Patent Publication Number: US-2023143650-A1

Title: Fuel system cover for an internal combustion engine

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The present application claims the benefit of the filing date of U.S. Provisional App. Ser. No. 63/263,831 filed on Nov. 10, 2021, which is incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to fuel systems for internal combustion engines, and more particularly to fuel system covers for internal combustion engines. 
     BACKGROUND 
     Fuel rails, lines, fittings, couplings, and other components are provided on internal combustion engines to provide fuel to one or more cylinders of the engine for combustion. These components may develop leaks or otherwise fail over time, which may cause the fuel to leak into the environment. This can be particularly problematic in certain environments, such as marine environments. Current solutions include providing double wall components so that redundant protection from failure of the component is provided. Other solutions include providing different configuration requirements for the fuel system components, such as an increased bend radius. 
     However, these solutions require using different components for the engine depending on whether or not the engine is to be used in an application that requires special protection from fuel leakage. In addition, special fuel leak detection equipment can impose additional costs to these systems. Therefore, further improvements in fuel leak prevention, mitigation, and detection for internal combustion engines are needed. 
     SUMMARY 
     Embodiments include an internal combustion engine with a cylinder head assembly. The cylinder head assembly extends between a rearward end and a forward end. a fuel system includes a portion extending externally along the cylinder head assembly. A fuel system cover is mounted to the cylinder head assembly. The fuel system cover encapsulates the portion of the fuel system that extends externally along the cylinder head assembly. 
     In an embodiment, a fuel system cover for a fuel system of an internal combustion engine is disclosed. The fuel system cover includes a housing defining an interior chamber configured to house at least part of a fuel system. The housing includes a first side wall forming an opening into the interior chamber. The first side wall is configured to mount to a cylinder head assembly of the internal combustion engine. The housing also includes a second side wall opposite the first side wall, a top wall and an opposite bottom wall each extending between the first and second side walls, and a front end wall and an opposite rear end wall. The first and second side walls and the top and bottom walls each extend between the front and rear end walls. 
     This summary is provided to introduce a selection of concepts that are further described below in the illustrative embodiments. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter. Further embodiments, forms, objects, features, advantages, aspects, and benefits shall become apparent from the following description and drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a schematic elevation view of an internal combustion engine and a fuel system cover of the present disclosure. 
         FIG.  2    is a schematic elevation view of the fuel system cover of  FIG.  1    looking at a side of the fuel system cover mountable to the internal combustion engine. 
         FIG.  3    is an elevation view of the internal combustion engine and fuel system cover of the present disclosure. 
         FIG.  4    is a perspective view of an embodiment of an internal combustion engine with an embodiment of the fuel system cover of  FIG.  3   . 
         FIG.  5    is a perspective view of an embodiment of a fuel leak sensor usable with the fuel system covers of the present disclosure. 
         FIG.  6    is a top elevation view of the embodiment of the fuel system cover of  FIG.  3   . 
         FIG.  7    is a back elevation view of the embodiment of the fuel system cover of  FIG.  3   . 
         FIG.  8    is a front elevation view of the embodiment of the fuel system cover of  FIG.  3   . 
     
    
    
     DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS 
     For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, any alterations and further modifications in the illustrated embodiments, and any further applications of the principles of the invention as illustrated therein as would normally occur to one skilled in the art to which the invention relates are contemplated herein. 
     Referring to  FIGS.  1 - 8   , there is shown an internal combustion engine system  100 . Internal combustion engine system  100  includes an internal combustion engine  102 ,  102 ′ including a cylinder head assembly  108 . The cylinder head assembly  108  extends between a rearward end  122  and an opposite forward end  120 . A fuel system  168  includes a portion  170  extending externally along the cylinder head assembly  108 . A fuel system cover  130 ,  130 ′ is mounted to the cylinder head assembly  108 . The fuel system cover  130 ,  130 ′ encapsulates the portion  170  of the fuel system  168  extending externally along the cylinder head assembly  108 . 
