Note: Descriptions are shown in the official language in which they were submitted.
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FUEL INJECTOR FOR AN INTERNAL COMBUSTION ENGINE
[0001] The p resent invention relates to fuel d elivery in a n internal
combustion engine. More particularly, a method and apparatus according
to the invention provides at least one heated capillary flow passage for
vaporizing fuel supplied to an internal combustion engine.
[0002] A variety of systems has been devised to supply fine liquid
fuel droplets and air to internal combustion engines. These systems either
supply fuel directly into the combustion chamber (direct injection) or utilize
a carburetor or fuel injector(s) to supply the mixture through an intake
manifold into a combustion chamber (indirect injection). In currently
employed systems, the fuel-air mixture is produced by atomizing a liquid
fuel and supplying it as fine droplets into an airstream.
[0003] In conventional spark-ignited engines employing port-fuel
injection, the injected fuel is vaporized by directing the liquid fuel
droplets
at hot components in the intake port or manifold, under normal operating
conditions. The I iquid fuel films on the surfaces of the hot components
and is subsequently vaporized. The mixture of vaporized fuel and intake
air is then drawn into the cylinder by the pressure differential created as
the intake valve opens and the piston moves towards bottom dead center.
To ensure a degree of control that is compatible with modern engines, this
vaporizing technique is typically optimized to occur in less than one engine
cycle.
[0004] Under most engine operating conditions, the temperature of
the intake components is sufficient to rapidly vaporize the impinging liquid
fuel droplets. However, under conditions such as cold-start and warm-up,
the fuel is not vaporized through impingement on the relatively cold engine
components. Instead, engine operation under these conditions is ensured
by supplying excess fuel such that a sufficient fraction evaporates through
heat and mass transfer as it travels through the air prior to impinging on a
cold intake component. Evaporation rate through this mechanism is a
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function of fuel properties, temperature, pressure, relative droplet and air
velocities and droplet diameter. Of course, this approach breaks down in
extreme ambient cold-starts, in which the fuel volatility is insufficient to
produce vapor in ignitable concentrations with air.
[0005] In order for combustion to be chemically complete, the fuel-
air mixture must be vaporized to a stoichiometric gas-phase mixture. A
stoichiometric combustible mixture contains the exact quantities of air
(oxygen) and fuel required for complete combustion. For gasoline, this air-
fuel ratio is about 14.7:1 by weight. A fuel-air mixture that is not
completely vaporized, nor chemically stoichiometric, results in incomplete
combustion and reduced thermal efficiency. The products of an ideal
combustion process are water (H20) and carbon dioxide (CO2). If
combustion is incomplete, some carbon is not fully oxidized, yielding
carbon monoxide (CO) and unburned hydrocarbons (HG).
[0006] The mandate to reduce air pollution has resulted in attempts
to compensate for combustion inefficiencies with a multiplicity of fuel
system and engine modifications. As evidenced by the prior art relating to
fuel preparation and delivery systems, much effort has been directed to
reducing liquid fuel droplet size, increasing system turbulence and
providing sufficient heat to vaporize fuels to permit more complete
combustion.
[0007] However, inefficient fuel preparation at lower engine
temperatures remain a problem which results in higher emissions,
requiring after-treatment and complex control strategies. Such control
strategies can include exhaust gas recirculation, variable valve timing,
retarded ignition timing, reduced compression ratios, the use of catalytic
converters and air injection to oxidize unburned hydrocarbons and
produce an exothermic reaction benefiting catalytic converter light-off.
[0008] Over-fueling the engine during c old-start and warm-up i s a
significant source of unburned hydrocarbon emissions in conventional
engines. Compounding the problem is the fact that the catalytic converter
is also cold during this period of operation and, thus, does not reduce a
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significant amount of the unburned hydrocarbons that pass through the
engine exhaust. As a result, the high engine-out concentrations of
unburned hydrocarbons pass essentially unreacted through the catalytic
converter and are emitted from the tailpipe. It has been estimated that as
much as 80 percent of the total hydrocarbon emissions produced by a
typical, modern passenger car occurs during the cold-start and warm-up
period, in which the engine is over-fueled and the catalytic converter is
essentially inactive.
[0009] Given the relatively large proportion of unburned
hydrocarbons emitted during startup, this aspect of passenger car engine
operation has been the focus of significant technology development
efforts. Furthermore, as increasingly stringent emissions standards are
enacted into legislation and consumers remain sensitive to pricing and
performance, these development efforts will continue to be paramount.
Such efforts to reduce start-up emissions from conventional engines
generally fall into two categories: 1) reducing the warm-up time for three-
way catalyst systems and 2) improving techniques for fuel vaporization.
Efforts to reduce the warm-up time for three-way catalysts to date have
included: retarding the ignition timing to elevate the exhaust temperature;
opening the exhaust valves prematurely; electrically heating the catalyst;
burner or flame heating the catalyst; and catalytically heating the catalyst.
As a whole, these efforts are costly and do not address HC emissions
during and immediately after cold start.
[0010] A variety of techniques have been proposed to address the
issue of fuel vaporization. U.S. Patents proposing fuel vaporization
techniques include U.S. Patent No. 5,195,477 issued to Hudson, Jr. et al,
U.S. Patent No. 5,331,937 issued to Clarke, U.S. Patent No. 4,886,032
issued to Asmus, U.S. Patent No. 4,955,351 issued to Lewis et al., U.S.
Patent No. 4,458,655 issued to Oza, U.S. Patent No. 6,189,518 issued to
Cooke, U.S. Patent No. 5,482,023 issued to Hunt, U.S. Patent No.
6,109,247 issued to Hunt, U.S. Patent No. 6,067,970 issued to
Awarzamani et al., U.S. Patent No. 5,947,091 issued to Krohn et al., U.S.
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Patent No. 5,758,826 issued to Nines, U.S. Patent No. 5,836,289 issued to
Thring, and U.S. Patent No. 5,813,388 issued to Cikanek, Jr. et al.
[0011] Other fuel delivery devices proposed include U.S. Patent No.
3,716,416, which discloses a fuel-metering device for use in a fuel cell
system. The fuel cell system is intended to be self-regulating, producing
power at a predetermined level. The proposed fuel metering system
includes a capillary flow control device for throttling the fuel flow in
response to the power output of the fuel cell, rather than to provide
improved fuel preparation for subsequent combustion. Instead, the fuel
is intended to be fed to the fuel cell for conversion to H2. In a preferred
embodiment, the capillary tubes are made of metal and the capillary
itself is used as a resistor, which is in electrical contact with the power
output of the fuel cell. Because the flow resistance of a vapor is greater
than that of a liquid, the flow is throttled as the power output increases.
The fuels suggested for use include any fluid that is easily transformed
from a liquid to a vapor phase by applying heat and flows freely through
a capillary. Vaporization appears to be achieved in the manner that
vapor lock occurs in automotive engines.
[0012] U.S. Patent No. 6,276,347 proposes a supercritical or near-
supercritical atomizer and method for achieving atomization or
vaporization of a liquid. The supercritical atomizer of U.S. Patent No.
6,276,347 is said to enable the use of heavy fuels to fire small, light
weight, low compression ratio, spark-ignition piston engines that typically
burn gasoline. The atomizer is intended to create a spray of fine droplets
from liquid, or liquid-like fuels, by moving the fuels toward their
supercritical temperature and releasing the fuels into a region of lower
pressure on the gas stability field in the phase diagram associated with the
fuels, causing a fine atomization or vaporization of the fuel. Utility is
disclosed for applications such as combustion engines, scientific
equipment, chemical processing, waste disposal control, cleaning, etching,
insect control, surface modification, humidification and vaporization.
