WO2015008638A1 - Injector and manufacturing method thereof - Google Patents
Injector and manufacturing method thereof Download PDFInfo
- Publication number
- WO2015008638A1 WO2015008638A1 PCT/JP2014/067914 JP2014067914W WO2015008638A1 WO 2015008638 A1 WO2015008638 A1 WO 2015008638A1 JP 2014067914 W JP2014067914 W JP 2014067914W WO 2015008638 A1 WO2015008638 A1 WO 2015008638A1
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- WIPO (PCT)
- Prior art keywords
- injector
- nozzle plate
- fuel
- manufacturing
- electroforming
- Prior art date
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Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M61/00—Fuel-injectors not provided for in groups F02M39/00 - F02M57/00 or F02M67/00
- F02M61/16—Details not provided for in, or of interest apart from, the apparatus of groups F02M61/02 - F02M61/14
- F02M61/168—Assembling; Disassembling; Manufacturing; Adjusting
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D1/00—Electroforming
- C25D1/08—Perforated or foraminous objects, e.g. sieves
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M61/00—Fuel-injectors not provided for in groups F02M39/00 - F02M57/00 or F02M67/00
- F02M61/16—Details not provided for in, or of interest apart from, the apparatus of groups F02M61/02 - F02M61/14
- F02M61/162—Means to impart a whirling motion to fuel upstream or near discharging orifices
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M61/00—Fuel-injectors not provided for in groups F02M39/00 - F02M57/00 or F02M67/00
- F02M61/16—Details not provided for in, or of interest apart from, the apparatus of groups F02M61/02 - F02M61/14
- F02M61/18—Injection nozzles, e.g. having valve seats; Details of valve member seated ends, not otherwise provided for
- F02M61/1853—Orifice plates
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M61/00—Fuel-injectors not provided for in groups F02M39/00 - F02M57/00 or F02M67/00
- F02M61/16—Details not provided for in, or of interest apart from, the apparatus of groups F02M61/02 - F02M61/14
- F02M61/18—Injection nozzles, e.g. having valve seats; Details of valve member seated ends, not otherwise provided for
- F02M61/1853—Orifice plates
- F02M61/186—Multi-layered orifice plates
Definitions
- the present invention relates to an injector and a manufacturing method thereof, and more particularly to a structure of a nozzle plate of the injector and a manufacturing method thereof.
- Patent Document 1 Japanese Patent No. 4646256.
- a fuel injection valve according to the present invention is characterized in that a disk with a hole having a large number of injection openings is arranged downstream of a valve seat body having a stationary valve seat.
- An inflow opening provided with an annular inflow hollow chamber is provided immediately downstream of the injection opening so that the valve seat body covers the inflow hollow chamber and the injection opening on the downstream side of the holed disk.
- the injection openings each have one inflow region whose diameter D1 is significantly larger than the diameter D2 of the region immediately downstream and with a sharp edge that follows the inflow region.
- the region forms the narrowest cross section of the injection opening, and the injection opening widens in a trumpet shape from the region to the diameter D3 in the flow direction.
- the injection valve is especially a mixture compression type Has been described as to have. "Suitable for use in a fuel injection apparatus for a spark ignition type internal combustion engine.
- Patent Document 2 Japanese Patent Publication No. 2010-511833.
- the present invention relates to a fuel injection valve, and this fuel injection valve has a valve seat body having an immovable valve seat surface.
- the valve seat is housed in the longitudinal opening of the valve seat support and is tightly coupled to the valve seat support, with the atomizing attachment directly on the lower end surface of the valve seat
- the atomizing attachment is provided with at least one injection opening, which is preferably enlarged in a funnel shape when viewed in the downstream direction.
- it is suitable for attachment to a fuel injection device of a fuel-air-compression type spark ignition type internal combustion engine.
- Patent Document 3 Japanese Patent Laid-Open No. 2002-98028.
- This publication provides “a nozzle for a fuel injector that can improve the atomization degree of the injected fuel without substantially increasing the cost of the fuel injector.
- the nozzle includes a plurality of flow paths and a plurality of vortex chambers.
- the swirl chamber receives the fuel from the flow path, and jets the received fuel from the nozzle hole as a swirl flow or a swirl flow, thereby finely and rapidly atomizing the fuel. Yes.
- Patent Document 2 discloses a fuel injection valve for a fuel injection device of an internal combustion engine, in which a valve longitudinal axis, a valve seat body provided with a stationary valve seat, and the valve seat of the valve seat body cooperate with each other.
- the structure of the fuel injection valve and the manufacturing method thereof are characterized in that, in the type having a valve closing body, the atomizing attachment is directly formed on the valve seat body by electroforming with a fixing strength. Has been.
- it is necessary to individually produce the atomization attachment it is necessary to improve the throughput.
- the swirl chamber has a convex shape when viewed from the side from which fuel is ejected, thereby providing a nozzle plate with good fuel cut-out.
- a reverse pattern of the lateral passage and swirl chamber is prepared on the substrate in advance by electroplating (hereinafter referred to as an “electroforming mold” in order to distinguish it from the nozzle plate manufactured by electroforming), and fuel injection
- the outer shape of the outlet and the nozzle plate is made of a disposable resist.
- a method is also provided for producing a nozzle plate by electroforming by improving the throughput by producing a plurality by batch electroforming and controlling the shape of the fuel injection port.
- the present application includes a plurality of means for solving the above-described problems.
