Fuel Injection System for Engine

1. Field of the Invention

This invention relates to a fuel injection system for an engine.

2. Description of the Prior Art

Recently electronic-control fuel injection systems have been in wide use in various vehicle engines. In such electronic-control fuel injection systems, so-called top-feed type fuel injection valves have been commonly used.

The top-feed type fuel injection valve is a solenoid-operated fuel injection valve and has a tubular valve body. In the top-feed type fuel injection valve, fuel is fed to the valve body through a feed port formed near the top end thereof and injected through an injection port formed on the bottom of the valve body. The top-feed type fuel injection valve having such a structure is advantageous in that since the fuel simply flows in the tubular body in the axial direction thereof, the injection valve may be simple in structure.

On the other hand, the top-feed type fuel injection valve is disadvantageous in the following point. That is, in the top-feed type fuel injection valve, the fuel return passage is provided upstream of the feed port, and accordingly, a certain amount of fuel dwells in the valve body. When the fuel dwelling in the valve body is evaporated by heat transmitted from the engine body or by radiation heat therefrom, vapor lock can occur.

Further, in some recent engines, the intake passage is long in order to increase the engine output by kinetic effect of intake air, and at the same time, a surge tank is disposed above the intake manifold and a cover is provided over the surge tank in order to compactly arrange the engine. In such engines, the fuel injection valves are more apt to be heated and the aforesaid problem is more serious.

In order to solve the problem, there has been proposed a bottom-feed type fuel injection valve as disclosed, for instance, in Japanese Unexamined Utility Model Publication Nos. 62(1987)-29469 and 62(1987)-193177. In the bottom-feed type fuel injection valve, fuel is fed to the valve through a feed port formed in a lower portion of the valve body and the residual fuel is returned to the fuel piping (generally the fuel feed piping for the next cylinder) through a fuel discharge port formed in the valve body at the substantially same level as the fuel feed port. Generally the bottom-feed type fuel injection valve comprises an outer casing, and an injector main body (formed of a solenoid coil and an on-off valve) which is housed in the outer casing, and the feed port and the fuel discharge port are formed in the lower portion of the outer casing. The solenoid coil is connected to a connector which is provided in a wire harness one for each cylinder.

However, various difficulties are encountered in actually incorporating the bottom-feed type fuel injection valves in the intake system of the engine and connecting them to the fuel piping and the power supply harness members. That is, unlike the top-feed type fuel injection valve, in the case of the bottom-feed type fuel injection valve, both the fuel feed port and the fuel discharge port are disposed in the lower portion of the outer casing and accordingly, the structure around the lower portion of the outer casing becomes complicated, thereby making it very difficult to provide means for fastening the valve and deteriorating the workability in incorporating the valves into the intake system.

In view of the foregoing observations and description, the primary object of the present invention is to provide a fuel injection system which is provided with a bottom-feed type fuel injection valve and which facilitates incorporation of the valve into the intake system.

In accordance with the present invention, there is provided a fuel injection system for an engine comprising a plurality of bottom-feed type fuel injection valve assemblies each having an outer casing and an injector main body which is accommodated in the outer casing and is electrically operated, the outer casing being provided with a fuel inlet and a fuel outlet in communication with each other, a fuel supply pipe which is connected to the fuel inlet of the upstreammost fuel injection valve assembly, a fuel return pipe which is connected to the fuel outlet of the downstreammost fuel injection valve assembly, a plurality of connection pipes each connecting the fuel outlet of each fuel injection valve assembly to the fuel inlet of the next fuel injection valve assembly, and a harness member through which a wire harness for supplying power to the injector main body extends and which has a plurality of valve holders, each being formed integrally with the harness member and fixed to the upper portion of the outer casing by the fastener means.

With this arrangement, the harness member and the injection valve assemblies can both mechanically and electrically connected with each other by simply connecting the valve holders of the tubular harness member to the injection valve assemblies. Further, since the connection of the harness member and the injection valve assembly is at the upper portion of the injection valve assembly, the injection valve assemblies can be easily incorporated into the intake system irrespectively of the complication around the lower part of the injection valve assembly.