     There is further shown a fuel system cover  130 ,  130 ′ for a fuel system  168  of an internal combustion engine  102 ,  102 ′. The fuel system cover  130 ,  130 ′ includes a housing  132  defining an interior chamber  134  configured to house at least part of a fuel system  168 . The housing  132  includes a first side wall  140 ,  140 ′ forming an opening  148  into the interior chamber  134 . The first side wall  140 ,  140 ′ is configured to mount to a cylinder head assembly  108  of the internal combustion engine  102 . The housing  132  also includes a second side wall  142 ,  142 ′ opposite the first side wall  140 ,  140 . Housing  132  includes a top wall  136 ,  136 ′ and an opposite bottom wall  138 ,  138 ′ each extending between the first side wall  140 ,  140 ′ and second side wall  142 ,  142 ′, and a front end wall  144 ,  144 ′ and an opposite rear end wall  146 ,  146 ′. The first side wall  140 ,  140 ′, the second side wall  142 ,  142 ′, the top wall  136 ,  136 , and the bottom wall  138 ,  138 ′ each extend between the front end wall  144 ,  144 ′ and the rear end wall  146 ,  146 ′. 
     Referring to  FIG.  1   , an internal combustion engine system  100  is shown that includes an internal combustion engine  102  and a fuel system  168 . Internal combustion engine  102  includes a block  104  housing a plurality of components such as a crankshaft, a crankcase, and a plurality of cylinders associated with a cylinder bank  106 . Internal combustion engine  102  further includes a cylinder head assembly  108  mounted on block  104 . Cylinder head assembly  108  includes a valve cover  110  on a cylinder head  111 , and valve cover  110  extends from rearward end  122  of cylinder head assembly  108  to forward end  120 . 
     A fuel system cover  130  is mounted to the cylinder head assembly  108 . The fuel system cover  130  can be mounted to only valve cover  110 , to only cylinder head  111 , or to both valve cover  110  and cylinder head  111 . A portion  170  of a fuel system  168  that is exterior of cylinder head assembly  108  is shown that is encapsulated by fuel system cover  130 . The fuel system portion  170  is connected between a fuel supply (not shown) and one or more injectors (not shown) within cylinder head assembly  108  that provide fuel for combustion within the cylinders of cylinder bank  106 . 
     Referring further to  FIG.  2   , fuel system cover  130  includes an elongated housing  132  that forms a chamber  134  for receiving the fuel system portion  170  along the exterior side of cylinder head assembly  108 . Housing  132  includes a top wall  136 , a bottom wall  138  opposite top wall  136 , a first side wall  140 , and a second side wall  142  opposite first side wall  140 . Top wall  136 , bottom wall  138 , first side wall  140 , and second side wall  142  extend between a front end wall  144  and an opposite rear end wall  146 . 
     The walls  136 ,  138 ,  140 ,  142 ,  144 ,  146  extend around the chamber  134 . First side wall  140  defines an opening  148  that is in communication with chamber  134 . First side wall  140  is positioned against and engaged to at least one of the valve cover  110  and cylinder head  111  with a plurality of fasteners  150 . The fuel system portion  170  is thereafter encapsulated in chamber  134  within housing  130  while housing  130  provides an enclosed environment around the fuel system portion  170  to capture any leaks therefrom. 
     In an embodiment, top wall  136  is outwardly convexly rounded between side walls  140 ,  142 . Bottom wall  138  is sloped toward top wall  136  from first side wall  140  to second side wall  142 . Other embodiments contemplate other shapes for walls  136 ,  138  depending on the engine packaging, external components, and space requirements. The junction of top wall  136  and first side wall  140  may include a plurality of tabs  152  with openings for receiving fasteners  150  to secure fuel system cover  130  to cylinder head assembly  108 . Second side wall  142  and/or bottom wall  138  may include openings  154  for receiving fasteners  150  to secure fuel system cover  130  to cylinder head  111 . Tabs and/or openings may also be provided at the junction of bottom wall  138  and first side wall  140 , and/or along front end wall  144  and rear end wall  146 , for receiving fasteners. 