- an injector for injecting fuel into an internal combustion engine an openable / closable valve body for injecting and stopping the fuel, and the valve body
- a valve seat that stops fuel injection in contact with the valve body, and a nozzle plate that injects fuel downstream of the valve body and the valve seat, the nozzle plate injecting fuel and a lateral passage through which fuel flows
- a swirl chamber that swirls the fuel, and the lateral passage, the spout, and the swirl chamber are formed in a convex shape when viewed from the fuel injection side.
- the structure of the nozzle plate of the injector that can be easily welded to the valve member can be provided at low cost. Problems, configurations, and effects other than those described above will be clarified by the following description of embodiments.
- Sectional drawing of the structure of the injector of this invention is shown.
- positioned at the injector of FIG. 1 is shown.
- the top view of the nozzle plate of an injector, the elements on larger scale, and a perspective view are shown.
- the manufacturing process (1) of the basic nozzle plate of an injector is shown.
- the manufacturing process (2) of the basic nozzle plate of an injector is shown.
- the pattern figure in the case of producing a nozzle plate industrially is shown.
- 4A and 4B are a sectional view and a plan view of the nozzle plate when manufactured in the manufacturing process of FIGS. 4A and 4B.
- the manufacturing process (1) which manufactures a nozzle plate with thickness is shown.
- the manufacturing process (2) which manufactures a nozzle plate with thickness is shown.
- Sectional drawing and a top view of a nozzle plate when it manufactures with the manufacturing process of FIG. 7A and FIG. 7B are shown. It is a figure explaining the shape of the horizontal direction passage and swirl chamber of the nozzle plate produced by electroforming. It is a figure explaining that the shape of a nozzle plate is controllable by changing the shape of the electroforming metal mold
- step difference in a peripheral part is shown.
- step difference in a peripheral part is shown.
- step difference in a peripheral part is shown.
- FIG. 1 is a sectional structural view of an injector according to Embodiment 1 of the present invention.
- 10 is an injector
- 100 is a valve seat support
- 101 is a coil
- 102 is a valve body
- 104 is a fuel inlet
- 105 is a valve body guide
- 106 is a jet outlet
- 107 is a side plate formed on a nozzle plate.
- the direction passage, 108 is a nozzle plate
- 113 is a conductor
- 114 is a connector.
- the injector 10 shown in FIG. 1 is a normally closed electromagnetic injector.
- a plug 114 that is supplied with electric power from a battery power source is connected to the connector 114 formed at the tip of the conductor 113, and on / off control of energization and non-energization is performed by a controller not shown.
- the valve seat 103 connected to the valve seat support 100 and the valve body 102 held by the valve body guide 115 are in close contact with each other, and fuel is not injected.
- the fuel is supplied from the fuel supply port in a state where pressure is applied by a fuel pump (not shown), and the fuel is filled from the fuel inlet 104 to the contact position between the valve body 102 and the valve seat 103.
- valve body 102 When the valve body 102 is separated from the valve seat 103 by the energization of the coil 101 and the valve body 102 supported by the valve body guide 105 being displaced upward in FIG. 1, the fuel passes through the gap between the valve seat 103 and the valve body 102. Then, it flows into the lateral passage 107 formed in the nozzle plate 108 on the downstream side thereof, and is ejected from the ejection port 106.
- FIG. 2 is a partially enlarged sectional view of the vicinity of the nozzle plate of the injector of the present invention.
- an elongated cylindrical valve body 102 is disposed in a central hole of a cylindrical valve seat support body 100, and a distal end portion of the valve body support body 100 forms a cylindrical hole.
- a valve body guide 105 that supports the valve body 102, a valve seat 103, and a nozzle plate 108 are sequentially arranged downstream.
- the valve seat 103 is a conical recess having a hole through which fuel can pass in the center.
- the valve body 102 has a sharp tip as a conical protrusion, and when the valve seat 103 and the valve body 102 overlap, there is no gap. Forming.
- the nozzle plate 108 is welded to the welded portion 112 at the tip of the valve seat support 100.
- the welding used here is desirably laser welding.
- FIG. 3A is a plan view of the nozzle plate
- FIG. 3B is a cross-sectional view taken along the line AA shown in FIG. 3A
- FIG. 3C is a perspective view.
- the nozzle plate 108 is a thin circular metal plate, and the material is a metal mainly composed of nickel, a metal mainly composed of chrome, etc., and has a diameter of about 4 to 6 mm and a thickness of 0.2. About 1 mm.
- a concave portion is formed in a cross shape on the surface of the nozzle plate 108, a lateral passage 107 of a passage through which fuel flows laterally is formed, and a circular shape having a diameter larger than the width of the cross shape is formed at each tip of the cross shape
- the swirl chamber 109 in which the fuel can swirl is disposed.
- the swirl chamber 109 swirls as necessary for effective fuel injection.
- a jet port 106 for injecting fuel is formed near the approximate center of the swirl chamber 109.
- FIG. 3B is a cross-sectional view taken along the line AA shown in FIG. 3A, and is a portion taken along a line passing through the spout 106 from the left swirl chamber 109 through the lateral passage 107 to the right swirl chamber 109.
- a sectional view is shown, and the lower side of the sectional view is a side from which fuel is ejected.
- the swirl chamber 109 is circular and has a space due to the concave shape, and fuel from the lateral passage swirls in the swirl chamber 109, and the fuel is given swirl force and is ejected from each of the ejection ports 106 to form a mist shape.