[0013] To minimize decomposition, U.S. Patent No. 6,276,347
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proposes keeping the fuel below the supercritical temperature until
passing the distal end of a restrictor for atomization. For certain
applications, heating just the tip of the restrictor is desired to minimize
the
potential for chemical reactions or precipitations. This is said to reduce
problems associated with impurities, reactants or materials in the fuel
stream which otherwise t end t o b e d riven out o f solution, c logging I
ines
and filters. Working at or near supercritical pressure suggests that the fuel
supply system operate in the range of 21.1 to 56.2 kg/cm2 (300 to 800
psig). While the use of supercritical pressures and temperatures might
reduce clogging of the atomizer, it appears to require the use of a
relatively more expensive fuel pump, as well as fuel lines, fittings and the
like that are capable of operating at these elevated pressures.
[0014] In one aspect, the present invention is directed to a fuel
injector for vaporizing a liquid fuel for use in an internal combustion
engine, comprising:
(a) at least one capillary flow passage, said at least one
capillary flow passage having an inlet end and an outlet end, said capillary
flow passage comprising a channel formed within a monolithic body
produced from a material selected from the group consisting of ceramics,
polymers, metals and composites thereof or a multi-layer ceramic body;
(b) a fluid control valve for placing said inlet end of said at
least one capillary flow passage in fluid communication with the liquid fuel
source and introducing the liquid fuel in a substantially liquid state; and
(c) a heat source arranged along said at least one
capillary flow passage, said heat source operable to heat the liquid fuel in
said at least one capillary flow passage to a level sufficient to change at
least a portion thereof from the liquid state to a vapor state and deliver a
stream of substantially vaporized fuel from said outlet end of said at least
one capillary flow passage.
[0015] In another aspect, the present invention is directed to a fuel
system for use in an internal combustion engine, comprising:
(a) a plurality of fuel injectors, each injector including (i)
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at least one capillary flow passage said at least one capillary flow
passage having an inlet end and an outlet end, said capillary flow
passage comprising a channel formed within a monolithic body produced
from a material selected from the group consisting of ceramics, polymers,
metals and composites thereof or a multi-layer ceramic body; (ii) a fluid
control valve for placing said inlet end of said at least one capillary flow
passage in fluid communication with the liquid fuel source and
introducing the I iquid fuel i n a substantially I iquid state; and (iii) a
heat
source arranged along the at least one capillary flow passage, said heat
source operable to heat the liquid fuel in said at least one capillary flow
passage to a level sufficient to change at least a portion thereof from the
liquid state to a vapor state and deliver a stream of substantially
vaporized fuel from said outlet end of said at least one capillary flow
passage;
(b) a liquid fuel supply system in fluid communication
with said plurality of fuel injectors; and
(c) a controller to control the supply of fuel to said
plurality of fuel injectors.
[0016] In yet another aspect, the present invention is directed to a
method of delivering fuel to an internal combustion engine, comprising the
steps of:
(a) supplying liquid fuel to at least one capillary flow
passage of a fuel injector;
(b) causing a stream of substantially vaporized fuel to
pass through an outlet of the at least one capillary flow passage by heating
the liquid fuel in the at least one capillary flow passage; and
(c) delivering the vaporized fuel to a combustion chamber
of the internal combustion engine.
wherein the capillary flow passage comprises a channel
formed within a monolithic body produced from a material selected from
the group consisting of ceramics, polymers, metals and composites
thereof or a multi-layer ceramic body.
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[0016.1] In yet another aspect, the present invention is directed to a
fuel injector for vaporizing a liquid fuel for use in an internal combustion
engine,
comprising: (a) at least one capillary flow passage, said at least one
capillary
flow passage having a hydraulic diameter of less than 2 mm, an inlet end and
an outlet end, said capillary flow passage comprising a channel formed within
a
monolithic body produced from a material selected from the group consisting of
ceramics, polymers, metals and composites thereof or a multi-layer ceramic
body; (b) a fluid control valve for placing said inlet end of said at least
one
capillary flow passage in fluid communication with the liquid fuel source and
introducing the liquid fuel in a substantially liquid state; (c) a heat source
arranged along said at least one capillary flow passage, said heat source
operable to heat the liquid fuel in said at least one capillary flow passage
to a
level sufficient to change at least a portion thereof from the liquid state to
a
vapor state and deliver a stream of substantially vaporized fuel from said
outlet
end of said at least one capillary flow passage; and (d) means for cleaning
deposits formed during operation of the apparatus, said means for cleaning
deposits includes said fluid control valve, said fluid control valve operable
for
placing said at least one capillary flow passage in fluid communication with a
solvent, enabling in-situ cleaning of said capillary flow passage when the
solvent
is introduced into said at least one capillary flow passage.
[0016.2] In yet another aspect, the present invention is directed to a
fuel system for use in an internal combustion engine, comprising: (a) a
plurality of fuel injectors, each injector including (i) at least one
capillary flow
passage, said at least one capillary flow passage having a hydraulic diameter
of
less than 2 mm, an inlet end and an outlet end, said capillary flow passage
comprising a channel formed within a monolithic body produced from a material
selected from the group consisting of ceramics, polymers, metals and
composites thereof or a multi-layer ceramic body; (ii) a fluid control valve
for
placing said inlet end of said at least one capillary flow passage in fluid
communication with the liquid fuel source and introducing the liquid fuel in a
substantially liquid state; (iii) a heat source arranged along the at least
one
capillary flow passage, said heat source operable to heat the liquid fuel in
said
at least one capillary flow passage to a level sufficient to change at least a
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portion thereof from the liquid state to a vapor state and deliver a stream of
substantially vaporized fuel from said outlet end of said at least one
capillary
flow passage; and (iv) means for cleaning deposits formed during operation of
the apparatus, said means for cleaning deposits includes said fluid control
valve,
said fluid control valve operable for placing said at least one capillary flow
passage in fluid communication with a solvent, enabling in-situ cleaning of
said
capillary flow passage when the solvent is introduced into said at least one
capillary flow passage; (b) a liquid fuel supply system in fluid communication
with said plurality of fuel injectors; and (c) a controller to control the
supply of
fuel to said plurality of fuel injectors.
[0016.3] In yet another aspect, the present invention is directed to a
method of delivering fuel to an internal combustion engine, comprising the
steps of: (a) supplying liquid fuel to at least one capillary flow passage of
a fuel
injector, the at least one capillary flow passage having a hydraulic diameter
of
less than 2 mm; (b) causing a stream of substantially vaporized fuel to be
formed within the at least one capillary flow passage and pass through an
outlet
of the at least one capillary flow passage by heating the liquid fuel in the
at
least one capillary flow passage; (c) delivering the vaporized fuel to a
combustion chamber of the internal combustion engine; and (d) cleaning
periodically the at least one capillary flow passage by placing the at least
one
capillary flow passage in fluid communication with a solvent, enabling in-situ
cleaning of the capillary flow passage when the solvent is introduced into the
at
least one capillary flow passage, wherein the capillary flow passage comprises
a
channel formed within a monolithic body produced from a material selected
from the group consisting of ceramics, polymers, metals and composites thereof
or a multi-layer ceramic body.
