Fluid line for uniform high-speed spraying over operating temperature range

Abstract

The invention describes a fluid geometry that produces a uniform oscillating spray. The geometry may be embodied as an insert, housing, or system in which the inlet supplies the interaction chamber. A main island is disposed at an upstream end of the chamber to form two power nozzles positioned off the centerline axis and downstream of the main island. A secondary island is also disposed within the interaction chamber but is spaced apart from and downstream of the primary island to define an exchange channel. The exchange channels create an inertial effect that can be controlled and adjusted to provide a desired oscillating fan spray created by the geometry. This arrangement exhibits consistent low and high temperature performance over a range of fluid components and operating conditions.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Patent Application Serial No. 63 / 548,044, filed on November 10, 2023, which is incorporated herein by reference. Technical Field

[0003] The present invention relates to fluid systems, components and apparatus capable of producing a controllable oscillating spray pattern and, more particularly, to a fluid geometry for producing a precisely controlled spray at relatively low temperatures typically associated with high viscosity fluids. Background Art

[0004] U.S. Patent No. 6,186,409 (incorporated herein by reference) provides an example of a fluid system, commonly known as having a "mushroom-shaped" configuration. In this patent, a plug or insert is formed with a pattern of holes in one surface thereof, and it is desired that the insert be sealingly received in a housing that receives the fluid, feed the fluid into an inlet or plenum formed on the insert, and then align the outlet of the insert with the hole in the housing so that the housing dispenses a fan-shaped spray from the hole. Due to the geometric configuration formed on the insert, the dispensed spray may oscillate or have specific characteristics.

[0005] Many other fluid geometries are known, so the mushroom-shaped configuration is presented only as an example. However, it is instructive in that it (like other geometries) has the features necessary to produce an oscillating spray. Specifically, the inlet / feed port leads to a channel that optionally has a series of spaced-apart pillars that help filter unwanted debris from the fluid. Downstream of these pillars, the channel is separated by an "island" that diverts the fluid into one of two opposing power nozzles. The power nozzle restricts the flow and ejects a lateral / oblique jet into an interaction chamber or oscillating chamber having a curved or dome-like shape (defined by the downstream face of the island and the peripheral wall of the insert / housing). Upon entering this chamber, the fluid jets from the power nozzles interact to produce a turbulent and varying flow pattern. Thus, upon exiting through the outlet at the downstream edge of the insert, the fluid is distributed as a fan-shaped cone within which the jet moves (i.e., oscillates) to produce a spray that can be used for a variety of cleaning operations (in this particular example, a spray known as a "heavy end," which will be described in more detail below).

[0006] U.S. Patents 7,472,848 and 7,267,290 describe further improvements and embodiments of other swinging geometries and inserts, while U.S. Patents 6,253,782; 11,305,297; and 11,712,707 depict a "reverse mushroom" configuration in which the interaction chamber has angled or curved sidewalls along its downstream section, and the motive nozzle (and perhaps even its corresponding feed or inlet) is closer to the outlet and positioned at an upstream angle than a conventional mushroom. U.S. Patent 9,987,639 describes structures that can be implemented at the outlet / throat to produce specific effects, while U.S. Patent Publication 2021 / 0114044 discloses features on and / or in the interaction chamber. All of these patents are also incorporated herein by reference.

[0007] Another example of a fluid geometry ("three jet islands") can be found in U.S. Patents 7,651,036 and 10,532,367, which are incorporated herein by reference and are schematically shown in FIG. 4B (including arrows representing fluid flow / turbulence). The common feature of these two patents involves positioning three independent islands between the inlet and the interaction chamber. Thus, compared to the above-mentioned mushroom-shaped configuration, an additional power nozzle PN3 is effectively provided on the centerline of the line between and above the positions of the power nozzles PN1, PN2. The island IS3 is also positioned downstream of the power nozzle PN3. The inlet IN3, the booster chamber or flow channel FC3, the interaction chamber IC3, and the outlet OT3 are similar to the other geometric structures described herein. In particular, this arrangement produces a more uniform oscillating spray pattern compared to the heavy-end mushroom-shaped line.

