Technical Field The present invention relates to a cold start fuel control system for an internal combustion engine.

Background Art Most modern day internal combustion engines of the type used in automotive vehicles include a plurality of internal combustion chambers. A primary intake manifold has one end open to ambient air and its other end open to the combustion chambers via the engine intake valves. During a warm engine condition, a multipoint fuel injector is associated with each of the internal combustion chambers and provides fuel to the internal combustion chambers. The activation of the fuel injectors is typically controlled by an electronic control unit.

During a cold start engine condition, however, a single cold start fuel injector is oftentimes used to provide fuel to the air intake of the primary manifold to the engine in lieu of the main fuel injectors. The cold start fuel injector injects a sufficient fuel/air mixture into the intake of the primary intake manifold to provide fuel for the engine combustion chambers during an engine warm up period.

As the engine warms up, the cold start fuel injector is gradually deactivated while, simultaneously, the multipoint fuel injectors are gradually activated in order to provide a smooth transition between a cold engine condition and a warm engine condition.

In order to ensure engine start up during a cold engine condition, these previously known cold start fuel control systems typically inject sufficient fuel to the engine to achieve a rich fuel/air mixture typically having a ratio in the range of 1: 10 to 1: 14.

While such a rich fuel/air mixture is sufficient to ensure proper starting of the engine during a cold engine condition, it disadvantageously results in undesirable hydrocarbon and nitrous oxide emissions.

In an effort to minimize or at least reduce such undesirable emissions, many previously known cold start fuel control systems have utilized heaters to vaporize the fuel prior to the induction of the fuel/air mixture into the inlet end of the primary intake manifold. However, since the fuel/air mixture from the cold start fuel injector must pass entirely through the primary intake manifold of the engine, fuel condensation can occur within the intake manifold during a cold engine condition. Such fuel condensation adversely affects the fuel efficiency of the engine.

Furthermore, with these previously known cold start fuel control systems, since the fuel/air mixture from the cold start fuel injector must travel entirely

through the relatively large volume primary intake manifold before the fuel/air mixture reaches the internal combustion chambers, an appreciable time delay occurs between the activation of the cold start fuel injector and the time that the fuel/air mixture reaches the engine combustion chambers. This time delay necessitates excessive engine cranking and also results in slow engine starting.

Disclosure of the Invention The present invention provides a cold start fuel control system which overcomes all of the above- mentioned disadvantages of the previously known systems.

In brief, the cold start fuel control system of the present invention is used in conjunction with an internal combustion engine having at least one, and typically several, combustion chambers. A primary intake manifold has an inlet end and an outlet end and has its outlet end fluidly connected with the engine combustion chambers. The engine further includes a source of fuel which provides fuel to the engine combustion chambers during a warm engine condition through a multipoint fuel injector system.

The cold start fuel control system of the present invention includes at least one cold start fuel injector having an inlet and an outlet. Upon activation, the cold start fuel injector assembly

injects fuel towards its outlet.

An auxiliary intake manifold having an interior chamber is attached to the engine such that the interior chamber of the auxiliary intake manifold is fluidly connected with each engine combustion chamber. Preferably, an orifice of a preset size is fluidly disposed in series between the interior of the auxiliary intake manifold and the engine combustion chambers to control the gas flow from the interior of the auxiliary intake manifold and to the engine combustion chambers.

The outlet of the cold start fuel injector assembly is fluidly connected with the interior chamber of the auxiliary intake manifold so that, upon activation of the cold start fuel injector, the fuel/air mixture from the cold start fuel injector is inducted through the auxiliary intake manifold and into the engine combustion chambers. In practice, the internal volume of the auxiliary intake manifold is substantially less than the internal volume of the primary intake manifold of the engine thus providing quicker engine starting than the previously known cold start fuel control systems and further minimizing the possibility of fuel condensation within the auxiliary intake manifold.

In order to ensure complete vaporization of the fuel from the cold start fuel injector prior to the induction of the fuel/air mixture into the engine, the

cold start fuel injector assembly preferably includes a heater to enhance vaporization of the fuel.

Optionally, the auxiliary intake manifold is also heated which minimizes the possibility of fuel condensation within the auxiliary intake manifold.