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[0017] The present invention provides a fuel injector and delivery
system that can supply vaporized fuel while requiring minimal power and
warm-up time, without the need for a h igh pressure fuel s upply system,
which may be utilized in a number of configurations including conventional
port-fuel injection, hybrid-electric, gasoline direct-injection, and alcohol-
fueled engines.
[0018] The invention will now be described in more detail with
reference to preferred forms of the invention, given only by way of
example, and with reference to the accompanying drawings, in which:
FIG. I illustrates a modified fuel injector, in partial cross
section, which includes a capillary flow passage in accordance with a
preferred form;
FIG. 2 is a side elevation view of an embodiment of the fuel
injector according to another preferred form;
FIG. 2A is an isometric view of an outlet of the capillary of
the embodiment illustrated in Fig. 2;
FIG. 3 is a side elevation view of another embodiment of a
fuel injector according to another preferred form;
FIG. 3A is an isometric view of another outlet design of the
capillary of the embodiment illustrated in Fig. 3;
FIG. 4 is a side elevation view of yet another embodiment of
a fuel injector according to a preferred form;
FIG. 4A is an isometric view of another outlet design of the
capillary of the embodiment illustrated in Fig. 4;
FIG. 5 is a schematic illustration of still another embodiment
of a fuel injector according to a preferred form;
FIG. 6 is a side view of yet still another embodiment of a fuel
injector according to a preferred form;
FIG. 7 is a cross-sectional view of another embodiment of
the fuel injector according to yet another preferred form;
FIG. 8 is a side view of another embodiment employing dual
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injectors in accordance with still another preferred form;
FIG. 9 is a side view of another embodiment of a fuel
injector according to a preferred form shown in partial cross-section;
FIG. 9A is an enlarged view of an identified portion of the
embodiment shown in Fig. 9;
FIG. 10 is a side view of another embodiment of a fuel
injector according to a preferred form, shown in partial cross-section;
FIG. IOA is an enlarged view of an identified portion of the
embodiment shown in Fig. 10;
FIG. 11 is a side elevation view of yet another preferred form
of a fuel injector in accordance herewith;
FIG. 11A is an isometric view of another outlet design of the
capillary of the embodiment illustrated in Fig. 11;
FIG. 12 is a side view of another embodiment of a fuel
injector having a capillary passage heated with recirculated exhaust
gas;
FIG. 13 is a schematic of a fuel delivery and control
system, in accordance with a preferred form;
FIG. 14 is a chart illustrating engine parameters during the
first 20 seconds of starting in engine using the fuel delivery device of the
invention;
FIG. 15 is a chart illustrating a comparison of engine
emissions from the fuel delivery device of the invention with conventional
port-fuel injectors;
FIG. 16 is a graph of gasoline mass flow as a function of time
showing the benefit to operation achieved through the use of the oxidation
cleaning method of the present invention;
FIG. 17 is a graph of fuel flow rate vs. time for a commercial-
grade gasoline;
FIG. 18 presents a graph of fuel flow rate vs. time comparing
various gasolines;
FIG. 19 is a graph of fuel flow rate vs. time comparing a jet
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fuel to a No. 2 diesel fuel;
FIG. 20 presents a graph of fuel flow rate vs. time for an
unadditized diesel fuel showing the effect of oxidation cleaning; and
FIG. 21 is a graph of fuel flow rate vs. time comparing an
unadditized diesel fuel to a diesel fuel containing an anti-fouling additive.
[0019] Reference is now made to the embodiments illustrated in
Figs. 1-21 wherein like numerals are used to designate like parts
throughout.
[0020] The present invention provides a fuel preparation and
delivery useful for cold-start, warm-up and normal operation of an
internal combustion engine. The fuel system includes a fuel injector
having a capillary flow passage, capable of heating I iquid fuel so that
substantially vaporized fuel is supplied into an engine cylinder. The
substantially vaporized fuel can be combusted with reduced emissions
compared to conventional fuel injector systems. Furthermore, the fuel
delivery system of the present invention requires less power, and has
shorter warm-up times than other vaporization techniques.
[0021] In general, gasolines do not readily vaporize at low
temperatures. During the cold start and warm-up period, relatively little
vaporization of the liquid fuel takes place. As such, it is necessary to
provide an excess of liquid fuel to each cylinder of the engine in order to
achieve an air/fuel mixture that will combust. Upon ignition of the fuel
vapor, which is generated from the excess of liquid fuel, combustion
gases discharged from the cylinders include unburned fuel and
undesirable gaseous emissions. However, upon reaching normal
operating temperature, the liquid fuel readily vaporizes, so that less fuel
is needed to achieve an air/fuel mixture that will readily combust.
Advantageously, upon reaching normal operating temperature, the air/fuel
mixture can be controlled at or near stoichiometry, thereby reducing
emissions of unburned hydrocarbons and carbon monoxide. Additionally,
when fueling is controlled at or near stoichiometry, just enough air is
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available in the exhaust stream for simultaneous oxidation of unburned
hydrocarbons and carbon monoxide and reduction of nitrogen oxides over
a three-way catalyst (TWC).
[0022] The system and method of the present invention injects fuel
that has been substantially vaporized into the intake flow passage, or
directly into an engine cylinder, thereby eliminating the need for excess
fuel during the start-up and warm-up period of an engine. The fuel is
preferably delivered to the engine in a stoichiometric or fuel-lean mixture,
with air, or air and diluent, so that virtually all of the fuel is burned
during
the cold start and warm-up period.
[0023] With conventional port-fuel injection, over-fueling is required
to ensure robust, quick engine starts. Under fuel-rich conditions, the
exhaust stream reaching the three-way catalyst does not contain enough
air to oxidize the excess fuel and unburned hydrocarbons as the catalyst
warms up. One approach to address this issue is to utilize an air pump to
supply additional air to the exhaust stream upstream of the catalytic
converter. The objective is to generate a stoichiometric or slightly fuel-
lean exhaust stream that can react over the catalyst surface once the
catalyst reach its light-off temperature. In contrast, the system and
method of the present invention enables the engine to operate at
stoichiometric or even slightly fuel-lean conditions during the cold-start and
warm-up period, eliminating both the need for over-fueling and the need
for an additional exhaust air pump, reducing the cost and complexity of the
exhaust after treatment system.
[0024] As mentioned, during the cold start and warm-up period, the
three-way catalyst is initially cold and is not able to reduce a significant
amount of the unburned hydrocarbons that pass through the catalyst.
Much effort has been devoted to reducing the warm-up time for three-
way catalysts, so as to convert a larger fraction of the unburned
hydrocarbons emitted during the cold-start and warm-up period. One
such concept is to deliberately operate the engine very fuel-rich during
the cold-start and warm-up period. Using an exhaust air-pump to supply
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air in this fuel-rich exhaust stream, a combustible mixture can be
generated which is burned either by auto-ignition or by some ignition
source upstream of, or in, the catalytic converter. The exotherm
produced by this oxidation process significantly heats up the exhaust gas
and the heat is largely transferred to the catalytic converter as the
exhaust passes through the catalyst. Using the system and method of
the present invention, the engine could be controlled to operate
alternating cylinders fuel-rich and fuel-lean to achieve the same effect but
without the need for an air pump. For example, with a four-cylinder
engine, two cylinders could be operated fuel-rich during the cold-start
and warm-up period to generate unburned hydrocarbons in the exhaust.
The two remaining cylinders would be operated fuel-lean during cold-
start and warm-up, to provide oxygen in the exhaust stream.