[0008] Figure 1A A comparative schematic diagram showing how to visualize the volumetric breakdown is shown, with the percentage of the total volume of the spray produced over time plotted on the y-axis, and the x-axis being a comparative schematic diagram of the position of the fan spray itself (i.e., the far left edge represents the volume dispensed at the edge of the fan, the middle shows the volume detected at the centerline, etc.). The mushroom-shaped line distribution M shows a heavy end distribution (with an M-shape), thereby delivering more volume at the edges of the spray pattern. To the extent that some applications may require a uniform distribution across the fan, the three-jet island distribution J retains some of the "smoothness" and M-shape of the mushroom-shaped distribution, but with less difference in maximum and minimum volumes. For comparison, the distribution F of a traditional "feedback loop" line is also depicted, the most notable feature of which is the variability and relatively uneven (or jagged / non-smooth) distribution that occurs in its middle section. It can be understood, therefore, that fluid lines that produce oscillating sprays can and should be further optimized based on the volumetric output of fan sprays, and that there are significant differences between known and established fluid geometries (e.g., mushroom-shaped vs. three-jet island, etc.).

[0009] Additionally, with the growing emphasis / need for cleanliness of sensors and camera systems, particularly in vehicles and other facilities exposed to varying and / or extreme weather conditions, there is a growing need for fluid circuits that can produce and maintain spray characteristics over a range of temperatures (e.g., -30°C to 75°C) and fluid types (e.g., water, ethanol, methanol, isopropyl aldehyde, ethylene glycol, etc.). Similarly, these systems may need to accommodate fluids with varying viscosities (e.g., 9Cp to 23Cp or higher) and be adapted to be set within a range of flow rates (e.g., less than 400mL / min at 22psi). Figure 1B and Figure 1C Providing insight and exemplary information about the range of conditions that are typically required / commonly encountered, curves M25, M50 and I25, I50 show the variation in viscosity with temperature for mixtures of 25% and 50% methanol (balance water) and 25% and 50% isopropanol (balance water), respectively, which have a wider range of variation than M75, M100 (75% and 100% methanol) and I75, I100 (75% and 100% isopropanol). Figure 1D A more direct comparative insight is provided by showing a corresponding 50 / 50 mixture of methanol (M50) and ethanol (E50), with the balance being water in each case, and more clearly emphasizes how mixtures of water and long chain alcohols exhibit significantly higher viscosities at lower temperatures. Since it is known in the art that fluid properties can be affected by viscosity, it is understood that the fluid geometry design must also take into account expected temperature fluctuations.

[0010] In the automotive industry, the antifreeze used in cleaning solutions will vary by region and / or regulatory scheme. Therefore, various alcohols (ethanol, isopropanol, methanol, etc.) can be mixed with water or other aqueous / miscible solutions in various proportions (e.g., 50 / 50, 75 / 25, etc.). In addition, the viscosity of the fluid passing through the flow geometry can vary by a factor of 3 or more (yielding higher viscosity at lower temperatures) as long as the operating conditions typically vary from -20°C to over 45° or 50°C.

[0011] In view of the above, a fluid geometry, insert, and / or system that produces a reliable oscillating spray over a wide range of operating parameters (e.g., temperature, fluid viscosity, low vs. high flow rates, desired size / shape / volume distribution of the fan spray, etc.) would be welcome. Specifically, a geometry is needed that produces a uniform spray pattern while accounting for the wide variety of different fluids, flow rates, and operating temperatures typically encountered by vehicles around the world. Summary of the invention

[0012] The fluid geometry is formed on the insert and / or as part of the housing or system. One or more inlets feed an interaction chamber having a primary island disposed at the upstream end of the chamber and a secondary island spaced apart and located downstream of the primary island to define an exchange channel within the interaction chamber. Two power nozzles are positioned offset from the centerline axis to feed the interaction chamber and the exchange channel. The lateral edges of the secondary island are positioned within the direct path of each power nozzle, and the secondary island itself can have a crescent, C-shape, or "speed bump" shape, all of which are aligned on the centerline axis at a position upstream of the throat and outlet. The exchange channel produces an inertial effect that can be controlled and adjusted to provide the desired oscillating fan spray produced by the geometry. This arrangement exhibits consistent low and high temperature performance over a range of fluid components and operating conditions. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The drawings constitute a part of this specification, and any information in the drawings is included literally (i.e., actual specified values) and relatively (e.g., ratios of various dimensions of parts, general comparisons, etc.). In the same manner, the relative positioning and relationship of the components shown in these drawings, as well as their functions, shapes, sizes, and appearances can further teach certain aspects of the present invention, as if fully reproduced herein. Unless otherwise specified, all dimensions in the drawings are in inches, and any printed information on / in the drawings constitutes a part of this written disclosure, including selected drawings that may be drawn to scale.

