Method and system for internal combustion engine fluid flow

Systems, methods, and a kit of two diverter blocks are provided for diverting a fluid from a fluid line and directing the fluid through a sensor. Fluid flows into a first a first diverter block and into a sensor before flowing out of the sensor and into a second diverter block, then into a downstream fluid line.

FIELD OF INVENTION

This invention generally relates to the field of internal combustion engines, and in particular, systems and methods to redirect the flow of fuel in a fuel line of internal combustion engines.

BACKGROUND

Combustion engine systems are commonly used to power vehicles and other machines. In some examples, a combustion engine system comprises a fuel storage system, an internal combustion engine, a fuel injection system for introduction of fuel into the engine, a catalytic converter and an exhaust system. The fuel line of combustion engines may include one or more sensors, such as flowmeters and temperature sensors, among others. Conventional approaches to install aftermarket fuel sensors along the fuel line may require disconnecting and/or cutting the fuel lines of the original equipment manufactured (OEM) engines and installing an external fuel line that includes or pass through the sensor. For example, the external fuel line may be connected to a first end of an open OEM fuel line and a second end of the open OEM fuel line. The aftermarket sensor may be positioned intermediate the first end and second end of the open OEM fuel line. Additionally, due to ever increasingly cramped engine compartments, retrofitting and adding new or modified components to a fuel system has become increasingly challenging. Such conventional approaches may suffer from one or more of the following limitations: relatively difficult to install, low reliability (e.g., ethanol in the fuel line may damage the lines construction), leaking at the connection points, and ethanol in the fuel line may damage the fuel line such that the fuel line does not provide sufficient direct structural support to the sensor which may cause the sensor's orientation to change over time. Fuel line degradation from ethanol-based fuels may also damage further downstream fuel injection system components in modern fuel injected vehicles. Accordingly, more efficient and reliable methods and systems to redirect the flow of fuel in a fuel line of internal combustion engines through a sensor may be desirable.

DETAILED DESCRIPTION

This disclosure generally describes systems and methods of making and using a fuel diverter block. It is understood, however, that this disclosure also embraces numerous alternative features, aspects, and advantages that may be accomplished by combining any of the various features, aspects, and/or advantages described herein in any combination or sub-combination that one of ordinary skill in the art may find useful. Such combinations or sub-combinations are intended to be included within the scope of this disclosure. As such, the claims may be amended to recite any features, aspects, and advantages expressly or inherently described in, or otherwise expressly or inherently supported by, this disclosure. Further, any features, aspects, and advantages that may be present in the prior art may be affirmatively disclaimed. Accordingly, this disclosure may comprise, consist of, consist essentially or be characterized by one or more of the features, aspects, and advantages described herein. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

All numerical quantities stated herein are approximate, unless stated otherwise. Accordingly, the term “about” may be inferred when not expressly stated. The numerical quantities disclosed herein are to be understood as not being strictly limited to the exact numerical values recited. Instead, unless stated otherwise, each numerical value stated herein is intended to mean both the recited value and a functionally equivalent range surrounding that value. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical value should at least be construed in light of the number of reported significant digits and by applying ordinary rounding processes. Typical exemplary degrees of error may be within 20%, 10%, or 5% of a given value or range of values. Alternatively, the term “about” refers to values within an order of magnitude, potentially within 5-fold or 2-fold of a given value. Notwithstanding the approximations of numerical quantities stated herein, the numerical quantities described in specific examples of actual measured values are reported as precisely as possible. Any numerical values, however, inherently contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.

All numerical ranges stated herein include all sub-ranges subsumed therein. For example, a range of “1 to 10” or “1-10” is intended to include all sub-ranges between and including the recited minimum value of 1 and the recited maximum value of 10 because the disclosed numerical ranges are continuous and include every value between the minimum and maximum values. Any maximum numerical limitation recited herein is intended to include all lower numerical limitations. Any minimum numerical limitation recited herein is intended to include all higher numerical limitations.

In the following description, certain details are set forth in order to provide a better understanding of various features, aspects, and advantages the invention. However, one skilled in the art will understand that these features, aspects, and advantages may be practiced without these details. In other instances, well-known structures, methods, and/or processes associated with methods of practicing the various features, aspects, and advantages may not be shown or described in detail to avoid unnecessarily obscuring descriptions of other details of the invention.

The terminology used herein is for the purpose of describing particular examples only and is not intended to be limiting. As used herein, the singular forms “a”, “an”, and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises”, “comprising”, “including”, “having”, and “characterized by”, are inclusive and therefore specify the presence of stated features, elements, compositions, steps, integers, operations, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. Although these open-ended terms are to be understood as a non-restrictive term used to describe and claim various aspects set forth herein, in certain aspects, the term may alternatively be understood to instead be a more limiting and restrictive term, such as “consisting of” or “consisting essentially of.” Thus, for any given embodiment reciting compositions, materials, components, elements, features, integers, operations, and/or process steps, described herein also specifically includes embodiments consisting of, or consisting essentially of, such recited compositions, materials, components, elements, features, integers, operations, and/or process steps. In the case of “consisting of”, the alternative embodiment excludes any additional compositions, materials, components, elements, features, integers, operations, and/or process steps, while in the case of “consisting essentially of”, any additional compositions, materials, components, elements, features, integers, operations, and/or process steps that materially affect the basic and novel characteristics are excluded from such an embodiment, but any compositions, materials, components, elements, features, integers, operations, and/or process steps that do not materially affect the basic and novel characteristics can be included in the embodiment.