(0025] The system and method of the present invention may also
be utilized with gasoline direct injection engines (GDI). In GDI engines,
the fuel is injected directly into the cylinder as a finely atomized spray
that evaporates and mixes with air to form a premixed charge of air and
vaporized fuel prior to ignition. Contemporary GDI engines require high
fuel pressures to atomize the fuel spray. GDI engines operate with
stratified charge at part load to reduce the pumping losses inherent in
conventional indirect injected engines. A stratified-charge, spark-ignited
engine has the potential for burning lean mixtures for improved fuel
economy and reduced emissions. Preferably, an overall lean mixture is
formed in the combustion chamber, but is controlled to be stoichiometric
or slightly fuel-rich in the vicinity of the spark plug at the time of
ignition.
The stoichiometric portion is thus easily ignited, and this in turn ignites
the remaining lean mixture. While pumping losses can be reduced, the
operating window currently achievable for stratified charge is limited to
low engine speeds and relatively light engine loads. The limiting factors
include insufficient time for vaporization and mixing at higher engine
speeds and insufficient mixing or poor air utilization at higher loads. By
providing vaporized fuel, the system and method of the present invention
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can widen the operating window for stratified charge operation, solving
the problem associated with insufficient time for vaporization and mixing.
Advantageously, unlike conventional GDI fuel systems, the fuel pressure
employed in the practice of the present invention can be lowered,
reducing the overall cost and complexity of the fuel system.
[0026] The invention provides a fuel delivery device for an internal
combustion engine which includes a pressurized liquid fuel supply that
supplies liquid fuel u nder p ressure, a t least one capillary f low passage
connected to the liquid fuel supply, and a heat source arranged along the
at least one capillary flow passage. The heat source is operable to heat
liquid fuel in the at least one capillary flow passage sufficiently to deliver
a stream of substantially vaporized fuel. The fuel delivery device is
preferably operated to deliver the stream of vaporized fuel to one or more
combustion chambers of an internal combustion engine during start-up,
warm-up and other operating conditions of the internal combustion
engine. If desired, the at least one capillary flow passage can be used to
deliver liquid fuel to the engine under normal operating conditions.
[0027] The invention also provides a method of delivering fuel to
an internal combustion engine, including the steps of supplying the
pressurized liquid fuel to at least one capillary flow passage, and heating
the pressurized liquid fuel in the at least one capillary flow passage
sufficiently to cause a stream of vaporized fuel to be delivered to at least
one combustion chamber of an internal combustion engine during start-
up, warm-up, and other operating conditions of the internal combustion
engine.
[0028] A fuel delivery system according to the invention includes at
least one capillary-sized flow passage through which pressurized fuel
flows before being injected into an engine for combustion. A capillary-
sized flow passage can be provided with a hydraulic diameter that is
preferably less than 2 mm, more preferably less than 1 mm and most
preferably less than 0.5 mm. Hydraulic diameter is used in calculating
fluid flow through a fluid carrying element. Hydraulic diameter is defined
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as the flow area of the fluid-carrying element divided by the perimeter of
the solid boundary in contact with the fluid (generally referred to as the
"wetted" perimeter). I n the case of a fluid carrying element of circular
cross section, the hydraulic radius when the element is flowing full is
(itD2/4)/ 7cD=D/4. For the flow of fluids in noncircular fluid carrying
elements, the hydraulic diameter is used. From the definition of hydraulic
radius, the diameter of a fluid-carrying element having circular cross
section is four times its hydraulic radius. Therefore, hydraulic diameter is
defined as four times the hydraulic radius.
[0029] Heat is applied along the capillary passageway, resulting in
at least a portion of the liquid fuel that enters the flow passage being
converted to a vapor as it travels along the passageway. The fuel exits
the capillary passageway as a vapor, which optionally contains a minor
proportion of heated liquid fuel, which has not been vaporized. By
substantially vaporized i s m eant t hat a t I east 5 0% volume o f the I
iquid
fuel is vaporized by the heat source, more preferably at least 70%, and
most preferably at least 80% of the liquid fuel is vaporized. Although it
may b e d ifficult t o achieve 100% vaporization d ue t o complex p hysical
effects that take place, nonetheless complete vaporization would be
desirable. These complex physical effects include variations in the
boiling point of the fuel since the boiling point is pressure dependent and
pressure can vary in the capillary flow passage. Thus, while it is believed
that a major portion of the fuel reaches the boiling point during heating in
the capillary flow passage, some of the liquid fuel may not be heated
enough to be fully vaporized with the result that a portion of the liquid fuel
passes through the outlet of the capillary flow passage along with the
vaporized fluid.
[0030] The capillary-sized fluid passage is preferably formed in a
capillary body such as a single or multilayer metal, ceramic or glass
body. The passage has an enclosed volume opening to an inlet and an
outlet either of which, or both, may be open to the exterior of the capillary
body or may be connected to another passage within the same body or
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another body or to fittings. The heater can be formed by a portion of the
body such as a section of a stainless steel tube or the heater can be a
discrete layer or wire of resistance heating material incorporated in or on
the capillary body. The fluid passage may be any shape comprising an
enclosed volume opening to an inlet and an outlet and through which a
fluid may pass. The fluid passage may have any desired cross-section
with a preferred cross-section being a circle of uniform diameter. Other
capillary fluid passage cross-sections include non-circular shapes such
as triangular, square, rectangular, oval or other shape and the cross
section of the fluid passage need not be uniform. The fluid passage can
extend rectilinearly or non-rectilinearly and may be a single fluid passage
or multi-path fluid passage. In the case where the capillary passage is
defined by a metal capillary tube, the tube can have an inner diameter of
0.01 to 3 mm, preferably 0.1 to 1 mm, most preferably 0.15 to 0.5 mm.
Alternatively, the capillary passage can be defined by transverse cross
sectional area of the passage, which can be 8 x 10"5 to 7 mm2, preferably
8 x 10-3 to 8 x 10-1 mm2 and more preferably 2 x 10"3 to 2 x 10-1 mm2.
Many combinations of a single or multiple capillaries, various pressures,
various capillary lengths, amounts of heat applied to the capillary, and
different cross-sectional areas will suit a given application.
[0031] The liquid fuel can be supplied to the capillary flow passage
under a pressure of at least 0.7 kg/cm2 (10 psig), preferably at least 1.4
kg/cm2 (20 psig). In the case where the capillary flow passage is defined
by the interior of a stainless steel tube having an internal diameter of
approximately 0.051 cm (0.020 in) and a length of approximately 15.2 cm
(6 in), the fuel is preferably supplied to the capillary passageway at a
pressure of 7 kg/cm2 (100 psig) or less to achieve mass flow rates
required for stoichiometric start of a typical size automotive engine
cylinder (on the order of 100-200 mg/s). The at least one capillary
passageway provides a sufficient flow of substantially vaporized fuel to
ensure a stoichiometric or nearly stoichiometric mixture of fuel and air
that can be ignited and combusted within the cylinder(s) of an engine
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without producing undesirably high I evels of unburned hydrocarbons or
other emissions. The capillary tube also is characterized by having a low
thermal inertia, so that the capillary passageway can be brought up to the
desired temperature for vaporizing fuel very quickly, preferably within 2.0
seconds, more preferably within 0.5 second, and most preferably within
0.1 second, which is beneficial in applications involving cold starting an
engine. The low thermal inertia also could provide advantages during
normal operation of the engine, such as by improving the responsiveness
of the fuel delivery to sudden changes in engine power demands.