Brief Description of the Drawings A better understanding of the present invention will be had upon reference to the following detailed description, when read in conjunction with the accompanying drawing, wherein like reference characters refer to like parts throughout the several views, and in which: FIG. 1 is a side diagrammatic view illustrating a preferred embodiment of the present invention; FIG. 2 is an elevational view illustrating a preferred embodiment of the present invention; FIG. 3 is a side sectional view illustrating a preferred embodiment of the cold start fuel injector assembly of the present invention; FIG. 4 is an exploded view illustrating a preferred embodiment of the present invention; FIG. 5 is a side diagrammatic view illustrating a further preferred embodiment of the present invention; FIG. 6 is a view taken substantially along line 6-6 in FIG. 3;

FIG. 7 is a view similar to FIG. 3 but illustrating a further preferred embodiment of the present invention; FIG. 8 is a view similar to FIG. 7 but illustrating a still further embodiment of the present invention; FIG. 9 is a view similar to FIG. 7 but illustrating a further preferred embodiment of the present invention ; FIG. 10 is a view similar to FIG. 7 but illustrating a further preferred embodiment of the present invention; FIG. 11 is a diagrammatic view illustrating a still further preferred embodiment of the present invention; FIG. 12 is a diagrammatic view illustrating a still further preferred embodiment of the present invention; FIG. 13 is a top diagrammatic view illustrating a preferred embodiment of the present invention ; FIG. 14 is a view similar to FIG. 13, but illustrating a still further preferred embodiment of the present invention; and FIG. 15 is a view similar to FIG. 13 but illustrating still a further preferred embodiment of the present invention.

Best Mode for Carrying Out the Invention With reference now to FIGS. 1 and 2, an internal combustion engine 30 is shown having at least one and more typically several internal combustion chambers 32. These internal combustion chambers 32 are typically arranged in one or two banks of three or four internal combustion chambers 32 per bank.

A primary intake manifold 34 has both an interior chamber 36, an inlet end 38 and an outlet port 40 fluidly connected to each combustion chamber 32.

Thus, upon engine cranking, the engine inducts air from the inlet 38 of the primary intake manifold 34, through the primary intake manifold interior chamber 36 and through each outlet port 40 to the combustion chambers 32. A throttle 42 fluidly connected in series with the inlet end 38 of the primary intake manifold 34 controls the air flow volume through the primary intake manifold 34.

The engine 30 further includes a source of fuel 44 (illustrated only diagrammatically) which provides fuel to the engine combustion chambers 32 during a warm engine condition through multipoint fuel injectors 46. One fuel injector 46 is associated with each engine combustion chamber 32 and is typically positioned immediately upstream an intake valve 48 associated with each combustion chamber 32. An engine control unit (ECU) 50, illustrated only diagrammatically, operatively controls the activation

of the fuel injectors 46 in the conventional fashion.

With reference now particularly to FIG. 1, the cold start fuel control system of the present invention comprises a cold start fuel injector assembly 52 as well as an auxiliary intake manifold 54. In a fashion which will be subsequently described in greater detail, the cold start fuel injector assembly provides a vaporized fuel/air mixture to the engine combustion chambers 32 through the auxiliary intake manifold 54 during a cold start engine condition.

The auxiliary intake manifold 54 preferably comprises an elongated tube 56 having an inlet end 58 fluidly connected to an outlet 60 of the cold start fuel injector assembly 52. The auxiliary intake manifold includes an interior chamber 62 which is smaller in volume than the volume of the interior chamber 36 of the primary intake manifold 34.

Preferably the ratio of the volume of the primary intake manifold 34 to the volume of the auxiliary manifold is 5: 1 or greater. Additionally, the interior chamber 62 of the auxiliary intake manifold 34 is fluidly connected by ports 64 to the interior chamber 36 of the primary intake manifold 34 immediately upstream from each of the combustion chambers 32.

Consequently, for the four engine combustion chambers 32 illustrated in FIG. 1, a separate port 64 fluidly connects the interior chamber 62 of the auxiliary intake manifold 54 to each engine combustion chamber

32.

With reference now to FIG. 4, in order to accurately control the amount of fuel/air mixture through each port 64, preferably a flow control orifice 70 is sandwiched in between the auxiliary intake manifold 54 and the primary intake manifold 34 so that one flow control orifice 70 is fluidly connected in series with each port 64. Although each control orifice 70 may be of the same size, optionally, the flow control orifices 70 may be of different sizes to ensure a uniform fuel/air mixture to each engine combustion chamber 32.

The auxiliary intake manifold 54 is preferably constructed separately from the primary intake manifold 34 and secured to the primary intake manifold 34 by any conventional means, such as clamps.

As shown in FIG. 1, the auxiliary intake manifold preferably slopes downwardly from the cold start fuel injector assembly 52 which provides for improved flow of the fuel/air mixture due to gravity. Optionally, however, as diagrammatically shown in FIG. 5, the primary intake manifold 34 and auxiliary intake manifold 54 may be of a one-piece construction.