[0014] Figure 1A is a graph comparing the volume distribution of sprays produced by various fluid geometries. Figure 1B and Figure 1C The viscosity of selected fluids (i.e., methanol and isopropanol, respectively) is plotted against the viscosity of the alcohol-water mixture in question (i.e., pure (100%) alcohol, 75 / 25 alcohol / water, etc.) over a range of temperatures, including formulas for each curve / set of conditions. Figure 1D It is a combined comparison chart of the relationship between viscosity and temperature for 50 / 50 ethanol / water (line E50) and 50 / 50 methanol / water (line M50).

[0015] Figure 2A and Figure 2B is a 3D view of the fluid geometry of the present invention as it can be implemented in various inserts / housings, Figure 2A Providing filter struts and lateral inlet / feed ports within an inverted mushroom shape, and Figure 2B Variable width exchange channels are implemented within the conventional mushroom shape.

[0016] Figure 3A and Figure 3B They are Figure 2A and Figure 2B Schematic diagram of the geometric structure. Figure 3C is a similar schematic diagram illustrating another variation that may be implemented on a secondary island in accordance with certain aspects of the present invention.

[0017] FIG. 4A is a photograph of the spray pattern produced by a three-jet island geometry.

[0018] FIG4B schematically illustrates the above three-jet island geometry.

[0019] FIG. 4C (composite of conventional mushroom and three-jet island geometry, as in the prior art) and Figure 4D (like Figure 7 ) is a comparative photograph of the spray pattern of a 50 / 50 ethanol mixture produced by each fluid geometry at 0°F and 20psi, highlighting the uniform volume distribution and wide spray pattern of the present invention compared to the prior art. Under these conditions, the three spray islands produce a narrow jet and the mushroom shape produces an uneven and narrow fan-shaped spray.

[0020] Figure 5A is a photograph of the spray pattern produced by the fluid geometry of various disclosed aspects of the present invention, which is compared with FIG. 4A , again emphasizing the relatively more uniform volume distribution of the present invention compared to the prior art.

[0021] Figure 5B (start up), Figure 5C (Time 1) and Figure 5D (Time 2) is a sequential schematic diagram of the expected flow pattern for the mushroom-shaped aspect of the present invention, the arrows in these figures represent the expected fluid flow / turbulence at a given point in time.

[0022] Figure 5E (start up), Fig. 5F (Time 1) and Figure 5G (Time 2) is a sequential schematic diagram of the expected flow pattern for the reverse mushroom aspect of the present invention, with the arrows in these figures again representing the expected fluid flow / turbulence at a given point in time.

[0023] Figure 6 yes Figure 3A and Figure 5E Schematic top view of the flow geometry of , where label 6A highlights the relative orientation of the power nozzle with respect to one of the terminal vertices on the secondary island.

[0024] Figure 7 is a schematic top view of another flow geometry, also relying on the dual jet island concept, but where the end of the secondary island is positioned flush with the protrusion defining the power nozzle. DETAILED DESCRIPTION

[0025] The operation of the present invention may be better understood by reference to the detailed description, drawings, claims, and abstract which form a part of this written disclosure. Although specific aspects and embodiments are contemplated, it should be understood that those skilled in the art will be able to adjust and / or substitute certain teachings without departing from the basic invention. Therefore, this disclosure should not be construed as an undue limitation of the present invention.

[0026] As used herein, the words "example" and "exemplary" mean an instance or an illustration. The words "example" or "exemplary" do not indicate a critical or preferred aspect or embodiment. Unless the context indicates otherwise, the word "or" is intended to be inclusive and not exclusive. For example, the phrase "A employs B or C" includes any inclusive arrangement (e.g., A employs B; A employs C; or A employs B and C). As another matter, the articles "a" and "an" are generally intended to mean "one or more" unless the context indicates otherwise.

[0027] Insofar as the present invention encompasses fluidic circuits, it will be understood that such inserts are typically formed in or on a flat cuboid-shaped "insert" whose length and width are significantly greater than its thickness. Thus, the fluidic geometry may be etched, molded or shaped within the thickness such that the intended flow will pass through the spatial plane defined by the length and width. Typically, the inlet will be positioned within, at or near one edge, while the outlet will be formed in the opposite edge.

[0028] These inserts can be positioned within a housing that includes a passageway that delivers fluid to an inlet on the insert and a nozzle that aligns with an outlet of the insert. In one aspect, the fluid geometry formed in or on the insert (i.e., interaction chamber, motive nozzle, throat / outlet, etc.) is aligned on the same spatial plane that coincides with at least one of the major, planar surfaces of the insert. The fluid geometry can include boundary walls formed in or on the insert, or the geometry can rely on an inner surface of the housing that abuts the insert to define a fluid flow path therein.