[0032] During vaporization of liquid fuel in a heated capillary
passage, deposits of carbon and/or heavy hydrocarbons can accumulate
on the capillary walls and the flow of the fuel can be severely restricted
which ultimately can lead to clogging of the capillary flow passage. The
rate at which these deposits accumulate is a function of capillary wall
temperature, fuel flow rate and fuel type. It is believed that fuel additives
may be useful in reducing such deposits. However, should clogging
develop, such clogging can be cleared by oxidizing the deposits.
[0033] FIG. 1 presents a fuel injector 10 for vaporizing a liquid fuel
drawn from a source of liquid fuel, in accordance with the present
invention. Apparatus 10 includes a capillary flow passage 12, having an
inlet end 14 and an outlet end 16. A fluid control valve 18 is provided for
placing inlet end 14 of capillary flow passage 12 in fluid communication
with a liquid fuel source F and introducing the liquid fuel in a substantially
liquid state into capillary flow passage 12.
[0034] As is preferred, fluid control valve 18 may be operated by
solenoid 28. Solenoid 28 has coil windings 32 connected to electrical
connector 30. W hen the coil windings 32 are energized, the solenoid
element 36 is drawn into the center of coil windings 32. When electricity
is cut off from the coil windings 32, a spring 38 returns the solenoid
element to its original position. A pintle 40 is connected to the solenoid
element 36. Movement of the solenoid element 36, caused by applying
electricity to the coil windings 32, causes the pintle to be drawn away
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from a hole 42 allowing fuel to flow through the hole 42.
[0035] A heat source 20 is arranged along capillary flow passage
12. As is most preferred, heat source 20 is provided by forming capillary
flow passage 12 from a tube of electrically resistive material, a portion of
capillary flow passage 12 forming a heater element when a source of
electrical current is connected to the tube at connections 22 and 24 for
delivering current therethrough. Heat source 20, as may be appreciated,
is then operable to heat the liquid fuel in capillary flow passage 12 to a
level sufficient to change at least a portion thereof from a liquid state to a
vapor state and deliver a stream of substantially vaporized fuel from
outlet end 16 of capillary flow passage 12.
[0036] Apparatus 10 also includes means for cleaning deposits
formed during operation of apparatus 10. The means for cleaning
deposits shown in FIG.1 includes fluid control valve 18, heat source 20
and an oxidizer control valve 26 for placing capillary flow passage 12 in
fluid communication with a source of oxidizer C. As may be appreciated,
the oxidizer control valve can be located at or near either end of capillary
flow passage 12 or configured t o be i n fluid communication with e ither
end of capillary flow passage 12. If the oxidizer control valve is located
at or near the outlet end 16 of capillary flow passage 12, it then serves to
place the source of oxidizer C in fluid communication with the outlet end
16 of capillary flow passage 12. In operation, heat source 20 is used to
heat the oxidizer C i n capillary f low p assage 12 t o a I evel s ufficient t
o
oxidize d eposits formed d uring the h eating oft he I iquid fuel F. I n o ne
embodiment, to switch from a fueling mode to a cleaning mode, the
oxidizer control valve 26 is operable to alternate between the introduction
of liquid fuel F and the introduction of oxidizer C into capillary flow
passage 12 and enable in-situ cleaning of capillary flow passage 12
when the oxidizer is introduced into the at least one capillary flow
passage.
[0037] One technique for oxidizing deposits includes passing air or
steam through the capillary. The flow passage is preferably heated
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during the cleaning operation so that the oxidation process is initiated
and nurtured until the deposits are consumed. To enhance this cleaning
operation, a catalytic substance may be either employed, as a coating
on, o r a s a component of, the capillary w all f o r educe the temperature
and/or time required for accomplishing the cleaning. For continuous
operation. of the fuel delivery system, more than one capillary flow
passage can b e used such t hat when a clogged condition is detected,
such as by the use of a sensor, fuel flow can be diverted to another
capillary flow passage and oxidant flow initiated through the clogged
capillary flow passage to be cleaned. As an example, a capillary body
can include a plurality o f capillary f low passages t herein and a v alving
arrangement can be provided to selectively supply liquid fuel or air to
each flow passage.
[0038] Alternatively, fuel flow can be diverted from a capillary flow
passage and oxidant flow initiated at preset intervals. Fuel delivery to a
capillary flow passage can be effected by a controller. For example, the
controller can activate fuel delivery for a preset time period and
deactivate fuel delivery after the preset amount of time. The controller
may also effect adjustment of the pressure of the liquid fuel and/or the
amount of heat supplied to the capillary flow passage based on one or
more sensed conditions. The sensed conditions may include inter alia:
the fuel pressure; the capillary temperature; and the air fuel mixture. The
controller may also control multiple fuel delivery devices attached to the
application. The controller may also control one or more capillary flow
passages to clear deposits or clogs therefrom. For example, cleaning of
a capillary flow passage can be achieved by applying heat to the capillary
flow passage and supplying a flow of an oxidant source to the capillary
flow passage.
[0039] The heated capillary f low passage 12, in accordance with
the invention can produce a vaporized stream of fuel, which condenses in
air to form a mixture of vaporized fuel, fuel droplets, and air commonly
referred to as an aerosol. Compared to a conventional automotive port-
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fuel injector, which delivers a fuel spray comprised of droplets in the
range of 150 to 200 pm Sauter Mean Diameter (SMD), the aerosol has
an average droplet size of less than 25 pm SMD, preferably less than 15
pm SMD. Thus, the majority of the fuel droplets produced by the heated
capillary according to the invention can be carried by an air stream,
regardless of the flow path, into the combustion chamber.
[0040] The difference between the droplet size distributions of a
conventional injector and the heated capillary flow passage according to
the invention is particularly critical during cold-start and warm-up
conditions. Specifically, using a conventional port-fuel injector, relatively
cold intake manifold components necessitate over-fueling such that a
sufficient fraction of the large fuel droplets, impinging on the intake
components, are vaporized to produce an ignitable fuel/air mixture.
Conversely, the vaporized fuel and fine droplets produced by the fuel
injector of the present invention are essentially unaffected by the
temperature of engine components upon start-up and, as such, eliminate
the need for over-fueling during engine start-up conditions. The
elimination of over-fueling combined with more precise control over the
fuel/air ratio to the engine afforded through the use of the heated capillary
injector of the present invention results in greatly reduced cold start
emissions compared to those produced by engines employing
conventional fuel injector systems. In addition to a reduction in over-
fueling, it should also be noted that the heated capillary injector according
to the i nvention further e nables fuel-lean o peration during c old-start a
nd
warm-up, which results in a greater reduction in tailpipe emissions while
the catalytic converter warms up.
[0041] Referring still to FIG. 1, capillary flow passage 12 can
comprise a metal tube such a s a stainless steel capillary tube a nd the
heater comprising a length of the tube 20 through which electrical current
is passed. In a preferred embodiment, the capillary tube is provided with
an internal diameter of approximately 0.051 to 0.076 cm (0.020 to 0.030
in), a heated length of approximately 5.08 to 25.4 cm (2 to 10 in), and
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fuel can be supplied to the tube 12 at a pressure of less than 7.0 kg/cm2
(100 psig), preferably less than 4.9 kg/cm2 (70 psig), more preferably
less than 4.2 kg/cm2 (60 psig) and even more preferably less than 3.1
kg/cm2 (45 psig) or less. It has been shown that this embodiment
produces vaporized fuel, which forms a distribution of aerosol droplets,
which mostly range in size from 2 to 30 pm SMD with an average droplet
size of about 5 to 15 pm SMD, when the vaporized fuel is condensed in
air at ambient temperature. The preferred size of fuel droplets to achieve
rapid and nearly complete vaporization at cold-starting temperatures is
less than about 25 pm. This result can be achieved by applying
approximately 10.2 to 40.8 kg/sec (100 to 400W), e.g., 20.4 kg/sec
(200W) of electrical power, which corresponds to 2-3% of the energy
content of the vaporized fuel, to a six-inch stainless steel capillary tube.