With reference again to FIG. 3, one preferred embodiment of the cold start fuel injector assembly 52 is there shown and includes a body 80 and an outlet tube 82 having an outlet end 84. The outlet end 84 is fluidly connected to the interior chamber 62 of the

auxiliary intake manifold 54.

A cold start fuel injector 86 is fluidly connected to the source of fuel 44. Furthermore, the cold start fuel injector 86 is mounted to the body 80 such that, upon activation by the ECU 50, the cold start fuel injector 86 injects fuel axially into the outlet tube 82 towards the end 84 of the outlet tube 82.

An air inlet valve 90 is also mounted to the cold start fuel injector body 80 so that air inducted through the air valve 90 intermixes and atomizes fuel injected by the cold start fuel injector 86.

Referring now to FIGS. 3 and 6, in order to further enhance the atomization of the fuel from the cold start fuel injector 86, a plurality of circumferentially spaced swirl fins 92 are preferably formed in or mounted to the cold start fuel injector body 80 such that these fins 92 are circumferentially disposed around the outlet end of the cold start fuel injector 86. An annular air inlet chamber 94 is fluidly disposed in series between the fins 92 and the air inlet valve 90 so that air inducted through the valve 90 passes through the fins 92 and, in doing so, the fins 92 impart a swirl to the inducted airflow.

The swirling air further enhances the atomization of the fuel from the cold start fuel injector 86.

Referring again to FIG. 3, in order to further enhance the vaporization of the fuel from the

cold start fuel injector assembly 52 prior to its induction into the auxiliary intake manifold 54, an electrical heater 100 is disposed within the outlet tube 86. The ECU also controls activation of the heater 100. Thus, during a cold start engine condition, the heater is activated so that fuel droplets from the cold start fuel injector 86 impinge upon the heater 82 which then vaporizes the fuel.

With reference now to FIG. 7, in order to provide additional heating to the outlet tube 82 of the cold start fuel injector assembly 52, a tubular and cylindrical chamber 102 is provided within the outlet tube 82. This chamber 102 is fluidly connected to the engine coolant system through a coolant duct 104 so that coolant from the engine coolant system flows into and fills the chamber 102. Such additional heating of the outlet tube 82 is particularly effective where the engine is restarted a relatively short period of time following a previous shutdown of a warm engine condition.

A modification of the cold start fuel injector assembly 52 is illustrated in FIG. 8 in which, in addition to the coolant chamber 102 surrounding the outlet tube 84, engine coolant chamber 106 is also provided within the body 80 of the cold start fuel injector assembly 52. The coolant flow through the body chamber 106 as well as the chamber 102 surrounding the outlet tube 82 results in additional heating of the

fuel injector body 80 thereby further enhancing vaporization of the fuel in the fuel/air mixture from the cold start fuel injector assembly 52.

With reference now to FIG. 9, a still further embodiment of the cold start fuel injector assembly 52 is shown in which, like the embodiment of the invention illustrated in FIG. 7, a tubular and cylindrical chamber 110 is provided around the outlet tube 82.

This outlet chamber 82 is fluidly connected to the exhaust gas from the internal combustion engine through an EGR inlet valve 112. Thus, upon engine start, a portion of the hot exhaust gasses is communicated to the chamber 110 thus heating the outlet tube 82 and enhancing the vaporization of the fuel from the cold start fuel injector 86.

With reference now to FIG. 10, a still further preferred embodiment of the cold start fuel injector assembly 52 is shown in which a heating passageway 113 is provided in the cold start fuel injector body 80 such that the passageway 113 is thermally coupled to the air inflow to the cold start fuel injector assembly 82 from the air inlet valve 90.

A portion of the exhaust gases from the engine are fluidly communicated to the chamber 113 through an EGR inlet valve 114 such that the engine exhaust gases preheat the inlet air prior to intermixing of the inlet air with the fuel from the cold start fuel injector 86.

The relatively warm inlet air, i. e. inducted the air

after heating by the engine exhaust gases, further enhances the vaporization of the fuel into the air from the cold start fuel injector assembly 52.

With reference now to FIG. 11, in order to further enhance the vaporization of the fuel during a cold start engine condition and to also minimize the possibility of fuel condensation or pooling within the auxiliary intake manifold 54, a heater assembly 120 is optionally disposed around at least a portion of the auxiliary intake manifold 54. This heater assembly 120 may comprise an electric heater disposed around the auxiliary intake manifold 54. Optionally, the heater assembly 120 can comprise a fluid passageway disposed around the auxiliary intake manifold 54 which is fluidly connected to either a portion of the exhaust gases from the engine or coolant from the engine coolant system.