[0029] In the accompanying drawings, in particular at least Figures 3A-3C , Figure 4B and Figure 5A-5GIn the drawings, the fluid geometry is drawn so that the inlet is at the top of each image and the outlet is at the bottom. Therefore, the flow and positioning of elements can be described as "upstream" or "downstream" relative to these elements. In addition, placing an item above or at the top of an insert will be understood to be directed toward the upper half where the inlet is located, while the lower half and bottom refer to items closer to the outlet. The vertical sides in these images are the edges, the lateral and side directions generally extend from edge to edge, and the axial or vertical direction refers to the flow from the inlet to the outlet. The images themselves are drawn in a common spatial plane, which is flat unless otherwise noted and does not include any steps, slopes, or elevation changes (relative to the flow of the fluid through that plane).

[0030] In general, the fluid geometry of the present invention is characterized by a pair of opposed motive nozzles aligned in a common plane. These motive nozzles are fed by one or more inlets that form a plenum chamber in the upstream portion of the insert. Alternatively, these inlets may be one or a series of holes that pass transversely through the body of the insert (i.e., orthogonal to the common plane).

[0031] It is noteworthy that the power nozzles are not aligned on the axial centerline AA of the insert (i.e., a line passing through the middle of the shell, typically passing through the middle of the outlet and throat), primarily because the first large island or main island is positioned upstream of these power nozzles, its lateral edges defining one side of each power nozzle, while the peripheral wall defining the entire line / geometry (either on the insert itself or as part of a cavity in the shell that houses the insert) defines the opposite side of the power nozzle.

[0032] A second small island or secondary island is spaced downstream of the primary island so that the secondary island is disposed within the interaction chamber. The smaller island extends transversely from edge to edge of the insert, passes through a common plane, and is symmetrically positioned about the centerline axis. In certain aspects, the smaller island has an upstream face that partially or completely conforms to the shape of the downstream face of the primary island, and in some cases is equidistantly spaced from the primary island. The shapes of the secondary islands may include: a) a crescent shape, wherein the edge is thinner from the upstream face to the downstream face than along the centerline axis (e.g., as shown in FIG. 1 ). Figure 3A ), b) a flat / horizontal downstream face and a curved or semi-circular upstream face (thus giving a "speed bump" appearance, e.g. Figure 3B ), or c) C-shaped, including a "serif" type thickening at the edge so as to protrude into the interaction chamber and provide a mushroom-shaped cap appearance (e.g., as Figure 3C shown).

[0033] As the fluid exits the nozzle and flows toward the interaction chamber, the end / outermost edge of the secondary island is defined by an edge or vertex 33A positioned within the initial flow path created by the motive nozzle (note: while this is nominally downstream, it is similar to Figure 5E-5G In general, the positioning of edge 33A falls within a pair of imaginary straight lines extending from the straight side walls defining power nozzle 34, thereby providing a lateral boundary (i.e., the "mouth" of the power nozzle) within which vertex 33A will be located. More specifically, referring to Figure 6 If straight line 34A is drawn across the opening at the mouth of power nozzle 34, offset line 34B extends orthogonally from line 34A so as to intersect vertex 33A, and the length of orthogonal line 34B will be approximately equal to, less than twice, or less than the length of straight line 34A.

[0034] As described in the previous paragraph, each edge of the secondary island is positioned within proximity of the mouth of each power nozzle, which will distribute the flow ejected from each power nozzle so as to direct at least a portion of the flow from each power nozzle into the interaction chamber. In certain aspects, the flow from one power nozzle is split into the interaction chamber and the exchange channel (described below), while the flow from the opposing power nozzle is directed into the interaction chamber until the flow pattern causes a reversal, which is believed to be the reason for the ability of the insert to produce an oscillating flow pattern (e.g., compare Figure 5C and Figure 5D and Figure 5E and Fig. 5F ), although it will be appreciated that the inventors do not necessarily intend to be bound by theory of operation. Moreover, the numerous examples of oscillating fluid circuits, including those described in detail in the Background of the Invention above, clearly demonstrate that fluidics can be a complex and unpredictable undertaking, where slight changes in geometry can lead to significant and useful improvements.