The electrical power can be applied to the capillary tube by forming the
tube entirely from an electrically conductive material such as stainless
steel, or by providing a conductive material over at least a portion of a
non-electrically conducting tube or laminate having a flow passage
therein such as by laminating or coating an electrically resistive material
to form a resistance heater on the tube or laminate. Electrical leads can
be connected to the electrically conductive material to supply the
electrical current to the heater to heat the tube along its length.
Alternatives for heating the tube along its length could include inductive
heating, such as by an electrical coil positioned around the flow passage,
or other sources of heat positioned relative to the flow passage to heat
the length of the flow passage through one or a combination of
conductive, convective or radiative heat transfer.
[0042] Although, a preferred capillary tube has a heated length of
approximately 15.2 cm (6 in) and an internal diameter of approximately
0.051 cm (0.020 in), other configurations of capillaries provide acceptable
vapor quality. For example, the internal diameter can range from 0.05 to
0.08 cm (0.02 to 0.03 in) and the heated portion of the capillary tube can
range from 2.5 to 25.4 cm (1 to 10 in). After cold-start and warm-up, it is
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not necessary to heat the capillary tube such that the unheated capillary
tube can be used to supply adequate liquid fuel to an engine operating at
normal temperature.
[0043] The vaporized fuel exiting from the fuel capillary according
to the invention can be injected into an engine intake manifold at the
same location as existing port-fuel injectors or at another location along
the intake manifold. If desired, however, the fuel capillary can be
arranged to deliver vaporized fuel directly into each cylinder of the
engine. The fuel capillary provides advantages over systems that
produce larger droplets of fuel that must be injected against the back side
of a closed intake valve while starting the engine. Preferably, the outlet
of the fuel capillary tube is positioned flush with the intake manifold wall
similar to the arrangement of the outlets of conventional fuel injectors.
[0044] After approximately 20 seconds (or preferably less) from
starting the engine, heat to the capillary flow passage 12 can be turned
off and liquid injection initiated using conventional fuel injectors, for
normal engine operation. Normal engine operation can alternatively be
performed by liquid fuel injection through an unheated capillary flow
passage 12 via continuous injection or possibly pulsed injection.
[0045] Referring to FIG. 2, a second exemplary embodiment of the
present invention is shown. A fuel injector 100 has a capillary flow
passage 112. Capillary flow passage 112 is heated along heated length
120. The capillary flow passage 112 is fitted with a flared end 150 with a
plurality of perforations 152 in a plate 154 covering the flared end 150 as
illustrated by FIG. 2A. The fuel injector 100 can include a fluid control
valve such as a solenoid valve of the type described above and shown in
FIG. 1, which allows delivery of pressurized liquid fuel to the capillary
flow passage 112. After the engine is sufficiently heated, heating of the
capillary flow passage 112 can be terminated and liquid fuel can be
supplied through the capillary flow passage 112.
[0046] Referring now to FIG. 3, a third exemplary embodiment of
the present invention is shown. A fuel injector 200 is depicted having a
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capillary flow passage 212. Capillary flow passage 212 is heated along
heated length 220. The capillary flow passage 212 is fitted with a flat end
250 with a plurality of perforations 252 in a plate 254 covering the flat end
250 as illustrated by FIG. 3A. The fuel injector 200 can include a fluid
control valve such as a solenoid valve of the type described above and
shown in FIG. 1, which allows delivery of pressurized liquid fuel to the
capillary flow passage 212. As described above, after an engine utilizing
a plurality of fuel injectors 200 is started, heating of the capillary flow
passage 212 can be terminated and liquid fuel can be supplied through
the capillary flow passage 212. Injector 200 can advantageously be
cleaned through the use of the, oxidation technique described above.
[0047] Referring now to FIG. 4, a fourth exemplary embodiment of
the present invention is shown. A fuel injector 300 is depicted having a
capillary flow passage 312. Capillary flow passage 312 is heated along
heated length 320. The capillary flow passage 312 is fitted with a conical
end 350 with a plurality of perforations 352 in a conical plate 354
covering the conical end 350 as illustrated by FIG. 4A. The fuel injector
300 can include a fluid control valve such as a solenoid valve of the type
described above and shown in FIG. 1, which allows delivery of
pressurized liquid fuel to the capillary flow passage 312. As described
above, after an engine utilizing a plurality of fuel injectors 300 is started,
heating of the capillary flow passage 312 can be terminated and liquid
fuel can be supplied through the capillary flow passage 212. Injector 300
can advantageously be cleaned through the use of the oxidation
technique described above.
[0048] Referring now to FIG. 5, a dual fuel injector 400, in
accordance with the present invention, is shown. FIG. 5 illustrates the
dual function fuel injector 400, which may comprise a conventional type
fuel injector 460 and a heated capillary injector 410. In this embodiment,
a heated capillary flow passage 412 is integrated into the fuel injector
400. After about 20 seconds from starting the engine, or preferably less,
the capillary injector 410 can be deactivated via a solenoid activated
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plunger 436 and the conventional injector 460 activated via another
solenoid-activated plunger 470 for continued operation of the engine.
[0049] Another exemplary embodiment of the present invention is
shown in FIG. 6. As shown, a fuel injector 500 may be fitted with a
heated capillary flow passage 512 and a liquid fuel injector nozzle 560.
Fuel flow can be selectively directed to the heated capillary flow passage
512 to provide vaporized fuel or the nozzle 560 to provide liquid fuel
through the use of valving arrangement 540, as shown in Fig. 6. After
approximately 20 seconds from the start of the engine, or preferably less,
fuel flow can be switched from the capillary flow passage 512 to the liquid
flow nozzle 560 by the valving arrangement 540 for normal operation of
the engine. The valving arrangement 540 can be operated by a
controller, forming part of an electronic engine control system.
[0050] Referring now to FIG. 7, yet another exemplary embodiment
of the present invention is shown. A fuel injector 600 has a helical
heated capillary flow passage 612 is wrapped around within the interior
of the fuel injector 600 as illustrated in FIG. 7. In this embodiment, the
capillary flow passage 612 is coiled around the solenoid assembly 628
and is heated along heated length 620, defined by electrical connections
622 and 624. This embodiment is useful in a situation where space is
limited and a linear capillary tube is not feasible. In addition, this
embodiment could b e adapted for u se with a conventional fuel i njector
(see FIG. 8) for delivering fuel to an engine during normal operating
conditions.
[0051] Referring now to FIG. 8, an engine intake port 700 is fitted
with a heated capillary injector 10 (of the type described with reference to
FIG. 1) and a conventional liquid fuel injector 750. In this embodiment,
fuel will be delivered to the engine by the capillary flow passage 12,
heated along its length 20, during the cold-start and warm-up of the
engine. After the first approximately 20 seconds from starting the engine,
or preferably less, the heated capillary injector 10 will be deactivated and
the conventional fuel i njector 7 50 a ctivated for n ormal operation of the
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engine.
