Dual fuel system and operating strategy metering fuel via varied fuel pump output

Patent metadata

Field	Value
Publication number	US-12486809-B2
Application number	US-202418627492-A
Country	US
Kind code	B2
Filing date	Apr 5, 2024
Priority date	Apr 5, 2024
Publication date	Dec 2, 2025
Grant date	Dec 2, 2025

Abstract

A dual fuel system includes a first fuel supply of a first fuel, a second fuel supply of a second fuel, and a variable-output fuel pump. A fuel injector in the dual fuel system includes a combined-fuel outlet passage, a nozzle check movable to open and close the combined-fuel outlet passage to nozzle outlets, and a check valve positioned at least partially in a first fuel passage connected to the first fuel supply by way of the variable-output fuel pump. The first fuel may include a compression-ignition fuel and the second fuel may include an alcohol fuel. Varying output of the fuel pump during an off-cycle of a cam actuating a plunger in the fuel injector meters the first fuel to the fuel injector for forming a fuel charge for injection. Related apparatus and methodology is also disclosed.

First claim

What is claimed is:

1 . A dual fuel system comprising:
a first fuel supply of a first fuel; a second fuel supply of a second fuel; a fuel injector including a nozzle having formed therein a plurality of nozzle outlets, a first fuel passage extending from a first fuel inlet for the first fuel, and a second fuel passage extending from a second fuel inlet for the second fuel; and the fuel injector further having formed therein a combined-fuel outlet passage, and including a nozzle check movable to open and close the combined-fuel outlet passage to the plurality of nozzle outlets, and a check valve positioned at least partially in the first fuel passage and movable between a first position permitting fuel flow to the combined-fuel outlet passage, and a second position preventing fuel backflow from the combined-fuel outlet passage.

2 . The dual fuel system of claim 1 further comprising a variable-output fuel pump fluidly connected to the first fuel inlet.

3 . The dual fuel system of claim 2 wherein the fuel injector further includes an injector case supported in the engine housing, and a stack within the injector case, and wherein a low pressure space is defined between the stack and the injector case and is fluidly connected to the variable-output fuel pump by way of the first fuel inlet.

4 . The dual fuel system of claim 1 wherein the check valve is located fluidly between the combined-fuel outlet passage and the first fuel inlet.

5 . The dual fuel system of claim 4 wherein the check valve includes a check plate.

6 . The dual fuel system of claim 1 wherein the fuel injector further includes a plunger movable in a plunger cavity fluidly connected to the second fuel passage, and a spill valve positioned fluidly between the plunger cavity and the second fuel inlet.

7 . The dual fuel system of claim 1 wherein the first fuel passage extends through the nozzle check.

8 . The dual fuel system of claim 7 wherein the first fuel passage extends between a fuel feed opening formed in the nozzle check and a plurality of transfer passages formed in the nozzle check and opening to the combined-fuel outlet passage.

9 . The dual fuel system of claim 8 wherein a fuel cavity extends circumferentially around the nozzle check and fluidly connects between the second fuel passage and the combined-fuel outlet passage, and the plurality of transfer passages open to the combined-fuel outlet passage at a location that is fluidly between the fuel cavity and the plurality of nozzle outlets.

10 . A method of operating an engine system comprising:
feeding a first fuel from a fuel pump into a fuel injector; feeding a second fuel into the fuel injector; injecting a first fuel charge pressurized in the fuel injector and containing the first fuel and the second fuel into a cylinder in an engine; injecting a second fuel charge pressurized in the fuel injector and containing the first fuel and the second fuel into the cylinder in the engine; and varying an output of the fuel pump to vary an amount of the first fuel in the second fuel charge relative to an amount of the first fuel in the first fuel charge.

11 . The method of claim 10 further comprising forming the first fuel charge and forming the second fuel charge in a combined-fuel outlet passage in the fuel injector.

12 . The method of claim 11 wherein the forming the first fuel charge includes forming the first fuel charge with the first fuel leading and the second fuel trailing.

13 . The method of claim 12 wherein the first fuel includes a compression-ignition fuel and the second fuel includes an alcohol fuel.

14 . The method of claim 11 wherein the forming the first fuel charge and the forming the second fuel charge each include feeding the first fuel through a nozzle check of the fuel injector to the combined-fuel outlet passage.

15 . The method of claim 11 wherein the feeding the first fuel includes feeding the first fuel through a flow restriction orifice, and further comprising limiting backflow of the first fuel during pressurizing the first fuel charge and during pressurizing the second fuel charge via a check valve positioned fluidly between the flow restriction orifice and the combined-fuel outlet passage.

16 . The method of claim 10 wherein the feeding the first fuel into the fuel injector occurs during an off-cycle of a cam coupled to a plunger in the fuel injector.

17 . A fuel injector comprising:
an injector housing including a nozzle having formed therein a plurality of nozzle outlets, a first fuel passage extending from a first fuel inlet, and a second fuel passage extending from a second fuel inlet; a plunger movable in a plunger cavity fluidly connected to the second fuel passage; a spill valve positioned fluidly between the plunger cavity and the second fuel inlet; and the fuel injector further having formed therein a combined-fuel outlet passage, a nozzle check movable to open and close the combined-fuel outlet passage to the plurality of nozzle outlets, and a check valve separate from the nozzle check and positioned at least partially in the first fuel passage.

18 . The fuel injector of claim 17 wherein the first fuel passage extends through the nozzle check.

19 . The fuel injector of claim 18 wherein the check valve includes a check plate.

20 . The fuel injector of claim 18 wherein:
the first fuel passage extends between a fuel feed opening formed in the nozzle check and a plurality of transfer passages formed in the nozzle check and opening to the combined-fuel outlet passage; and
a fuel cavity extends circumferentially around the nozzle check and fluidly connects between the second fuel passage and the combined-fuel outlet passage; and
the plurality of transfer passages open to the combined-fuel outlet passage at a location that is fluidly between the fuel cavity and the plurality of nozzle outlets.

Assignees

• Caterpillar Inc

Inventors

• Kim Hoisan

Classifications

• F02D19/08

  simultaneously using pluralities of fuels (F02D19/12 takes precedence) · CPC title

• F02D19/0689

  for in-cylinder direct injection · CPC title

• F02D19/0684

  High pressure fuel injection systems; Details on pumps, rails or the arrangement of valves in the fuel supply and return systems · CPC title

• F02D19/0681

  Shut-off valves; Check valves; Safety valves; Pressure relief valves · CPC title

• F02D19/0649

  Liquid fuels having different boiling temperatures, volatilities, densities, viscosities, cetane or octane numbers · CPC title