- the nozzle plate 108 has a lateral passage 107 and the swirl chamber 109 has a convex shape in the direction in which fuel is injected.
- FIG. 3C is a perspective view of the nozzle plate 108, in which a cross-shaped concave portion having a lateral passage 107 through which fuel flows and a swirl chamber 109 in which the fuel swirls formed at the tip thereof are arranged. Is shown.
- FIG. 4A and 4B are process diagrams showing a method for manufacturing the nozzle plate 108.
- FIG. 5 shows a pattern diagram when the nozzle plate 108 is arranged in a matrix on a large substrate 110 and mass-produced industrially.
- 4A and 4A show one nozzle plate 108, a plurality of nozzle plates 108 are manufactured at a time as shown in FIG.
- a pattern of the lateral passage 107 and the swirl chamber 109 is formed with a resist 202 on a substrate 201 such as a substrate made of a spring material that can facilitate the process.
- a reverse pattern is fabricated with the metal 203 using electroplating. If the oxide film is removed by dry etching or wet etching before electroplating, non-deposition of electroplating can be prevented. In particular, a substrate having a strong oxide film such as stainless steel or nickel covering the surface has a great effect of removing the oxide film.
- the metal 203 to be filled is preferably a metal that can be produced by electroplating and can be easily peeled off in the step (8) in FIG. 4B.
- a metal containing copper as a main component, a metal containing nickel as a main component, a metal containing chromium as a main component, or a reverse pattern shape or a nozzle plate 108 in step (5) of FIG. 4A is used. It is desirable to combine them according to the ease of peeling from the metal.
- a nozzle pattern resist 204 and a nozzle plate outer pattern resist 205 to be the nozzle 106 are prepared.
- the nozzle plate 108 is manufactured using an electroforming technique. Prior to electroforming, the nozzle plate 108, the metal 203, and the substrate 201 are brought into a state where they can be peeled off.
- Specific surface treatment methods for exfoliation before electroforming include coating the surface with inorganic substances such as chromate, sulfide, iodide, and oxide, coating with a hydrophilic colloid of protein, and organic systems. Or covering with material. Also, apply wax, grease, paint, and finely pulverized graphite. These surface treatments for peeling can be performed in the above-described step (3), in particular, covering with inorganic substances such as chromate, sulfide, iodide, oxide and the like.
- the metal used here needs to be a metal that can withstand the use conditions of the nozzle plate 108. Specifically, it is necessary to consider corrosion, pressure at the time of fuel injection, repetitive stress at the time of fuel injection, and ease of welding when assembling at the tip of the injector of FIG. Specifically, it is desirable to laminate a metal having nickel as a main component, a metal having chromium as a main component, or a multilayer thereof depending on the application.
- the surface is cut using a mechanical processing technique. Specifically, it is desirable to polish, grind and combine them.
- the reason is that not all of the “electroforming mold” is used and the ejection port pattern 204 is formed using a resist because it is necessary to perform machining in this process. If a uniform thickness can be realized with advanced electroplating technology, this step can be omitted if not necessary. However, even in this case, it is difficult to produce the ejection port with an “electroforming mold” from the viewpoint of peelability.
- the nozzle plate 108 is peeled from the substrate 201 and the metal 203 which is an “electroforming mold”.
- the “electroforming mold” peeled off here is the same as in step (3) of FIG. 4A and can be used repeatedly.
- the peeled surface of the peeled nozzle plate 108 is the same as the arithmetic average roughness Ra of the substrate 201, and the size thereof is extremely smooth at 1 micrometer or less although it depends on the surface treatment conditions of the substrate 201. Moreover, the generation
- FIG. 6 (a) shows a cross-sectional view of the nozzle plate manufactured according to Example 1
- FIG. 6 (b) shows a plan view thereof. Since the lateral passage 107, the jet outlet 106, and the swirl chamber 109 are convex when viewed from the side where fuel is injected, the fuel does not cling to the nozzle plate surface when fuel is injected. Good cut. Further, since the thickness of the nozzle plate 108 can be reduced except for necessary portions, welding with the valve seat support 100 and the valve seat 103 shown in FIG. 1 is facilitated.
- Example 2 Next, the structure of the nozzle plate of the injector that requires the nozzle plate thickness and the manufacturing method thereof will be described.
- 7A and 7B show a manufacturing process of the thick nozzle plate 108 and will be described in the order of the processes.
- a pattern of the lateral passage 107 and the swirl chamber 109 is formed with a resist 202 on a substrate 201 such as a substrate made of a spring material that can be easily formed.
- a reverse pattern is fabricated with the metal 203 using electroplating. If the oxide film is removed by dry etching or wet etching before electroplating, non-deposition of electroplating can be prevented.
- a substrate having a strong oxide film such as stainless steel or nickel covering the surface has a great effect of removing the oxide film.
- the metal 203 to be filled is preferably a metal that can be produced by electroplating and can be easily peeled off in the step (8) in FIG. 7B.
- a metal containing copper as a main component, a metal containing nickel as a main component, a metal containing chromium as a main component, or a reverse pattern shape or a nozzle plate 108 in step (5) of FIG. 7A is used. It is desirable to combine them according to the ease of peeling from the metal.
- a nozzle pattern resist 204 and a nozzle plate outer pattern resist 205 to be the nozzle 106 are prepared.
- the resist is made thick so as not to come into contact with the adjacent nozzle plate 111 when the plating is performed thickly using the electroforming technique in the step (5).
- the nozzle plate 108 is produced using an electroforming technique.