[0035] A secondary island is disposed below and axially along the downstream face of the primary island, which forms and defines an exchange channel. The openings at the opposite ends of the exchange channel are placed adjacent to and slightly above / upstream of the mouth of each power nozzle. In operation, it is believed that a portion of the fluid stream from the power nozzle is partially or almost completely diverted through the exchange channel and the primary fluid stream will reverse in a regular pattern. As a result, a temporary vortex is formed and moved within the interaction chamber as the fluid flows from the inlet through the outlet (see, for example, FIG. 5C to FIG. 5F ), thereby producing an oscillating spray pattern out of the throat. Notably, the exchange channel will be narrower along its entire length (ie, transverse to the intended flow path) than the lateral width or axial height of the interaction chamber at its narrowest point.

[0036] Another feature of the fluid geometry is that the primary and secondary islands can be symmetrical about the centerline axis. Furthermore, the secondary island has a smaller lateral width than the primary island, and since it defines the upper boundary of the interaction chamber, the primary island must always have a larger maximum lateral width than any part of the secondary island.

[0037] In some aspects, the lowermost edge of the secondary island will be substantially or completely flush with, or above, the lowermost boundary of the power nozzle. However, the main island may extend axially below the downstream edge of the secondary island (see Figure 3A and Figure 3C In terms of surface area, most of the main island (see Figure 3A and Figure 3C ) or all (see Figure 3B ) and accordingly, the entirety of the secondary island will occupy an axial position that is the same as or higher than the lower / downstream edge of the power nozzle.

[0038] In addition, the downstream face of the interaction chamber will curve from the protrusion defining the downstream portion of the motive nozzle into a straight horizontal line leading to the outlet. That is, the lowermost wall of the interaction chamber will include walls immediately adjacent to either side of the throat / outlet that extend along straight sides that are orthogonal to the centerline axis of the insert. In certain aspects, the horizontal section of each wall is within + / - 10% of the width of the outlet at its narrowest point. Additional aspects have the horizontal section of each wall on the lowermost edge of the interaction chamber extending transversely to a dimension that is at least the same as, at most twice as large, or at most three times as large as, the width of the outlet at its narrowest point.

[0039] In some aspects, the widest lateral width of the interaction chamber will be greater than the width of the exchange channel (see Figure 3B In an alternative aspect, the lateral width of the exchange channel at its widest point will be greater than the lateral width of the interaction chamber at its widest point (see Figure 3A and Figure 3C ).

[0040] Start conditions and flow patterns see Figure 5B This line will naturally allow one side to start up as the dominant outlet flow (indicated by the set of arrows on the right hand side of the diagram, but it will be appreciated that any number of variations may determine whether the right or left side of the insert dominates at start up). Figure 5CAs shown, when the left-hand side flow is blocked, a portion of the jet from the power nozzle is diverted through the exchange channel, and the remaining flow is partially or completely diverted by the main flow, thereby generating a clockwise vortex B at the lower left corner of the interaction chamber. Similarly, when the diverted flow leaves the exchange channel, it may merge and / or peel off with the main flow to generate a clockwise vortex A at the lower right corner of the interaction chamber. Since the fluid flow tends to adhere to the peripheral wall or be affected / impacted by the peripheral wall, the size and intensity of vortices A and B will become larger or weaker. Therefore, as Figure 5D As shown, when the vortex A is large enough, the discharge jet inside the interaction area will be pushed from the right to the left, thereby switching the left-hand discharge of the discharge jet to the right-hand discharge. Therefore, the geometric structure will regularly switch back and forth, producing corresponding effects and influences on the spray distributed from the outlet (i.e., this contributes to the oscillation and volume ratio changes on the fan-shaped spray).

[0041] Figure 4D and Figure 5A It is shown that these spray patterns are more uniform (i.e., the volume distribution over the fan has less variation) than conventional lines, such as the three-jet island shown in Figures 4A and 4C. Equally important, Figure 3A and Figure 3B The geometries of the present invention (and as otherwise described or contemplated herein) exhibit more consistent performance over a wide range of temperatures, flow conditions, and fluid types.

[0042] Without wishing to be bound by any particular theory of operation, the inventors believe that the exchange channel can be used as an inertial loop. Therefore, U.S. Patent Publication 2023 / 0355470 and U.S. Patent 9,765,491 are both incorporated herein by reference. In general, an inertial loop can be employed to create desired flow conditions (e.g., instability and / or oscillation in the subsequent output spray). Reference FIG. 5B to FIG. 5F , adjustments and / or intentional variations may be made along the length, diameter, height and / or width of the exchange channels to affect flow patterns through and from them.

[0043] For example, Figure 3A As shown, the islands can extend across the width of the interaction chamber to increase the length of the exchange channels. Axially aligned extensions on the secondary islands can further extend and lengthen the exchange channels.