The diverter block according to the present invention may provide a more cost-effective and/or efficient system and method install an external (e.g., non-OEM) sensor in line with a fuel line. The present invention may not require the addition of any external fuel lines when it intercepts the OEM line at its original OEM connection points. This may reduce and/or eliminate a common source of failure and wear when conventional aftermarket lines are used. The diverter block according to the present invention may provide rigid structural to support the sensor and hold it in a predetermined area along the fluid flow path. The diverter block according to the present invention may be constructed from materials that are more resistant to corrosion from ethanol and/or ethanol-based fuels, such as aluminum, for example.

According to some aspects, the diverter block system may be configured to fit into the space and/or dimensions of the original and/or OEM engine system with minimal or no alternations to the original and OEM engine system, respectively. According to some aspects, the dimensions of the OEM engine system before installation of the diverter block system may be similar to the dimensions of the OEM engine system after installation of the diverter block system. According to some aspects, the dimensions of the OEM engine system before installation of the diverter block system may be substantially similar to the dimensions of the OEM engine system after installation of the diverter block system. According to some aspects, the dimensions of the OEM engine system before installation of the diverter block system may be essentially similar to the dimensions of the OEM engine system after installation of the diverter block system. According to some aspects, the dimensions of the OEM engine system before installation of the diverter block system may be completely similar to the dimensions of the OEM engine system after installation of the diverter block system. According to some aspects, the dimensions of the OEM engine system before installation of the diverter block system may be the same as the dimensions of the OEM engine system after installation of the diverter block system. As generally used herein, the phrase “similar” refers to having 20% or less by volume, “substantially similar” refers to having 10% or less by volume, “essentially similar” means less than 5% by volume and “completely similar” means less than 1% by volume.

According to some aspects, the diverter block system may be configured to fit within the OEM engine system. The diverter block system may not substantially exceed the dimensions of the OEM engine. For example, the diverter block system may not exceed the dimensions of the OEM engine by more than 20% by volume, 10% by volume, 5% by volume, or 1% by volume. According to some aspects, the diverter block system may not exceed the dimensions of the OEM engine. For example, the diverter block may be located in the same and/or substantially the same OEM fuel line position after the diverter block is installed. The engine system may be modified from its original OEM configuration such that the fluid flow is redirected after the OEM inlet by the first diverter block to contact the sensor and redirected by the second diverter block to the OEM outlet and along the original OEM flow path. The diverter block system may be configured to use the OEM engine housing.

The diverter block system100comprises at least one (e.g., two) diverter blocks (110,120), as illustrated inFIGS.1-20. A first diverter block110may comprise a first opening111, wherein a fluid enters the first diverter block110before the fluid exits the first diverter block110at a second opening112. The second diverter block120may comprise a first opening121and a second opening122, wherein the fluid enters the first opening121after the fluid exited the second opening112of the first diverter block110. After entering the first opening121of the second diverter block120, the fluid may exit the second diverter block120from the second opening122of the second diverter block120.

As illustrated inFIGS.2-4B, according to some aspects, the first opening111of the first diverter block110may be connected, directly or indirectly, to a downstream opening210of a fluid line adapter200with the upstream opening220connecting, directly or indirectly, to a downstream opening of an OEM fuel line300. The second opening122of the second diverter block120may be connected, directly or indirectly, to an upstream opening220of a fluid line adapter200with a downstream opening225connecting, directly or indirectly, to an OEM line310without use of an external line between the fluid line300and the first diverter block110or the second diverter block120.

According to some aspects, a sensor230may comprise a first opening231and a second opening232, as illustrated inFIG.2, wherein the sensor230may receive the fluid into the first opening231of the sensor230after the fluid exits the second opening112of the first diverter block110and the fluid may enter the first opening121of the second diverter block120after exiting the second opening232of the sensor230without use of an external line between the sensor230and the first diverter block110or the second diverter block120. According to some aspects, the sensor230may comprise a commercially available sensor and/or non-OEM sensor.

According to some aspects, the first diverter block110and the second diverter block120may provide structural support to the sensor230, as depicted inFIG.3. According to aspects, the first diverter block110and the second diverter block120may hold the sensor230in a predetermined location along the fluid flow path. The structural support may be provided by the first diverter block110and the second diverter block120being made of a rigid material. According to some aspects, the first diverter block110and the second diverter block120may comprise aluminum. According to some aspects, the first diverter block110and the second diverter block120may comprise 6061 aluminum. Such materials, such as aluminum and 6061 aluminum, may provide durability advantages, as ethanol may not corrode aluminum in the way it does with OEM fuel lines.