- the nozzle plate 108, the metal 203, and the substrate 201 are brought into a peelable state.
- Specific surface treatment methods for exfoliation before electroforming include coating the surface with inorganic substances such as chromate, sulfide, iodide, and oxide, coating with a hydrophilic colloid of protein, and organic systems. Or covering with material. Also, apply wax, grease, paint, and finely pulverized graphite. These surface treatments for peeling can be performed in the above-described step (3), in particular, coating with an inorganic substance such as chromate, sulfide, iodide, or oxide.
- the metal used here needs to be a metal that can withstand the use conditions of the nozzle plate 108. Specifically, it is necessary to consider corrosion, pressure at the time of fuel injection, repetitive stress at the time of fuel injection, and ease of welding when assembling at the tip of the injector of FIG. Specifically, it is desirable to laminate a metal having nickel as a main component, a metal having chromium as a main component, or a multilayer thereof depending on the application.
- the surface is cut using a mechanical processing technique. Specifically, it is desirable to polish, grind and combine them.
- the reason is that not all of the “electroforming mold” is used and the ejection port pattern 204 is formed using a resist because it is necessary to perform machining in this process. If a uniform thickness can be realized with advanced electroplating technology, this step can be omitted if not necessary. However, even in this case, it is difficult to produce the ejection port with an “electroforming mold” from the viewpoint of peelability.
- the nozzle plate 108 is peeled from the substrate 201 and the metal 203 which is an “electroforming mold”.
- the “electroforming mold” peeled off here is the same as that in the step (3) of FIG. 7A and can be used repeatedly.
- the peeled surface of the peeled nozzle plate 108 is the same as the arithmetic average roughness Ra of the substrate 201, and the size thereof is extremely smooth at 1 micrometer or less although it depends on the surface treatment conditions of the substrate 201. Moreover, the generation
- FIG. 8 shows a cross-sectional view and a plan view of a nozzle plate manufactured according to Example 2 and having a thickness greater than that of Example 1.
- the fuel outage is inferior to the shape of the nozzle plate shown in FIG. 6, there is an effect that it is possible to cope with high-pressure fuel injection by the thicker nozzle plate 108.
- FIG. 9A is a plan view of the nozzle plate and a partially enlarged view of the swirl chamber 109
- FIG. 9B is a cross-sectional view taken along the line AA ′ of FIG. 9A
- FIG. 9C shows the case of machining by electroforming.
- FIG. 9B shows a case where it is manufactured by machining such as a general end mill, and it is difficult to make the corner portion of the bottom portion of the concave shape close to a right angle.
- FIG. 9C when the transverse passage 107 of the nozzle plate 108 is manufactured using the electroforming technique, the corner portion at the bottom of the concave shape can be formed in a shape close to a right angle.
- the metal 202 can have various shapes ranging from a shape close to a right angle to a shape with a rounded corner.
- the “electroforming mold” By using the “electroforming mold”, the lateral passage 107 and the swirl chamber 109 of the nozzle plate 108 are used. It becomes possible to control the corner shape of the bottom of the concave shape.
- FIG. 10 (a) shows a standard electroforming mold in which a metal 203 is formed on a substrate 201, and an upper corner portion of the metal 203 is formed at a right angle.
- FIG. 10B shows an electroforming mold in which the metal 203 is formed on the substrate 201 and the upper corner portion of the metal 203 is chamfered.
- the molded product manufactured with the chamfered electroformed mold has a shape in which the corner portion at the bottom of the recess has a radius of curvature R, and the radius of curvature R can be arbitrarily set. Therefore, it is a convenient manufacturing technique.
- Example 4 Next, as Example 4, a method for producing an “electroformed mold” used for production by the production method of Example 1 or Example 2 will be described.
- FIG. 11 shows a process of manufacturing a structure that increases the bonding strength between the metal 203 for forming a reverse pattern and the substrate 201 using electroplating. The manufacturing process will be described with reference to FIG.
- the substance to be removed is an oxide film or an organic substance.
- a connection film / Cu301 is formed from the substrate side by sputtering.
- the connection film may be a metal having adhesive strength with both Cu and the substrate, and specifically, Ti and Cr are preferably used.
- the reverse pattern is filled with metal 203 using electroplating.
- the metal 203 to be filled is preferably a metal that can be produced by electroplating and can be easily peeled off in the step (8) in FIG. 4B or the step (8) in FIG. 7B.
- a metal containing copper as a main component, a metal containing nickel as a main component, a metal containing chromium as a main component, or a reverse pattern shape or a step (5) in FIG. 4A or a step in FIG. 7A It is desirable to combine them according to the electroformed metal composition described in 5).
- the resist 202 produced in (2) is peeled off.
- the nozzle plate 108 is manufactured using the process (4) of FIG. 4A or the process after the process (4) of FIG. 7A.
- Example 5 a method for producing an “electroforming mold” manufactured by the manufacturing method of Example 1 or Example 2 will be described.
- FIG. 12 shows a process of manufacturing this structure by using electroplating to increase the bonding strength between the metal 203 for forming the reverse pattern and the substrate 201. Further, the difference from the fourth embodiment is that a protective film is used rather than the connection film / Cu301.
- Plasma etching is performed on the surface of the substrate 201 such as a substrate made of a spring material capable of facilitating releasability by deforming and removing substances that hinder electroplating deposition.
- the substance to be removed is an oxide film or an organic substance.
- a protective metal film is formed by sputtering in a vacuum.