[0044] Figure 3B represents an alternative or additional way of influencing the inertial effect of the exchange channel. Here, the curvature of the upstream face of the secondary island is different compared to the curvature of the downstream face of the primary island. This arrangement enables a variable width along the exchange channel, thereby creating the possibility of a Venturi effect, which further affects the flow patterns and vortices described herein.

[0045] Figure 5E This inertial effect is illustrated. Flow from the right power nozzle (lighter arrows) dominates the interaction chamber and travels around it (possibly attaching to and / or interacting with features on the downstream face of the secondary island). This flow pattern blocks the less dominant left power nozzle (dark arrows) and redirects flow from the left nozzle down into the throat and / or exchange channel. Eventually, the opposing power nozzle will overwhelm the dominant nozzle, causing the flow to "switch" and follow a regular cycle.

[0046] As disclosed in the above references, the flow diversion produced by the exchange channel acts as a type of inertia loop. It is well known that inertia loops can be used to adjust the frequency in the feedback loop geometry, but the inventors are not aware of any similar structure or process that is arranged within the interaction chamber itself (i.e., in the same plane) that does not require the flow to be diverted or redirected through holes in the body or channels formed in the shell (either of which intersect at an angle (usually orthogonal) relative to the plane / direction of the geometry of the present invention). The higher the inertia of the exchange channel, the slower the pressure wave propagates to the other side of the line and the longer the jet stays at the edge of the fan. The lower inertia value of the loop will cause the pressure wave to propagate faster to the other side of the loop, thereby causing the jet to return to the other side of the fan more quickly after reaching the end, thereby improving the uniformity of the spray. Therefore, the present invention also includes a method of controlling, changing and fine-tuning the characteristics of the oscillation and spray pattern produced by the fluid geometry contemplated herein.

[0047] As shown herein, a smooth, symmetrical C-shaped curve may be preferred for the upstream face of the secondary island and the downstream face of the primary island (as well as the upstream face of the primary island, although that face will not play a direct role in the flow pattern and characteristics of the exchange channel). The downstream face of the secondary island may also be a smooth, symmetrical C-shaped curve (e.g., Figure 3A ), although it may be given a straight line, preferably aligned orthogonally to the centerline axis (e.g. Figure 3B The lateral opposite ends of the secondary island can be inserted from the power nozzle opening (e.g. Figure 3B ), or they may be aligned with extensions, fingers or projections on the peripheral wall that help define the downstream side of the motive nozzle ( Figure 3A ).

[0048] Figure 3CAn example of how the downstream face of the secondary island can be further improved is provided. As shown, small and preferably mirrored protrusions can be added to these internal faces (effectively forming a serif type C-shape). Such features help separate the fluid flow from the inner wall, especially under high viscosity conditions. In a similar manner, vertex protrusions (as described in US Patent Publication 2021 / 0114044) can be used as an additional or alternative embodiment on the interaction chamber / downstream facing the secondary island.

[0049] In some cases, the main island may have fingers, extensions or protrusions on the inner, downstream face to define the top / upstream side of the power nozzle ( Figure 3A ). In these cases, the fingers / extensions / protrusions help determine the angle and, possibly, the degree to which the jet exiting the motive nozzle will initially be diverted into the exchange channel (rather than into the interaction chamber).

[0050] It is noteworthy that the dual jet island approach contemplated herein can be adapted to function with such geometries (and any modifications or additional features thereof) as long as the fluid geometry relies on two opposing power nozzles feeding the interaction chamber. As will be understood in the art, the power nozzle necessarily involves the use of a narrowed or constricted flow path to produce a directed fluid jet introduced into the interaction chamber, and as such, the power nozzle is not: a) a simple flow path around an obstacle, and b) a throat at the exit of any fluid geometry (as long as the feature ejects a final fan spray and is not connected to the interaction chamber).

[0051] It is worth noting that neither power nozzle is located on the centerline axis (or on a straight line between the inlet and outlet when both are located in the central portion of the insert / chip / housing). In the same manner, the secondary island and / or power nozzle are preferably symmetrical about the centerline axis, which means that they can be mirrored relative to the centerline axis.

