel injector is operating in a homogeneous charge compression ignition mode, injecting fuel in a first spray pattern from said fuel injector when said piston is nearer a bottom dead center position than a top dead center position; 
 if said fuel injector is operating in a conventional mode, injecting fuel in a second spray pattern from said fuel injector when said piston is nearer to said top dead center position than said bottom dead center position; and 
 applying high pressure to a closing hydraulic surface of at least one needle valve member movably positioned in said fuel injector; and 
 at least one of the injecting steps includes energizing an electrical actuator of the fuel injector. 
 
     
     
       51. The method of  claim 50  wherein said step of injecting fuel when said piston is nearer a bottom dead center position includes a step of opening a first portion of fuel injector nozzle outlets; and
 said step of injecting fuel when said piston is nearer to said top dead center position includes a step of opening a second portion of said fuel injector nozzle outlets. 
 
     
     
       52. The method of  claim 50  wherein said step of injecting fuel from said fuel injector when said piston is nearer a bottom dead center position includes a step of moving said at least one needle valve member from a first position to a second position; and
 said step of injecting fuel from said fuel injector when said piston is nearer to said top dead center position includes a step of moving said at least one needle valve member to a third position. 
 
     
     
       53. The method of  claim 50  wherein said step of injecting fuel when said piston is nearer a bottom dead center position includes a step of injecting fuel in a first spray pattern with respect to a centerline of said cylinder; and
 said step of injecting fuel when said piston is nearer to said top dead center position includes a step of injecting fuel in a second spray pattern with respect to said centerline. 
 
     
     
       54. The method of  claim 50  wherein said step of injecting fuel in a first spray pattern includes a step of injecting fuel at a relatively small angle with respect to said centerline; and
 said step of injecting fuel in a second spray pattern includes a step of injecting fuel at a relatively large angle with respect to said centerline. 
 
     
     
       55. The method of  claim 50  including the steps of operating said fuel injector in said homogeneous charge compression ignition mode when said engine is operating in a low load condition; and
 operating said fuel injector in said conventional mode when said engine is operating in a high load condition. 
 
     
     
       56. The method of  claim 50  including the step of operating said fuel injector in a mixed mode, at least in part by injecting fuel when said piston is nearer a bottom dead center position and injecting fuel when said piston is relatively close to its top dead center position in a same piston stroke. 
     
     
       57. A fuel injector comprising:
 a plurality of assembled components having a centerline and defining a plurality of nozzle outlets; 
 a homogeneous charge subset of said plurality of nozzle outlets being oriented at a relatively small average angle with respect to said centerline; 
 a conventional subset of said plurality of nozzle outlets being oriented at a relatively large average angle with respect to said centerline; 
 said assembled components including at least one needle valve member movable between a first configuration in which said plurality of nozzle outlets are closed, a second configuration in which said homogeneous charge subset is open but said conventional subset is closed, and a third configuration in which said homogeneous charge subset is closed but said conventional subset is open; 
 said plurality of assembled components including a plunger that defines a portion of a fuel pressurization chamber that is fluidly connected to one of said homogeneous charge subset and said conventional subset when a portion of said plurality of nozzle outlets is open; and 
 said plurality of assembled components including an electronically operated pressure control valve and at least one electronically operated needle control valve. 
 
     
     
       58. The fuel injector of  claim 57  wherein said plurality of assembled components include an intensifier piston operably coupled to said plunger. 
     
     
       59. The fuel injector of  claim 57  wherein said needle control valve includes a three-way valve member trapped to move between a first seat and a second seat. 
     
     
       60. The fuel injector of  claim 57  wherein said homogeneous charge subset and said conventional subset are mutually exclusive. 
     
     
       61. The nozzle assembly of  claim 1  wherein said homogeneous charge compression ignition portion of said plurality of nozzle outlets is separated from said conventional portion of said plurality of nozzle outlets by a sealing member; and
 said sealing member is continuously biased toward a position separating said homogeneous charge compression ignition portion of said plurality of nozzle outlets from said conventional portion of said plurality of nozzle outlets. 
 
     
     
       62. A method of operating an engine, comprising the steps of:
 injecting fuel from a fuel injector via a first at least one nozzle outlet in a first spray pattern directly into an engine cylinder;   mixing the fuel with air in the cylinder;   combusting the fuel after the mixing step;   injecting additional fuel from the fuel injector via a second at least one nozzle outlet in a second spray pattern directly into the engine cylinder when a piston of the engine cylinder is nearer top dead center than bottom dead center; and   at least one of the fuel injecting step and the additional fuel injecting step includes energizing at least one electrical actuator of the fuel injector.   
     
     
       63. The method of claim 62 wherein the first at least one nozzle outlet has a relatively small average angle with respect to a centerline; and
 the at least one second nozzle outlet has a relatively large average angle with respect to the centerline.   
     
     
       64. The method of claim 62 wherein the at least one electrical actuator includes a first electrical actuator and a second electrical actuator;
 the step of injecting fuel includes energizing the first electrical actuator; and   the step of injecting additional fuel includes energizing the second electrical actuator.   
     
     
       65. The method of claim 62 wherein the step of injecting fuel in the first spray pattern occurs during a compression stroke. 
     
     
       66. A nozzle assembly comprising: a plurality of assembled components defining a plurality of nozzle outlets;
 a homogenous charge compression ignition portion of said plurality of assembled outlets being oriented at a first average angle with respect to a centerline;   a conventional portion of said plurality of nozzle outlets being oriented a second average angle with respect to said centerline;   said assembled components including a needle valve being positioned to move between positions that open and close said plurality of nozzle outlets, and being moveable between a first configuration in which said first portion are open but said second portion are closed, and a second configuration in which said second portion are open but said first portion are closed;   said assembled components also including at least one control valve member positioned to move between a high pressure seat and a low pressure seat; and   said assembled components further including at least one electrical actuator operably coupled to said needle valve via said at least one control valve member.   
     
     
       67. The nozzle assembly of claim 66 wherein said first average angle is relatively small and said second average angle is relatively large. 
     
     
       68. The nozzle assembly of claim 66 wherein at least one of a first needle valve member and a second needle valve member of the needle valve includes a closing hydraulic surface exposed to fluid pressure in a needle control chamber. 
     
     
       69. An engine having at least two modes of operation comprising: an engine housing defining a plurality of cylinders;
 a solitary fuel injector for each of said plurality of cylinders, each said fuel injector having a tip at least partially positioned in one of said plurality of cylinders;   each said fuel injector having a first configuration for a homogeneous charge compression ignition mode of operation in which fuel is injected in a first spray pattern; and   each said fuel injector having a second configuration for a conventional mode of operation in which fuel is injected in a second spray pattern; and   each said fuel injector including at least one control valve member positioned to move between a high pressure seat and a low pressure seat.   
     
     
       70. A fuel injector comprising:
 a plurality of assembly components having a centerline and defining a plurality of nozzle outlets;   a homogenous charge compression ignition portion of said plurality of nozzle outlets being oriented at a first average angle with respect to said centerline;   a conventional portion of said plurality of nozzle outlets being oriented at a second average angle with respect to said centerline;   said assembled components including at least one needle valve member being positioned adjacent said plurality of nozzle outlets;   said at least one needle valve member having a first position in which said homogenous charge portion is open but said conventional portion is closed, and a second position in which said conventional portion is open but said homogenous charge portion is closed;   said at least one needle valve member including a closing hydraulic surface exposed to fluid pressure in a needle control chamber;   said assembled components includes at least one control valve member positioned to move between a high pressure seat and a low pressure seat; and   said assembled components further includes at least one electrical actuator.