- the protective metal 302 only needs to be removed by etching in the next step (2).
- Ti, Cr, or Al is preferably used.
- the reverse pattern is filled with metal 203 using electroplating.
- the metal 203 to be filled is preferably a metal that can be produced by electroplating and can be easily peeled off in the step (8) in FIG. 4B or the step (8) in FIG. 7B.
- a metal containing copper as a main component, a metal containing nickel as a main component, a metal containing chromium as a main component, or a reverse pattern shape or a step (5) in FIG. 4A or a step in FIG. 7A It is desirable to combine them according to the electroformed metal composition described in 5).
- a nozzle plate is produced using the process (4) of FIG. 4A or the process after the process (4) of FIG. 7A.
- Example 6 Next, in the manufacturing method of the nozzle plate of Example 1 or Example 2, it is easy to peel off the nozzle plate 108 from the substrate 201 and the metal 203 in the step (7) of FIG. 4B or the step (7) of FIG. 7B. It was difficult to peel off.
- a shape having a step around the nozzle plate 108 is produced, and a nozzle plate having a configuration that can be easily peeled off by pins or the like from the substrate 201 and the metal 203 is produced.
- the manufacturing process is shown in FIGS. 13A, 13B, and 13C, and will be described along this process.
- a pattern of the lateral passage 107 and the swirl chamber 109 is formed on the substrate 201 such as a substrate made of a spring material capable of facilitating the process using the resist 202-1.
- a reverse pattern is fabricated with the metal 203 using electroplating. If the oxide film is removed by dry etching or wet etching before electroplating, non-deposition of electroplating can be prevented. In particular, a substrate having a strong oxide film such as stainless steel or nickel covering the surface has a great effect of removing the oxide film.
- the metal 203 to be filled is preferably a metal that can be produced by electroplating and can be easily peeled off in the step (8) in FIG. 4B.
- a metal containing copper as a main component a metal containing nickel as a main component, a metal containing chromium as a main component, or a reverse pattern shape or nozzle plate 108 described in step (5) of FIG. 4A. It is desirable to combine them according to the ease of peeling from the metal used.
- the ultraviolet light 402 is shielded and exposed by a photomask 401 smaller than the outermost size of the nozzle plate by 20 micrometers or more on one side. Then, the resist 205 irradiated with the ultraviolet light 402 is solidified.
- the exposure area here may be the entire peripheral part of the nozzle plate or only a part of the peripheral part.
- a resist 202-3 is pasted to a thickness that is optimal for manufacturing a nozzle plate.
- the nozzle pattern outer pattern resist 206 and the nozzle pattern resist pattern 206 are produced by shielding the ultraviolet light 402 with the photomask 401 that has the outermost size of the nozzle plate and forming the nozzle 106.
- the resist 206 is a portion solidified by irradiation with the ultraviolet light 402, and has a step of length t inside the resist 205 in the step (5).
- the resists 202-2 and 202-3 are developed.
- resists 205 and 206 having a nozzle plate outer shape pattern and an ejection port pattern resist 204 are formed.
- the nozzle plate 108 is manufactured using an electroforming technique. Prior to electroforming, the nozzle plate 108, the metal 203, and the substrate 201 are brought into a state where they can be peeled off.
- Specific surface treatment methods for exfoliation before electroforming include coating the surface with inorganic substances such as chromate, sulfide, iodide, and oxide, coating with a hydrophilic colloid of protein, and organic systems. Or covering with material. Also, apply wax, grease, paint, and finely pulverized graphite. These surface treatments for peeling can be performed in step (3), in particular, covering with inorganic substances such as chromate, sulfide, iodide, oxide and the like.
- the metal used here needs to be a metal that can withstand the use conditions of the nozzle plate 108. Specifically, it is necessary to consider corrosion, pressure at the time of fuel injection, repetitive stress at the time of fuel injection, and ease of welding when assembling at the tip of the injector of FIG. Specifically, it is desirable to laminate a metal having nickel as a main component, a metal having chromium as a main component, or a multilayer thereof depending on the application.
- the surface is shaved using a mechanical processing technique. Specifically, it is desirable to polish, grind and combine them.
- a mechanical processing technique it is desirable to polish, grind and combine them.
- not all of the “electroforming mold” is used, and the jet pattern 204 is manufactured using a resist because it is necessary to perform machining in this process. If a uniform thickness can be realized with advanced electroplating technology, this step can be omitted if not necessary. However, even in this case, it is difficult to produce the ejection port with an “electroforming mold” from the viewpoint of peelability.
- the nozzle plate 108 is peeled from the substrate 201 and the metal 203 which is an “electroforming mold”. Further, when peeling, the step 207 produced by the resists 205 and 206 in the step (7) is peeled off by pushing up with a pin or the like.
- the “electroforming mold” peeled off here is the same as in step (3) of FIG. 4A and can be used repeatedly.
- the peeled surface of the peeled nozzle plate 108 is the same as the arithmetic average roughness Ra of the substrate 201, and the size thereof is extremely smooth at 1 micrometer or less although it depends on the surface treatment conditions of the substrate 201. Moreover, the generation
- the nozzle plate 108 formed in this embodiment can be easily peeled off from the substrate 201 by inserting a wedge-shaped jig into the step formed in the peripheral portion.
- this invention is not limited to the above-mentioned Example, Various modifications are included.
- the above-described embodiments have been described in detail for easy understanding of the present invention, and are not necessarily limited to those having all the configurations described.