[0052] As will be appreciated, the apparatus and system for
preparing and delivering fuel depicted in FIGS. I through 4 and 7 may
also be used in connection with another embodiment of the present
invention. Referring again to FIG. 1 , the means for cleaning deposits
includes fluid control valve 28, a solvent control valve 26 for placing
capillary flow passage 12 in fluid communication with a solvent, solvent
control valve 26 disposed at one end of capillary flow passage 12. In one
embodiment of the apparatus employing solvent cleaning, the solvent
control valve 26 (the oxidizer control valve in the preferred form
employing the oxidation cleaning technique, described above) is
operable to alternate between the introduction of liquid fuel and the
introduction of solvent into capillary flow passage 12, enabling the in-situ
cleaning of capillary flow passage 12 when the solvent is introduced into
capillary flow passage 12. While a wide variety of solvents have utility,
the solvent may comprise liquid fuel from the liquid fuel source. When
this is the case, no solvent control valve is required, as there is no need
to alternate between fuel and solvent, and the heat source should be
deactivated during the cleaning of capillary flow passage 12.
[0053] Another embodiment of the present invention is shown in
partial cross-section in FIG. 9. A fuel injector 800 having a heated
capillary flow passage tube 812 for delivering fuel to an internal
combustion engine is shown in FIG. 9. Details of the tube for delivering
fuel to an internal combustion engine are illustrated in FIG. 9A. As
shown, an axially moveable rod 850 is positioned inside of capillary flow
passage 812. The distal end 816 of capillary flow passage 812 is flared
and the distal end 852 of axially moveable rod 850 is tapered to form a
valve 854 wherein axial movement of the rod 850 opens and closes the
valve 854. As may be appreciated, the repeated movement of axially
moveable rod 850 is effective for abrading deposits formed during
operation of the fuel injector of the present invention.
[0054] Referring now to FIG. 10, yet another embodiment of the
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present i nvention i s s hown i n p artial c ross-section. A fuel i njector 9
00
having a heated capillary flow passage tube 912 for delivering fuel to an
internal combustion engine is shown in FIG. 10. Details of the tube for
delivering fuel to an internal combustion engine are illustrated in FIG.
10A. As shown, an axially moveable rod 950 is positioned inside of
capillary flow passage 912. The distal end 916 of capillary flow passage
912 is flared and the distal end 952 of axially moveable rod 950 is
tapered to form a valve 954 wherein axial movement of the rod 950
opens and closes the valve 954. Also arranged inside the capillary flow
passage 912 are a plurality of brushes 960 arranged along axial
moveable rod 950 for cleaning the capillary flow passage 912. As may
be appreciated, the repeated movement of axially moveable rod 950 is
effective for abrading deposits formed during operation of the fuel injector
of the present invention.
[0055] Referring now to F IG. 11, a nother exemplary embodiment
of the present invention is shown in partial cross-section. A fuel injector
1000 has multiple capillaries 1012 arranged in parallel for delivering fuel
to an internal combustion engine. In this embodiment, fuel will be
delivered to the engine by one or more of the capillary flow passages
1012, heated along their length 1020, during specific periods of engine
operation (e.g., cold-start, warm-up and acceleration conditions). As less
vaporized fuel is required for reduction of unburned hydrocarbons, heat
to one or more capillaries in this configuration can be deactivated.
[0056] FIG. 12 shows, in simplified form, how a fuel injector 10,
having a capillary flow passage 12 can be arranged so that liquid fuel
traveling therethrough can be heated to an elevated temperature through
the use of recirculated exhaust gas (EGR) to reduce power requirements
of the fuel-vaporizing resistance heater 20. As shown, capillary flow
passage 12 passes through EGR passage 1100 for heating. For initial
engine start-up, resistance heater 20 comprising a section of the capillary
flow passage 12 or a separate resistance heater is connected to a power
source such as a battery, to initially vaporize the liquid fuel F. After about
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20 seconds of operation the capillary flow passage 12 can be heated by
the heat of EGR to reduce the power otherwise needed for continued
vaporization of the fuel by the resistance heater 20. Thus, the fuel in the
capillary flow passage 12 can be vaporized without using the resistance
heater 20 so that power can be conserved.
[0057] FIG. 13 shows an exemplary schematic of a control system
2000 used to operate an internal combustion engine 2110 incorporating
a liquid fuel supply valve 2220 in fluid communication with a liquid fuel
supply 2010 and a liquid fuel injection path 2260, a vaporized fuel
supply valve 2210 in fluid communication with a liquid fuel supply 2010
and capillary flow passages 2080, and an oxidizing gas supply valve
2020 in fluid communication with an oxidizing gas supply 2070 and
capillary flow passages 2080. The control system includes a controller
2050, which typically receives a plurality of input signals from a variety
of engine sensors such as engine speed sensor 2060, intake manifold
air thermocouple 2062, coolant temperature sensor 2064, exhaust air-
fuel ratio sensor 2150, fuel supply pressure 2012, etc. In operation, the
controller 2050 executes a control algorithm based on one or more input
signals and subsequently generates an output signal 2024 to the
oxidizer supply valve 2020 for cleaning clogged capillary passages in
accordance with the invention, an output signal 2014 to the liquid fuel
supply valve 2220, an output signal 2034 to the vaporized fuel supply
valve 2210, and a heating power command 2044 to a power supply
which delivers heat to the capillaries 2080.
[0058] In operation, the system according to the invention can be
configured to feed back heat produced during combustion through the
use of exhaust gas recycle heating such that the I iquid fuel i s heated
sufficiently to substantially vaporize the liquid fuel as it passes through
the capillary flow passages 2080 reducing - or eliminating or
supplementing the need to electrically or otherwise heat the capillary
flow passages 2080.
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Examples
Example 1
[0059] Tests were performed wherein JP 8 jet fuel was vaporized by
supplying the fuel to a heated capillary flow passage at constant pressure
with a micro-diaphragm pump system. In these tests, capillary tubes of
different diameters and lengths were used. The tubes were constructed of
304 stainless steel having lengths of 2.5 to 7.6 cm (1 to 3 in) and internal
diameters (ID) and outer diameters (OD), in cm (in), as follows: 0.025
ID/0.046 OD (0.010 ID/0.018 OD), 0.033 ID/0.083 OD (0.013 ID/ 0.033
OD), and 0.043 ID/0.064 OD (0.017 ID/0.025 OD). Heat for vaporizing the
liquid fuel was generated by passing electrical current through a portion of
the metal tube. The droplet size distribution was measured using a Spray-
Tech laser diffraction system manufactured by Malvern. Droplets having a
Sauter Mean Diameter (SMD) of between 1.7 and 4.0 pm were produced.
SMD is the diameter of a droplet whose surface-to-volume ratio is equal to
that of the entire spray and relates to the spray's mass transfer
characteristics.
Example 2
[0060] Tests were performed again using gasoline that was
vaporized by supplying the fuel to a heated capillary flow passage at
constant pressure with a micro-diaphragm pump system. In these tests,
capillary flow passages of different diameters and lengths were used.
The following table shows empirical findings for various capillary tube
configurations.
[0061]
Internal Heated Fuel Results
Diameter Length Pressure
cm (in) cm (in) kg/cm2 (psig)
0.069 (0.027) 17.2 (6.75) 5.3 (75) Generated fully vaporized flow and flow
rate
of 180 mg/s.
0.074 (0.029) 18.4(7.25) 4.6 (65) Generated high flow rates with a heating
voltage of 20v.