With reference now to FIG. 12, in order to further enhance the vaporization of the fuel from the cold start fuel injector assembly 52, the outlet tube 82 includes an internal heater 100 (see FIG. 3) to enhance the vaporization of the fuel. Additionally, however, the cold start fuel injector assembly 52 is oriented such that the outlet tube 82 extends in a generally vertical direction with the cold start fuel injector 86 mounted at the bottom of the tube while the outlet end 84 of the tube is connected to the auxiliary intake manifold 54. In operation, any unatomized fuel

droplets from the cold start fuel injector 86 will return by gravity to the heater 100 for further vaporization.

With reference now to FIG. 13, an exemplary engine 30 is there shown having two spaced apart and parallel banks of four cylinders, and thus four combustion chambers, each. In order to provide fuel to each of the engine combustion chambers 32 during a cold start engine condition, the auxiliary intake manifold 54 includes two elongated tubular sections 130 and 132 such that one tubular section 130 extends along one bank of engine combustion chambers 32 while, similarly, the other linear section 132 extends along the other bank of combustion chambers 32. The cold start fuel injector assembly 52 then has fuel/air mixture outlet 60 fluidly connected to both linear sections 130 and 132 through a Y fluid connector 134. The Y fluid connector 134 thus ensures a supply of the fuel/air mixture to both banks of internal combustion chambers 32.

With reference now to FIG. 14, like the embodiment illustrated in FIG. 12, the engine 30 includes two spaced apart but parallel banks of engine combustion chambers 32. The auxiliary intake manifold 54 also includes two linear sections 130 and 132 with one linear section 130 positioned along one bank of cylinders and the other linear section 132 positioned along the other bank of engine combustion chambers 32.

Unlike the embodiment illustrated in FIG. 13, however, the cold start fuel injector assembly 52 is fluidly connected to one end 134 of the section 130 while the opposite end 136 of the section 130 is fluidly connected by a connecting tube 138 to the other section 132.

With reference now to FIG. 15, a still further embodiment of the present invention is there shown for use with an engine 30 having two engine banks which are spaced apart and parallel to each other. As in the embodiments illustrated in FIGS. 12 and 13, the auxiliary intake manifold includes a first elongated tubular section 130 extending along one bank of cylinders and, likewise, a second elongated tubular and cylindrical section 132 extending along the other bank of engine cylinders. Unlike the embodiments illustrated in FIGS. 12 and 13, however, one cold start fuel injector assembly 52 is associated with the section 130 while a second cold start fuel injector assembly 52'is fluidly connected to the other section 132. Since the fuel injectors 52 and 52'in FIG. 14 each provide only substantially one-half the fuel to the engine as the single cold start fuel injector assembly 52 shown in FIGS. 12 and 13, a smaller construction of the cold start fuel injector assembly 52 may be used and/or better control of the fuel/air mixture to the engine may be obtained.

In operation, during a cold start engine

condition, the ECU 50 controls activation of the cold start fuel injector 86 and its air supply valve 90 (FIG. 3) to provide atomized fuel to the engine internal combustion chamber 32 via the auxiliary intake manifold 54. The ECU 50 also controls activation of any and all heaters or heating mechanisms employed with the cold start fuel injector assembly 52 and/or the auxiliary intake manifold 54 to ensure vaporization of the fuel prior to its induction into the internal combustion chambers.

During a cold start engine operating condition, the ECU 50 typically deactivates the multipoint fuel injectors so that the cold start fuel assembly 52 provides all of the fuel to the engine during the cold start engine condition. However, as the engine warms, the ECU 50 decreases the amount of fuel provided by the cold start fuel assembly 52 while simultaneously increasing the amount of fuel provided by the multipoint fuel injectors to achieve a smooth transition from a cold and to a warm engine operating condition.

A primary advantage of the cold start fuel control system of the present invention is that, since the auxiliary intake manifold 54 has a much smaller internal volume than the primary intake manifold, quicker engine starting can be achieved as well as a decreased likelihood of fuel condensation within the auxiliary intake manifold. This, in turn, results in

more efficient engine operation and reduced engine emissions.

Having described my invention, however, many modifications thereto will become apparent to those skilled in the art to which it pertains without deviation from the spirit of the invention as defined by the scope of the appended claims.