- a part of the configuration of one embodiment can be replaced with the configuration of another embodiment, and the configuration of another embodiment can be added to the configuration of one embodiment.
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Abstract
Description
本願は上記課題を解決する手段を複数含んでいるが、その一例を挙げるならば、内燃機関内に燃料を噴射するインジェクタにおいて、燃料の噴射と停止を行う開閉可能な弁体と、該弁体と接触して燃料の噴射の停止を行う弁座と、前記弁体と前記弁座の下流に燃料を噴射するノズルプレートとを備え、該ノズルプレートは、燃料を流す横方向通路と燃料を噴射する噴出口と燃料を旋回する旋回室とより形成され、燃料が噴射される側から見て横方向通路、噴出口、及び旋回室部を凸部形状としたことを特徴とする。 In order to solve the above problems, for example, the configuration described in the claims is adopted.
The present application includes a plurality of means for solving the above-described problems. For example, in an injector for injecting fuel into an internal combustion engine, an openable / closable valve body for injecting and stopping the fuel, and the valve body A valve seat that stops fuel injection in contact with the valve body, and a nozzle plate that injects fuel downstream of the valve body and the valve seat, the nozzle plate injecting fuel and a lateral passage through which fuel flows And a swirl chamber that swirls the fuel, and the lateral passage, the spout, and the swirl chamber are formed in a convex shape when viewed from the fuel injection side.
本発明の実施例1では、インジェクタのノズルプレートの構造及び製造方法について説明する。図1は、本発明の実施例1に係るインジェクタの断面構造図を示す。図1において、10はインジェクタ、100は弁座支持体、101はコイル、102は弁体、104は燃料流入口、105は弁体ガイド、106は噴出口、107はノズルプレートに形成された横方向通路、108はノズルプレート、113は導体、114はコネクタである。 Example 1
In the first embodiment of the present invention, a structure and a manufacturing method of a nozzle plate of an injector will be described. FIG. 1 is a sectional structural view of an injector according to
図2において、円筒形の弁座支持体100の中央の孔には、細長い円柱形の弁体102が配置され、弁体支持体100の先端部は円柱形の孔を形成し、この孔に弁体102を支持する弁体ガイド105、弁座103及びノズルプレート108を順に下流に向かって配置している。弁座103は、円錐形状の凹部で中央に燃料を通過させる孔を有し、弁体102は先端を円錐形状の凸部として尖らし、弁座103と弁体102は重なると隙間がないように形成している。弁体102が中心軸方向に可動し、弁座103と重なると隙間がなくなり塞がった状態となるので、弁座103の孔からは燃料は流れない構成となっている。また、弁座支持体100の先端は、ノズルプレート108が溶接部分112を溶接して配置されている。ここで用いる溶接は、具体的には、レーザー溶接を用いることが望ましい。 FIG. 2 is a partially enlarged sectional view of the vicinity of the nozzle plate of the injector of the present invention.
In FIG. 2, an elongated
図4A及び図4Aでは、ノズルプレート108が1つ記載しているが、製造する際には、図5に示すように複数個を一括して製造する。 Next, the manufacturing method of the
4A and 4A show one
次に、ノズルプレートの厚みが必要なインジェクタのノズルプレートの構造及びその製造方法について説明する。図7A及び図7Bは、厚みのあるノズルプレート108の製造工程を示し、工程順に沿って説明する。 (Example 2)
Next, the structure of the nozzle plate of the injector that requires the nozzle plate thickness and the manufacturing method thereof will be described. 7A and 7B show a manufacturing process of the
または、ここで用いる金属は、ノズルプレート108の使用条件に耐える金属である必要がある。具体的には、腐食、燃料噴射時の圧力、燃料噴射時の繰り返し応力また、図1のインジェクタの先端に組み付ける際の溶接の容易さを考慮する必要がある。具体的には、ニッケルを主成分とする金属、クロムを主成分とする金属、または、用途に応じてそれらを多層に積層することが望ましい。 (5) The
Alternatively, the metal used here needs to be a metal that can withstand the use conditions of the
次に、実施例1または実施例2の製造方法によって製造したノズルプレートの形状について、図9を用いて説明する。図9において、図9(a)はノズルプレートの平面図及び旋回室109の部分拡大図を示し、図9(b)は図9(a)のA-A‘断面図で、機械加工の場合を示し、図9(c)は電鋳による加工の場合を示している。図9(b)は、一般的なエンドミル等の機械加工で製造した場合を示し、凹部形状の底部のコーナ部を直角に近い形状にすることは困難である。これに対し、図9(c)は、電鋳技術を用いてノズルプレート108の横方向通路107を製造した場合、凹部形状の底部のコーナ部を直角に近い形状にすることができる。 Example 3
Next, the shape of the nozzle plate manufactured by the manufacturing method of Example 1 or Example 2 will be described with reference to FIG. 9A is a plan view of the nozzle plate and a partially enlarged view of the
次に、実施例4として、実施例1または実施例2の製造方法によって製造するために用いる「電鋳金型」の作製方法を説明する。図11は、電気めっきを用いて、逆パターンを作製する金属203と基板201の接合強度を高める構造体を製造する工程を示す。その製造工程を図11に沿って説明する。 Example 4
Next, as Example 4, a method for producing an “electroformed mold” used for production by the production method of Example 1 or Example 2 will be described. FIG. 11 shows a process of manufacturing a structure that increases the bonding strength between the
以下、図4Aの工程(4)または図7Aの工程(4)以降の工程を用いてノズルプレート108を作製する。 (4) The resist 202 produced in (2) is peeled off.