[0052] exist Figure 2A and Figure 2BIn the embodiment of the present invention, the insert 10 is a rectangular or polygonal body 11, whose features are carved, etched or formed in one or both of the two main planes. One or more inlets are formed as holes 20a or booster chambers 20b (where the adjacent housing defines and includes a hole for introducing fluid into the booster chamber). These inlets are arranged at opposite areas of the body 11 compared to the outlet 40. The edges / sides of the body 11, along with the portions of the planes that may be expected to contact the nozzle housing (not shown), may include angled, inclined or specially shaped areas to facilitate these connections, and it is further understood that the insert 10 is received in the nozzle housing in a sealed manner so that the fluid flows through the inlet 20, through the geometric structure 30, and is dispensed from the outlet 40 without significant leakage, pressure loss, etc. It is worth noting that the intended fit / engagement between the insert 10 and the housing (or other system parts) enables such a design in which portions of the peripheral wall within the geometric structure 40 or elsewhere can actually be established by the housing / other parts. Similarly, the open faces of the geometry 40 (on one or both sides) will be sealed by corresponding flat surfaces in the housing / other parts.

[0053] The inlet 20, the geometric structure 30 and the outlet 40 are defined by a sunken or recessed floor, which is defined by a peripheral wall (formed by the body 11 and / or the housing). In the area near the inlet, the floor defines a flow channel 21. A series of pillars or columns 22 (substantially matching the height of other blocking components (i.e., peripheral walls, primary and secondary islands, etc.) defining the geometric structure 30) can be spaced apart and arranged in a straight or regular pattern to act as a filter to prevent debris from entering the geometric structure 30, thereby reducing the risk of clogging. The peripheral wall 23 can include notches, guides or other guiding members 24 to ensure that the insert 10 is correctly positioned and assembled in the housing. The wall 23 guides the fluid from the inlet 20 to the geometric structure 30.

[0054] The geometric structure 30 is defined at its boundaries by a curved and / or angled peripheral wall 37. The main island 32 is positioned in the middle of the bottom plate 31 so that the fluid can bypass its outer lateral edges. The bottom plate 31 may include a stepped section 31a that divides the transition from the flow channel 21 associated with the inlet 20 to the actual geometric structure 30. As seen herein, the bottom plate 31 of the entire geometric structure will remain in the same common plane. The end or opposite lateral end 32a of the main island 32 defines one side (i.e., the upstream edge) of the power nozzle 34, and the end 32a may include a protrusion or other feature as described elsewhere herein (e.g., see Figure 3C ). The opposite sides of the motive nozzles 34 will be formed by the wall 37 and more specifically by the protrusions 36b within the interaction chamber 36. In this way, the motive nozzles 34 each direct a fluid jet towards opposite / lateral ends of the secondary island 33.

[0055] The secondary island 33 is spaced apart from but downstream of the primary island 32. The island 33 also has various features and characteristics described elsewhere herein, and the passage between the islands 32, 33 defines an exchange channel 35. Thus, the channel 35 has opposite ends that are in fluid communication with the jet output portion output by the motive nozzle 34 and are in fluid communication with the interaction chamber 36, respectively.

[0056] The interaction chamber 36 is free of any obstructions or features (except for the island 32). The chamber 36 will have a common fluid geometry with a curved perimeter that may define a mushroom, reverse mushroom, or other shape. In some aspects, the downstream wall defining the chamber 36 may be orthogonal to the centerline axis AA, although curved and / or angled sections extend from the downstream edge of the power nozzle 34 to the outlet 40. The outlet 40 may be defined by a throat opening in the lower face of the interaction chamber 36 with straight edge walls 36a (i.e., extending perpendicular to the centerline axis aa) extending away from the throat in opposite directions and then curving upward to form an opposing protrusion 36b that defines one side (i.e., the downstream edge) of the power nozzle 34.

[0057] exist Figure 7 In another aspect shown, each edge 33A of the secondary island 33 can be aligned with the downstream edge of the power nozzle 34 (i.e., aligned with the curved portion of the protrusion 36b), but still within the above-mentioned specified distance (i.e., less than twice the width of the power nozzle, more preferably, a spacing that is approximately the same as the width of the power nozzle). This arrangement effectively guides most of the jet from the power nozzle into the exchange channel 35. Here, the radius curved section 36c is located in the lower lateral corner of the interaction chamber 36 to form a spherical recess or depression on the outer edge of each straight wall section 36a. The lowermost edge of the spherical recess 36c will be located closer to the bottom edge of the insert (along the axis) than the straight wall section 36a.

[0058] exist Figure 7 In terms of Figure 3B The "flatter" secondary island of the speed bump is shown in FIG. 1 , but the exchange channel 35 is narrower and its width remains substantially constant over the entire length (i.e., the spacing between the primary and secondary islands does not change, or varies by less than 10% or 5% at most, with the widest section located on the centerline axis). The other features and characteristics of the fluid geometry of the present invention still apply to this particular aspect.