According to some aspects, fluid may be redirected in a Z-shaped pattern though the sensor230by the first diverter block110and the second diverter block120.FIG.3depicts the diverter block system100installed on the fluid line adapter200to connect the sensor230and structurally holding the sensor230in a predetermined location. Fluid flows through the fluid line adapter200upstream, into the first diverter block110through the first opening111of the first diverter block110and out the second opening112of the first diverter block110. After the fluid flows out the second opening112of the first diverter block110, it flows through the sensor230and into the first opening121of the second diverter block120. After flowing into the first opening121of the second diverter block120, the fluid flows out of the second opening222of the second diverter block and into the downstream fuel line adapter opening220of the fluid line200. In other words, the engine, first diverter block, sensor, and second diverter block are in fluid communication. The flow path of the fuel may comprise an engine outlet, the first diverter block, sensor, second diverter block, and an engine inlet.

According to some aspects, the fluid lines300and310may comprise OEM fuel lines of a combustion engine. According to some aspects, the fluid is a fuel.

A method of redirecting a flow of a fluid may comprise providing a first diverter block110having a first111and a second112opening and providing a second diverter block120having a first121and second opening122, wherein the fluid enters the first diverter block110through the first opening111of the first diverter block110and exits through the second opening112of the first diverter block110, and wherein the fluid enters the first opening121of the second diverter block120after the fluid exits the second opening112of the first diverter block110and exits the second diverter block120through the second opening122of the second diverter block120.

According to some aspects, the first opening111of the first diverter block110may be directly connected to a downstream opening210of a fluid line adapter200and the upstream opening220of a fluid line adapter200directly connected to a downstream opening of an OEM fuel line300. The second opening122of the second diverter block120may be directly connected to an upstream opening220of a fluid line adapter200and a downstream opening225of a fluid line adapter200directly connected to an OEM line310without use of an external line between the fluid line300and the first diverter block110or the second diverter block120.

According to some aspects, a sensor230may comprise a first opening231and a second opening232. The sensor230may be configured to receive the fluid after into the first opening231of the sensor230after the fluid exits the second opening112of the first diverter block110and the fluid enters the first opening121of the second diverter block120after exiting the second opening232of the sensor230.

The first diverter block110and the second diverter block120may redirect the fluid in a Z-shaped pattern through the sensor and in some aspects, provide structural support to the sensor230and hold the sensor230in a predetermined location. The first diverter block and the second diverter block may comprise aluminum, such as 6061 aluminum, for example.

According to some aspects, the first diverter block110and the second diverter block120may be installed in a combustion engine for a vehicle and the fluid line200may comprise an OEM fuel line. The vehicle may comprise an automobile (car, truck, SUV), motorcycle, boat, or aircraft.

According to some aspects, an adapter kit for redirecting a flow of a fluid through a sensor230may comprise two diverter blocks (110,120), as illustrated inFIG.1. A first diverter block110may comprise a first opening111, wherein a fluid enters the first diverter block110before the fluid exits the first diverter block110at a second opening112. The second diverter block120may comprise a first opening121and a second opening122, wherein the fluid enters the first opening121after the fluid exited the second opening112of the first diverter block110. After entering the first opening121of the second diverter block120, the fluid may exit the second diverter block120from the second opening122of the second diverter block120.

As depicted inFIG.2, according to some aspects, the first opening111of the first diverter block110may be connected, directly or indirectly, to an upstream opening210of a fluid line200and the second opening122of the second diverter block120may be connected, directly or indirectly, to a downstream opening220of the fluid line200without the use of an external line between the fluid line200and the first diverter block110or the second diverter block120.

According to some aspects, the sensor230may comprise an adapter kit having a first opening231and a second opening232, as depicted inFIG.2, wherein the sensor230receives the fluid (i.e., is in fluid communication) into the first opening231of the sensor230after the fluid exits the second opening112of the first diverter block110and the fluid enters the first opening121of the second diverter block120after exiting the second opening232of the sensor230without the use of an external line between the sensor230and the first diverter block110or the second diverter block120. According to some aspects, the sensor230may comprise a commercially available sensor.

According to some aspects, the first diverter block110and the second diverter block120may provide structural support to the sensor230and hold the sensor230in a predetermined location. According to some aspects, the first diverter block110and the second diverter block120may comprise aluminum, such as 6061 aluminum, for example.

All documents cited herein are incorporated herein by reference, but only to the extent that the incorporated material does not conflict with existing definitions, statements, or other documents set forth herein. To the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern. The citation of any document is not to be construed as an admission that it is prior art with respect to this application.

While particular embodiments have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications may be made without departing from the spirit and scope of the invention. Those skilled in the art will recognize or be able to ascertain using no more than routine experimentation, numerous equivalents to the specific apparatuses and methods described herein, including alternatives, variants, additions, deletions, modifications and substitutions. This application including the appended claims is therefore intended to cover all such changes and modifications that are within the scope of this application.