FIG. 1 is an exploded perspective view showing a fuel injection system in accordance with a first embodiment of the present invention,

FIG. 2 is a cross-sectional view showing the injection valve assembly,

FIG. 3 is perspective view showing the fuel injection system together with the intake manifold of the engine,

FIG. 4 is an exploded perspective view for illustrating a second embodiment of the present invention,

FIG. 5 is an exploded perspective view for illustrating a third embodiment of the present invention,

FIG. 6 is an exploded perspective view for illustrating a fourth embodiment of the present invention,

FIG. 7 is an exploded perspective view for illustrating a fifth embodiment of the present invention,

FIG. 8 is an exploded perspective view for illustrating a sixth embodiment of the present invention,

FIG. 9 is an exploded perspective view for illustrating a seventh embodiment of the present invention, and

FIG. 10 is a cross-sectional view for illustrating an eighth embodiment of the present invention.

In FIG. 3, reference numeral 1 denotes an intake manifold in which discrete intake passages 2a to 2d for respective cylinders (four in number in this particular embodiment) are formed. The intake manifold 1 is provided with a flange portion 3 at an end portion to be connected to the intake ports (not shown) for the respective cylinders.

In FIG. 3, reference numerals 4a to 4d respectively denote bottom-feed type fuel injection valves which are mounted on the intake manifold 1 with their fuel injections ends inserted into the intake ports for the respective cylinders.

As shown in FIG. 2, each fuel injection valve comprises a tubular outer casing 5 and an injector main body 6 housed in the outer casing 5. The lower end portion of the outer casing 5 is smaller in diameter than the upper end portion and is connected with the upper end portion by a tapered portion. An engaging opening 5a is formed in the lower end face of the outer casing 5. As shown in FIG. 1, a fuel feed port 5b and a fuel discharge port 5c are formed in the side wall of the upper end portion of the outer casing and are diametrically opposed to each other. An opening 5d is formed in the upper end face of the outer casing 5 and the injector main body 6 is inserted into the outer casing 5 through the opening 5d. The injector main body 6 is seated in the outer casing 5 with its lower end portion engaged with the engaging opening 5a of the outer casing. A fuel injection port 6a is formed in lower end face of the injector main body 6. An O-ring 7 seals between the opening 5a and the lower end portion of the injector main body 6 in a liquid-tight fashion. Further, the injector main body 6 is held in the outer casing 5 by a sleeve-like holder 8 which has upper and lower projections 8a and 8b which are engaged with an inner wall portion 10 of the outer casing 5.

The fuel injection port 6a is provided with a needle valve 21 which is closed and opened by a solenoid 22. The solenoid 22 is held above the needle valve 21 by way of a spacer 23. A fuel chamber 24 is formed around the spacer 23. Fuel F supplied through the fuel feed port 5b flows through the fuel chamber 24 to the fuel discharge port 5c and is sucked toward the fuel injection port 6a through a suction port 25 when the needle valve 21 is opened. The fuel F constantly flows through the fuel chamber 24. As clearly shown in FIG. 3, the fuel feed port 5b of the fuel injection valve 4a is connected to a fuel pump (not shown) by a pipe 14a, the fuel discharge port 5c of the fuel injection valve 4a is connected to the fuel feed port 5b of the fuel injection valve 4b by a pipe 14b, the fuel discharge port 5c of the fuel injection valve 4b is connected to the fuel feed port 5b of the fuel injection valve 4c by a pipe 14c, the fuel discharge port 5c of the fuel injection valve 4c is connected to the fuel feed port 5b of the fuel injection valve 4d by a pipe 14d, and the fuel discharge port 5c of the fuel injection valve 4d is connected to a fuel return pipe 92 by a pipe 14e. The fuel pressure at each fuel injection valve is regulated to a predetermined pressure by a pressure regulator 90 provided at the downstream end of the fuel passage formed by the pipes 14a to 14e. The fuel pressure is controlled on the basis of the intake vacuum introduced into the pressure regulator 90 through a vacuum introduction pipe 91.