     Referring to  FIGS.  3 - 4   , an embodiment of system  100  is shown with an internal combustion engine  102 ′. Engine  102 ′ extends along and defines a longitudinal axis  118  that is, or is parallel to, a rotational axis of flywheel  112  and/or the rotational axis of the crankshaft. Flywheel  112  is located in a flywheel housing  114  on a rearward end  116  of the internal combustion engine  102 ′. Other components are also contemplated but not illustrated, such as pistons, gears, pumps, housings, turbines, etc. that would normally be found on an internal combustion engine. The internal combustion engine  102 ′ may be any type of internal combustion engine that requires a fuel system, including at least a diesel, gasoline, hydrogen, or natural gas engine, and/or combinations thereof. 
     The valve cover  110 ′ extends along longitudinal axis  118  from a forward end  120  to a rearward end  122  that is oriented toward flywheel  112 . Sides  124 ,  26  of valve cover  110 ′ extend along axis  118  between the forward and rearward ends  120 ,  122  of valve cover  110 ′. An embodiment of fuel system cover  130 , designated as fuel system cover  130 ′, is mounted to side  124  of valve cover  110 ′ and is also elongated along the longitudinal axis  118 . Fuel system cover  130 ′ can include features like fuel system cover  130  discussed above, such as a housing  132  with an interior chamber  34  for receiving fuel system portion  170 , and the same or similar features may not be re-described herein for brevity. 
     Fuel system cover  130 ′ includes a fuel inlet or fuel supply line  172  extending therethrough for connection exteriorly to the fuel supply (not shown). In an embodiment, the encapsulated fuel system portion  170  includes a fuel rail  174  connected to fuel supply line  172 , and injector lines  176  for connection to injectors (not shown) located within the cylinder head assembly  108 , such as shown in  FIG.  1   . Fuel system cover  130 ′ also includes a fuel leak sensor  180 , such as a pressure sensor, extending therethrough that is operable to detect a fuel leak from the portion  170  of the fuel system located within the fuel system cover  130 ′. 
     As shown in  FIG.  5   , fuel leak sensor  180  includes a sensor part  182  that is located within the chamber of fuel system cover  130 ′, and a harness  184  connected to sensor part  182  with wiring  186 . The wiring  186  extends away from fuel system cover  130 ′ to harness  184 . Harness  184  is connectable to a communication bus or other structure to provide output signals to an engine control unit (not shown) or other device that can provide an indication of a fuel leak in the chamber of fuel system cover  130 ′. Fuel leak sensor  180  could also be employed with fuel system cover  130 , as shown in  FIG.  1   . 
       FIGS.  6 - 8    show further views of the embodiment of fuel cover  130 ′. Fuel system cover  130 ′ includes top wall  136 ′ outwardly convexly rounded between opposite first and second side walls  140 ′,  142 ′. Bottom wall  138 ′ is sloped toward top wall  136 ′ from first side wall  140 ′ to second side wall  142 ′. Top wall  136 ′, bottom wall  138 ′, first side wall  140 ′, and second side wall  142 ′ extend between a front end wall  144 ′ and an opposite rear end wall  146 ′. First side wall  140 ′ defines an opening that is in communication with an interior chamber that houses the fuel system portion  170 , such as discussed above with respect to fuel cover housing  130 . 
     Rear end wall  146 ′ is located toward flywheel  112  and the rearward end  122  of valve cover  110 ′. The first side wall  140 ′ is positioned against the valve cover  110 ′ and cylinder head  111 ′. Tabs  152 ′ along the top of first side wall  140 ′ can receive fasteners that secure the fuel cover housing  130 ′ to valve cover  110 ′. Other fasteners  150  through second side wall  142 ′, bottom wall  140 ′, and/or end walls  144 ′,  146 ′ to engage fuel system cover  130 ′ to cylinder head  111 ′. For example, rear end wall  146 ′ can include a node  160 ′ for receiving a fastener. 
     Second side wall  142 ′ can include inset portions  154 ′,  156 ′ forming concave recesses in fuel system cover  140 ′. Inset portion  154 ′ can include a bore to receive fuel leak sensor  180 , and inset portion  156 ′ can include a bore to receive fuel supply line  172 . Second side wall  142 ′ can also include a number of inspection ports  158 ′. 