Hereinafter, the
次に、実施例5として、実施例1または実施例2の製造方法によって製造する「電鋳金型」の作製方法について説明する。図12は、電気めっきを用いて、逆パターンを作製する金属203と基板201の接合強度を高める構造体で、この構造体を作製する工程を示す。また、実施例4との違いは、接続膜/Cu301より保護膜を用いることである。 (Example 5)
Next, as Example 5, a method for producing an “electroforming mold” manufactured by the manufacturing method of Example 1 or Example 2 will be described. FIG. 12 shows a process of manufacturing this structure by using electroplating to increase the bonding strength between the
以下、図4Aの工程(4)または、図7Aの工程(4)以降の工程を用いてノズルプレートを作製する。 (5) The
Hereinafter, a nozzle plate is produced using the process (4) of FIG. 4A or the process after the process (4) of FIG. 7A.
次に、実施例1または実施例2のノズルプレートの製造方法において、図4Bの工程(7)または図7Bの工程(7)で、ノズルプレート108を基板201及び金属203より剥離する場合、容易に剥離し難いことがあった。本発明の実施例6は、ノズルプレート108の周辺に段差を有する形状を作製し、基板201及び金属203よりピン等により剥がし易い構成のノズルプレートを製造する。その製造工程を図13A、図13B及び図13Cに示し、この工程に沿って説明する。 (Example 6)
Next, in the manufacturing method of the nozzle plate of Example 1 or Example 2, it is easy to peel off the
基板201と金属203の上にはノズルプレート外形パターンのレジスト205、206と、噴出口パターンレジスト204が形成される。 (8) The resists 202-2 and 202-3 are developed.
On the
本実施例で形成したノズルプレート108は、周辺部に形成された段差に楔状冶具を差し込むことで基板201から容易に引き剥がすことが可能となる。 (12) The
The
100‥弁座支持体
101‥コイル
102‥弁体
103‥弁座
104‥燃料流入口
105‥弁体ガイド
106‥噴出口
107‥横方向通路
108‥ノズルプレート
109‥旋回室
110‥大きな基板
111‥隣接するノズルプレート
112‥溶接部分
113‥導体
114‥コネクタ
201 基板
202、202-1、202-2、202-3‥レジスト
203‥金属
204‥噴出口パターンレジスト
205‥ノズルプレート外形パターンレジスト
301‥接続膜/Cu
302‥保護金属
401‥フォトマスク
402‥紫外光 DESCRIPTION OF
302
Claims (15)
- 内燃機関内に燃料を噴射するインジェクタにおいて、
燃料の噴射と停止を行う開閉可能な弁体と、
該弁体と接触して燃料の噴射の停止を行う弁座と、
前記弁体と前記弁座の下流に燃料を噴射するノズルプレートとを備え、
該ノズルプレートは、燃料を流す横方向通路と燃料を噴射する噴出口と燃料を旋回する旋回室とより形成され、燃料が噴射される側から見て横方向通路、噴出口、及び旋回室部を凸部形状としたことを特徴とするインジェクタ。 In an injector for injecting fuel into an internal combustion engine,
A valve body that can be opened and closed to inject and stop fuel;
A valve seat in contact with the valve body to stop fuel injection;
A nozzle plate for injecting fuel downstream of the valve body and the valve seat;
The nozzle plate is formed by a lateral passage through which fuel flows, a jet outlet for injecting fuel, and a swirling chamber for swirling the fuel, and viewed from the fuel injection side, the lateral passage, the spout, and the swirling chamber section An injector characterized by having a convex shape. - 請求項1記載のインジェクタにおいて、
前記ノズルプレートに形成された前記横方向通路と前記旋回室が作製されている層と前記噴出口が作製されている層が一括掲載されていることを特徴とするインジェクタ。 The injector according to claim 1, wherein
An injector characterized in that the lateral passage formed in the nozzle plate, the layer in which the swirl chamber is formed, and the layer in which the ejection port is manufactured are listed together. - 請求項1記載のインジェクタにおいて、
前記弁体及び前記弁座と溶接する前記ノズルプレートの面の算術平均粗さRaは1マイクロメータ以下であることを特徴とするインジェクタ。 The injector according to claim 1, wherein
An injector having an arithmetic mean roughness Ra of a surface of the nozzle plate welded to the valve body and the valve seat is 1 micrometer or less. - 請求項1記載のインジェクタにおいて、
前記ノズルプレートの溶接面側の横方向通路及び前記旋回室のエッジには、バリ取り痕が無いことを特徴とするインジェクタ。 The injector according to claim 1, wherein
An injector characterized in that there is no deburring mark in a lateral passage on the welding surface side of the nozzle plate and an edge of the swirl chamber. - 請求項1記載のインジェクタにおいて、
前記ノズルプレートに形成した横方向通路と旋回室の側壁の算術平均粗さRaは500ナノメータ以下であることを特徴とするインジェクタ。 The injector according to claim 1, wherein
An injector having an arithmetic average roughness Ra of 500 nanometers or less between a lateral passage formed in the nozzle plate and a side wall of a swirl chamber. - 請求項1記載のインジェクタにおいて、
前記ノズルプレートは、前記横方向通路と前記旋回室の側壁と底面の角度が85度以上90度以下であり、かつ、側壁と底面の境界部が角形状となっていることを特徴とするインジェクタ。 The injector according to claim 1, wherein
In the injector, the nozzle plate has an angle between a side wall and a bottom surface of the lateral passage and the swirl chamber of 85 degrees or more and 90 degrees or less, and a boundary portion between the side wall and the bottom surface has an angular shape. . - 請求項1記載のインジェクタにおいて、
前記ノズルプレートは、前記横方向通路と燃料を噴射する噴出口と燃料を旋回する旋回室で形成され、該噴出口と該旋回室の相対位置が同じであることを特徴とするインジェクタ。 The injector according to claim 1, wherein