A pair of engaging projections 12a and 12b are formed on the outer peripheral portion of the upper end portion of the outer casing 5. The side surface of each engaging projection is tapered upward and the lower surface thereof forms an engaging shoulder. The engaging projections 12a and 12b are engaged with a valve holder 9 and fix the injection valve assembly (formed of the injector main body 6 and the outer casing 5) to the valve holder 9.

Four valve holders 9 are formed integrally with a harness member 16 which is tubular and rectangular in cross-section and through which six wire harnesses 35 and 36 for controlling the injectors extend. The harness member 16 may be formed of synthetic resin and should have a sufficient stiffness. Each of the wire harnesses 35 and 36 is connected in parallel to sockets (not shown) formed in the respective valve holders 9. Further one end of each of the wire harnesses 35 and 36 is connected to one of six terminals in a connector 18 provided on the power supply side end of the harness member 16. Reference numeral 93 in FIG. 3 denotes a wire harness coupler for an engine control unit which is connected to the connector 18.

Pin plugs 37 (positive) and 38 (negative) which are mated with the socket formed in each valve holder 9 project from the top end face of the injector main body 6. A pair of clip members 11a and 11b are provided on the outer surface of the valve holder 9 and are diametrically opposed to each other. When the valve holder 9 is pushed downward against the injection valve assembly, the clip members 11a and 11b are once forced outward away from each other by the tapered side surfaces of the engaging projections 12a and 12b, and resiliently moves toward each other and are engaged with the engaging shoulders of the engaging projections 12a and 12b when they pass the tapered side surfaces. The valve holder 9 is further provided with engaging edge portions 13a and 13b which prevent the clip members 11a and 11b from moving away from each other and keep them in engagement with the engaging projections 12a and 12b, The clip members 11a and 11b and the engaging edge portions 13a and 13b are formed integrally with the valve holder 9.

That is, as can be understood from FIG. 2, the clip members 11a and 11b are formed of synthetic resin having high resiliency and flexibility, and the hook-like end portions of the clip members 11a and 11b are engaged with or released from the engaging shoulders of the engaging projections 12a and 12b by movement of the upper end portions of the clip members 11a and 11b in the directions shown by the arrows in FIG. 2. Once the clip members 11a and 11b are engaged with the projections 12a and 12b, the engaging edge portions 13a and 13b prevents the clip members 11a and 11b from moving away from each other by a distance larger than a predetermined distance.

Thus in this embodiment, the connector for supplying the control signal to the solenoid 22 of the injector main body 6 also functions as means for fixing the injector main body 6 in the outer casing 5. In other words, the valve holder 9 for fixing the injection valve assembly also functions as the connector for supplying the control signal to the solenoid 22 of the injector main body 6. Accordingly, by simply connecting the valve holders 9 of the tubular harness member 16 to the injection valve assembly, the harness member 16 and the injection valve assembly can be both mechanically and electrically connected with each other. Further, since the connection of the harness member 16 and the injection valve assembly is at the upper portion of the injection valve assembly, the injection valve assemblies can be easily incorporated into the intake system.

FIGS. 4-10 show additional embodiments of the present invention. The fuel injection system in accordance with the following embodiments mainly differs from the first embodiment in the means for connecting the valve holder 9 and the outer casing 5. FIG. 4 shows a second embodiment. In this embodiment, the valve holder 9 has a lower extension 9a which can be inserted into the opening 5d in the upper end face of the outer casing 5 and a pair of projections 41 are provided on the lower extension 9a. On the other hand, a pair of guide grooves 44 and 45 which extend in the axial direction are provided on the outer casing 5 and an annular engaging groove 43 is formed on the outer peripheral surface of the upper end portion of the outer casing 5. The lower extension 9a of the valve holder 9 is inserted into the opening 5d with the projections 41 thereon received in the guide grooves 44 and 45, and then a lock spring 40 formed with a resilient wire is fitted on the upper end portion of the outer casing 5 along the annular engaging groove 43. Thus, the lock spring 40 is engaged with the projections 41 and fixes the outer casing 5 to the valve holder 9.