     Various aspects of the present disclosure are contemplated as indicated in the claims appended hereto and as discussed above. According one aspect, an internal combustion engine system includes an internal combustion engine and a fuel system. The internal combustion engine includes a cylinder head assembly. The cylinder head assembly extends between a rearward end and an opposite forward end. The fuel system includes a portion extending externally along the cylinder head assembly. A fuel system cover is mounted to the cylinder head assembly. The fuel system cover encapsulates the portion of the fuel system extending externally along the cylinder head assembly. 
     In an embodiment, the rearward end of the cylinder head assembly is oriented toward a flywheel of the internal combustion engine, and the cylinder head assembly includes elongated opposite sides extending between the rearward end and the forward end, and the fuel system cover is mounted along one of the opposite sides of the cylinder head assembly. In a refinement of this embodiment, the fuel system cover is elongated and extends along an axis that parallels a rotational axis of the flywheel. 
     In an embodiment, the internal combustion engine system includes a sensor engaged to the fuel system cover. The sensor is configured to detect fuel within the fuel system cover. In an embodiment, the sensor includes a sensor part within the fuel system cover, and wiring extending from the sensor part away from the fuel system cover to a wiring harness. 
     In an embodiment, the fuel system cover includes a first side wall for mounting to the cylinder head assembly, an opposite second side wall, a top wall, and a bottom wall. The top and bottom walls extend between the first and second side walls. In a refinement of this embodiment, the fuel system cover includes a first end wall oriented toward the rearward end of the internal combustion engine and a second end wall oriented toward the forward end of the internal combustion engine, and the top and bottom walls and the first and second side walls extend between the first and second end walls. In a further refinement, the top wall is convexly rounded between the first and second side walls and the bottom wall is sloped toward the top wall from the first side wall to the second side wall. 
     In another refinement of the above embodiment, the first side wall forms an opening, and the opening is positioned along the cylinder head assembly. In a further refinement, the fuel system cover includes a chamber extending from the opening, and the portion of the fuel system is housed in the chamber. 
     In another refinement of the above embodiment, the second side wall includes a bore for receiving a fuel supply line that connects the portion of the fuel system encapsulated by the fuel system cover to a fuel supply. 
     In an embodiment, the cylinder head assembly includes a cylinder head mounted to the block and a valve cover mounted to the cylinder head, and the fuel system cover is engaged to at least one of the cylinder head and the valve cover. In a refinement of this embodiment, the fuel system cover is engaged to each of the cylinder head and the valve cover. 
     In an embodiment, the portion of the fuel system encapsulated by the fuel system cover includes a fuel rail extending along the cylinder head assembly. 
     According to another aspect of the present disclosure, a fuel system cover for a fuel system of an internal combustion engine is disclosed. The fuel system cover includes a housing defining an interior chamber configured to house at least part of a fuel system. The housing includes a first side wall forming an opening into the interior chamber. The first side wall is configured to mount to a cylinder head assembly of the internal combustion engine. The housing includes a second side wall opposite the first side wall, a top wall and an opposite bottom wall each extending between the first and second side walls, and a front end wall and an opposite rear end wall. The first and second side walls and the top and bottom walls each extend between the front and rear end walls. 
     In an embodiment, the second side wall includes a first inset portion with a first bore for receiving a fuel supply line therethrough. The second side wall also includes a second inset portion with a second bore for receiving a fuel leak sensor therethrough. 
     In an embodiment, the housing includes a plurality of tabs along a junction between the top wall and the first side wall. Each of the plurality of tabs includes a hole for fasteners. The fasteners engage the fuel system cover to a valve cover of the cylinder head assembly. In a refinement of this embodiment, the second side wall includes a plurality of holes for fasteners. The fasteners engage the fuel system cover to a cylinder head of the cylinder head assembly. 
     In an embodiment, a fuel leak sensor is mounted in the interior chamber of the housing. In an embodiment, the top wall is convexly rounded between the first and second side walls. The bottom wall is sloped toward the top wall from the first side wall to the second side wall. 
     While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only certain exemplary embodiments have been shown and described. Those skilled in the art will appreciate that many modifications are possible in the example embodiments without materially departing from this invention. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims. 
     In reading the claims, it is intended that when words such as “a,” “an,” “at least one,” or “at least one portion” are used there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. When the language “at least a portion” and/or “a portion” is used the item can include a portion and/or the entire item unless specifically stated to the contrary.