The injector is characterized in that the nozzle plate is formed by the lateral passage, a jet port for injecting fuel, and a swirl chamber for swirling fuel, and the relative positions of the jet port and the swirl chamber are the same. - 請求項1記載のインジェクタにおいて、
前記ノズルプレートは、その周辺部の少なくとも一部分に段差形状を有していることを特徴とするインジェクタ。 The injector according to claim 1, wherein
The nozzle plate has a stepped shape at least at a part of its peripheral portion. - 内燃機関内に燃料を噴射するインジェクタの製造方法において、
前記インジェクタのノズルプレートは、燃料を流す横方向通路と燃料を噴射する噴出口と燃料を旋回する旋回室とより形成され、
該横方向通路及び該旋回室の逆のパターン形状を複数回利用できる電鋳金型として作製し、
前記噴出口及び前記ノズルプレートの外形を使い捨てのレジストで作製し、
ノズルプレートを電鋳法で作製することを特徴とするインジェクタの製造方法。 In a method of manufacturing an injector for injecting fuel into an internal combustion engine,
The nozzle plate of the injector is formed by a lateral passage through which fuel flows, a jet port for injecting fuel, and a swirl chamber for swirling fuel,
Produced as an electroformed mold that can use the transverse pattern and the reverse pattern shape of the swirl chamber multiple times,
The outer shape of the jet nozzle and the nozzle plate is made of a disposable resist,
A method of manufacturing an injector, comprising producing a nozzle plate by electroforming. - 請求項9記載のインジェクタの製造方法において、
前記インジェクタのノズルプレートの噴出口の形状をレジストの形状により変更することができることを特徴とするインジェクタの製造方法。 In the method of manufacturing an injector according to claim 9,
A method of manufacturing an injector, characterized in that the shape of the nozzle outlet of the nozzle plate of the injector can be changed according to the shape of the resist. - 請求項9記載のインジェクタの製造方法において、
前記インジェクタのノズルプレートを電鋳法で製造するために用いる基板と電鋳金型の密着強度を高めるため、電鋳の前にドライエッチングまたはウェットエッチングを用いて前記基板をエッチングすることを特徴とするインジェクタの製造方法。 In the method of manufacturing an injector according to claim 9,
In order to increase the adhesion strength between a substrate used for manufacturing the nozzle plate of the injector by electroforming and an electroforming mold, the substrate is etched using dry etching or wet etching before electroforming. Injector manufacturing method. - 請求項9記載のインジェクタの製造方法において、
前記インジェクタのノズルプレートを電鋳法で製造するために用いる基板と電鋳で作製する「電鋳金型」の密着強度を高めるため、ドライエッチングで酸化膜や不純物をエッチングし、連続して保護膜を成膜し、レジスト作製、電鋳、レジスト剥離の一連の操作を行なうことを特徴とするインジェクタの製造方法。 In the method of manufacturing an injector according to claim 9,
In order to increase the adhesion strength between the substrate used for producing the nozzle plate of the injector by electroforming and the “electroforming mold” produced by electroforming, the oxide film and impurities are etched by dry etching, and the protective film is continuously formed. A method of manufacturing an injector characterized by performing a series of operations of resist preparation, electroforming, and resist stripping. - 請求項9記載のインジェクタの製造方法において、
前記インジェクタのノズルプレートを電鋳法で製造するために用いる基板と「電鋳金型」の密着強度を高めるため、ドライエッチングで酸化膜や不純物をエッチングし、連続して保護膜を成膜し、レジスト作製を行い、連続して保護膜除去、電鋳を行い、レジスト剥離の一連の操作を行なうことを特徴とするインジェクタの製造方法。 In the method of manufacturing an injector according to claim 9,
In order to increase the adhesion strength between the substrate used for producing the nozzle plate of the injector by electroforming and "electroforming mold", an oxide film and impurities are etched by dry etching, and a protective film is continuously formed. A method of manufacturing an injector, comprising: producing a resist; successively removing a protective film; performing electroforming; and performing a series of operations for removing the resist. - 請求項9記載のインジェクタの製造方法において、
前記インジェクタのノズルプレートを電鋳法で製造するために用いる基板として、バネ材を用いることを特徴とするインジェクタの製造方法。 In the method of manufacturing an injector according to claim 9,
A method of manufacturing an injector, comprising using a spring material as a substrate used for manufacturing the nozzle plate of the injector by electroforming. - 請求項9記載のインジェクタの製造方法において、
前記インジェクタのノズルプレートを電鋳法で製造するために用いる基板として、樹脂の上に金属箔が作製された基板を用いることを特徴とするインジェクタの製造方法。 In the method of manufacturing an injector according to claim 9,
A method for manufacturing an injector, wherein a substrate in which a metal foil is formed on a resin is used as a substrate used for manufacturing the nozzle plate of the injector by electroforming.
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JP5997358B2 (en) | 2016-09-28 |
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