In a third embodiment shown in FIG. 5, the lower extension 9a of the valve holder 9 is provided with three slits 55a, 56a and 57a and the upper end portion of the outer casing 5 is provided with three slits 55b, 56b and 57b which are aligned with the slits 55a, 56a and 57a on the lower extension 9a when the lower extension 9a is inserted into the opening 5d in the upper end face of the outer casing 5. In this embodiment, the outer casing 5 is fixed to the valve holder 9 by inserting the lower extension 9a into the opening 5d and fitting a lock member 50 on the upper end portion of the outer casing 5 so that three inward projections 51, 52 and 53 formed on the lock member 50 are engaged with the three slit pairs 55a-55b, 56a-56b and 57a-57b. In this embodiment, the outer casing 5 is more firmly fixed to the valve holder than in the second embodiment since the outer casing 5 is engaged with the valve holder 9 at three points. The lock member 50 is formed of a leaf spring member.

In a fourth embodiment of the present invention shown in FIG. 6, the valve holder 9 is rested on the upper end portion of the outer casing 5 and held thereon by a lock spring 60 which is rotatably supported on the upper end portion of the outer casing 5. The lock spring 60 is formed of a resilient wire and has opposite end portions 61 and 62 which are rotatably inserted into diametrically opposed holes formed on the side surface of the upper end portion of the outer casing 5, a parallel straight portions 63 and 64 which are seated in a pair of grooves 9b and 9c formed on the top surface of the valve holder 9, and a bight portion 65 which is fitted on the lower end portion of the outer casing 5. When the outer casing 5 is fixed to the valve holder 9, the lock spring 60 is first rotated upward as shown by the arrow and then the valve holder 9 is rested on the outer casing 5. When the lock spring 60 is rotated downward over the dead center until the bight portion 65 is snugly fitted on the lower end portion of the outer casing 5, the lock spring 60 presses the valve holder 9 against the outer casing 5 and they are fixed together. With this arrangement, the injection valve assembly can be easily mounted on the harness member 16 and can be easily demounted therefrom.

In a fifth embodiment of the present invention shown in FIG. 7, the valve holder 9 is rested on the upper end portion of the outer casing 5 and held thereon by a lock spring 70 formed by a leaf spring material. The lock spring 70 has a pair of semicircular gripping portions 71 which are fitted on the fuel pipes on opposite sides of the injection valve assembly and resiliently grip the fuel pipes so that the lock spring 70 can be rotated about the fuel pipes, and an arcuate engaging portions 72 provided with a pair of engaging pieces which are brought into engagement with a pair of engaging slits 73 and 74 formed in the harness member 16 on opposite sides of the valve holder 9.

In a sixth embodiment shown in FIG. 8, the outer casing 5 is provided with a pair of knock pins 81 and 82 and the harness member 16 is provided with a pair of guide holes 83 and 84. When the valve holder 9 is rested on the outer casing 5, the knock pins 81 and 82 are inserted into the guide holes 83 and 83, thereby guiding the valve holder 9.

In a seventh embodiment shown in FIG. 9, a skirt portion 85 guides the valve holder 9 when it is rested on the outer casing 5.

In the sixth and seventh embodiments, the pin plugs can be easily mated with the socket under the guidance of the guide means. This is advantageous since the pin plugs and the socket are behind the valve holder 9 while the injection valve assembly is incorporated into the intake system, and accordingly this further improves the workability in incorporating the fuel injection system into the intake system.

In an eighth embodiment shown in FIG. 10, the outer casing 5 is provided with a pair of protrusions 86 on opposite sides thereof. Each of the protrusions 86 has a threaded hole, and the harness member 16 has a pair of through holes on opposite sides of the valve holder 9. The injection valve assembly is fixed to the harness member 16 by a pair of bolts 87 which are screwed into the threaded holes in the protrusions 86 through the through holes in the harness member 16.