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0.051 (0.020) 15.2 (6.0) 4.9 (70) Generated at least 200 mg/s flow rate with
substantially adequate vapor characteristics.
Example 3
[0062] In tests using a Ford 4.6 liter V8 engine, one bank of four
cylinders was modified to include fuel delivery devices of the invention as
shown in FIG. 1. The capillary heating elements were mounted with the
tip of the capillary positioned flush with the intake port wall, this being
the
location of the stock fuel injection nozzle. The tests were carried out with
continuous injection (100% duty cycle) and, therefore, fuel pressure was
used to regulate the fuel vapor flow rate.
[0063] Referring to FIG. 14, a graph illustrating results of the
capillary fuel delivery device during the first 20 seconds of cold start of an
engine is presented. Plot line I represents the engine speed, in
revolutions per minute, as time progresses along the x-axis. Plot line 2
represents the fuel flow, in grams per second, as time progresses along
the x-axis. Plot line 3 represents lambda as time progresses along the x-
axis, wherein a lambda of unity represents the stoichiometric ratio of air to
fuel. Plot line 4 represents the total hydrocarbon emissions output, in
methane equivalent parts per million, from the exhaust of the engine as
time progresses along the x-axis.
[0064] As illustrated by plot line 3 in FIG. 14, the initial over-fueling
required for the stock engine hardware and control strategy was eliminated
through the use of the fuel delivery device of the invention. That is, the
fuel delivery device of the invention efficiently vaporized liquid fuel during
the initial start-up period such that the engine was started with a near-
stoichiometric fuel/air ratio. FIG. 15 is a graph, which illustrates the
emission reduction resulting from the near-stoichiometric start achieved
with the fuel delivery device of the invention (plot line 6), compared to the
conventional o ver-fueling s tart-up strategy (plot I ine 5). S pecifically,
the
results in FIG. 15 demonstrate that the fuel delivery device of the invention
reduced integrated hydrocarbon emissions by 46% during the first ten
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seconds of cold-start as compared to the stock configuration, which
requires over-fueling. The area indicated by circle 7 illustrates the
dramatic reduction of hydrocarbon emissions during the first four seconds
of starting the engine.
Example 4
[0065] Tests were conducted to demonstrate the benefits of the
oxidation cleaning technique on a heated capillary flow passage using
an unadditized, sulfur-free base gasoline known to produce high levels
of deposit formation. The capillary flow passage employed for these
tests was a 5.1 cm (2 in) long heated capillary tube constructed of
stainless steel, having an inner diameter of 0.058 cm (0.023 in). Fuel
pressure was maintained at 0.7 kg/cm2 (10 psig). Power was supplied
to the capillary to achieve various levels of R/Ro; where R is the heated
capillary resistance and Ro is the capillary resistance under ambient
conditions.
[0066] FIG. 16 presents a graph of fuel flow rate vs. time. As
shown, for this gasoline containing no detergent additive, significant
clogging was experienced in a very short period of time, with a 50% loss
in flow rate observed in as little as 10 minutes.
[0067] After substantial clogging was experienced, fuel flow was
discontinued and air at 0.7 kg/cm2 (10 psig) substituted. Heating was
provided during this period and, in as little as one minute later,
significant cleaning was achieved, with flow rates returning to prior
levels.
Example 5
[0068] This example demonstrates that clogging is far less severe
in the heated capillary flow passage of Example 4, when a commercial-
grade gasoline employing an effective additive package is employed.
As shown in FIG. 17, less than a 10% reduction in fuel flow rate was
experienced after running the device for nearly four hours.
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Example 6
[0069] To compare various g asolines a nd the i mpact o f d etergent
additives on clogging, five test fuels were run in the heated capillary flow
passage of Example 4. The fuels tested included an unadditized base
gasoline containing 300 ppm sulfur, an unadditized base gasoline
containing no sulfur, the sulfur-free base gasoline with a commercially
available after-market additive (additive A) added and the sulfur-free base
gasoline with another commercially available after-market additive
(additive B) added.
[0070] As shown in FIG. 18, the additized fuels performed
similarly, while unadditized fuels experienced severe clogging in less
than one hour of operation.
Example 7
[0071] This example compares the operation over time of a
capillary flow passage operating on an unadditized jet fuel (JP-8) to the
same capillary flow passage operating on an unadditized No. 2 diesel
fuel operated in a capillary flow passage having an I.D. of 0.036 cm
(0.014 in) and a 5.1 cm (2 in) length. Fuel pressure was set to 1.1
kg/cm2 (15 psig). Power was supplied to the capillary to achieve a level
of R/Roof 1.19; where R is the heated capillary resistance and R0 is the
capillary resistance under ambient conditions.
[0072] As shown in FIG. 19, the fuels performed similarly over the
first ten minutes of operation, with the diesel fuel suffering more severe
clogging thereafter.
Example 8
[0073] Tests were conducted to assess the efficacy of the
oxidation cleaning technique on a heated capillary flow passage using
an unadditized, No. 2 diesel fuel known to produce high levels of
deposit formation. The capillary flow passage employed for these tests
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was a 5.1 cm (2 in) long heated capillary tube constructed of stainless
steel, having an inner diameter of 0.036 cm (0.014 in). Fuel pressure
was maintained at 1.1 kg/cm2 (15 psig). Power was supplied to the
capillary to achieve a level of R/Ro of 1.19; where R, once again, is the
heated capillary resistance and, R0 is the capillary resistance under
ambient conditions.
[0074] FIG. 20 presents a graph of fuel flow rate vs. time. As
shown, for this fuel containing no detergent additive, significant clogging
was experienced in a very short period of time, with a 50% loss in flow
rate observed in about 35 minutes of continuous operation.
[0075] In a second run, after five minutes of operation, fuel flow
was discontinued and air at 0.7 kg/cm2 (10 psig) substituted for a period
of five minutes. Heating was also provided during this period. This
procedure was repeated every five minutes. As shown in FIG. 20, the
oxidation cleaning process increased fuel flow rate in virtually every
instance and tended to slow the overall decline in fuel flow rate over
time. However, the efficacy of the process was somewhat less than
was achieved using an unadditized gasoline, as described in Example
4.
Example 9
[0076] Tests were conducted to assess the effect of a commercial
grade anti-fouling detergent additive blended with the No. 2 diesel fuel
of Example 8 on fuel flow rate over time in a heated capillary flow
passage. The capillary flow passage employed for these tests, once
again, was a 5.1 cm (2 in) long heated capillary tube constructed of
stainless steel, having an inner diameter of 0.036 cm (0.014 in). Fuel
pressure was maintained at 1.1 kg/cm2 (15 psig) and power was
supplied to the capillary to achieve a level of R/R0 of 1.19.
[0077] FIG. 21 presents a comparison of fuel flow rate vs. time for
the additized No. 2 diesel fuel and an unadditized diesel fuel. As
shown, for the fuel containing no detergent additive, significant clogging
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31
was experienced in a very short period of time, with a 50% loss in flow
rate observed in about 35 minutes of continuous operation, while the
same base fuel containing the detergent showed far less clogging over
an extended period of time.
[0078] While the subject invention has been illustrated and
described in detail in the drawings and foregoing description, the
disclosed embodiments are illustrative and not restrictive in character.
All changes and modifications that come within the scope of the invention
are desired to be protected. As an example, a plurality of capillary
passages can be provided, with the fuel being passed through the
passages in parallel when a higher volume flow rate is desired.