[0059] The outlet 40 can be located on the axis AA on the downstream edge of the body 11. The outlet 40 is characterized by a narrow throat 41 that is coupled to the downstream wall of the chamber 36. On opposite edges of the throat 41, discharge walls 42 diverge from each other to define the outlet 40 visible on the edge of the body 11. In some aspects, the discharge walls 42 can include discrete segments 42a, 42b that are angled relative to each other. As described elsewhere herein, additional structural features can be provided in, on, or near the throat / outlet.

[0060] In view of the above, one aspect of the present invention contemplates a fluid insert for producing an oscillating spray pattern at lower temperatures. The insert is formed by a body defining an inlet located at an upper portion of the body and an outlet located at a lower edge of the body such that fluid flows from the inlet to the outlet along a major face of the body in a common spatial plane. A primary island and a secondary island are formed on the major face symmetrically about a centerline axis of the body, and wherein the primary island: i) is closer to the inlet than the secondary island, ii) includes a lower edge spaced apart from an upper edge of the secondary island to define an exchange channel, and iii) has a greater maximum lateral width than the secondary island. An interaction chamber is located between the inlet and the outlet and has: i) an upper face defined by a lower edge of the secondary island, and ii) a lower face including a pair of straight-sided wall segments that expand in opposite directions from an opening defining the outlet, extend a certain wall distance perpendicular to the centerline axis, and then bend axially upward to define opposing protrusions. Finally, relative power nozzles defined by relative protrusions and relative lateral ends of the primary island are provided and positioned so that each power nozzle directs a fluid jet toward the relative lateral ends of the secondary island. Additional aspects may include any one or combination of the following features:

[0061] Among them, the secondary island is in the shape of a crescent, C or speed bump;

[0062] wherein the opposite lateral ends of the secondary island include thickened portions to impart a serif-type C-shape;

[0063] wherein the lower edge of the primary island and the upper edge of the secondary island are spaced apart at a substantially constant distance along the entire exchange channel;

[0064] wherein the interaction chamber has an inverted mushroom-shaped configuration;

[0065] wherein the wall distance is equal to or at most three times the outlet distance defined by the narrowest point between pairs of straight-sided wall segments defining the outlet;

[0066] wherein the opposite lateral end of the main island is located axially closer to the lower edge of the body than the opposite protrusion;

[0067] wherein the power nozzle width is defined as the narrowest point between the relative protrusion of each power nozzle and the relative lateral end of the primary island, wherein the secondary island spacing is defined as the shortest distance between the relative lateral end of the secondary island and the power nozzle associated therewith, and wherein the secondary island spacing is less than twice the power nozzle width;

[0068] wherein the bottom plate formed on the main surface includes a step section between the inlet and the main island;

[0069] Therein, a spherical recess is disposed between each straight-sided wall section and its associated projection.

[0070] Another aspect of the invention is an oscillating spray nozzle comprising any of the above iterations of a fluid insert. A method of producing an oscillating spray using any of these inserts is also contemplated. In all of the above aspects, the oscillating spray produced thereby will maintain its desired characteristics (shape, volume distribution, etc.) over a wide range of temperatures and fluid mixtures, including Figure 1B and Figure 1C Furthermore, in each of these aspects, the fluid from the inlet flows around the two laterally opposite ends of the main island, thereby generating a pair of vortices in the interaction chamber, the intensity of these vortices and / or the fluid flow in the exchange channel changing alternately to form an inertial circuit alternately fed by only one of the power nozzles, in either / both cases, the fluid flow pattern generating and maintaining an oscillating spray in the fluid ejected from the outlet.

[0071] As used herein, axial direction and axial or longitudinal direction refer to the general direction of flow from an inlet through a fluid geometry and dispensed from an outlet in a spray pattern. Thus, as a single and non-limiting example, Figures 3A-3C The axial direction in the drawings is consistent with the vertical direction. Therefore, throughout the drawings and this disclosure, the lateral direction or width direction intersects the axis at right angles. In all cases, these and other terms should be read in conjunction with the context of the present disclosure and the language commonly used in the field.

[0072] All parts should be made of materials that have adequate flexibility and structural integrity, as well as being chemically inert, resistant to corrosion and other conditions typically encountered by vehicle exterior parts. Certain grades of injection moldable polymers may be particularly advantageous, as may various processes for forming detailed shapes in / on blocks of metal, polymer, composite materials, or other types of materials. Additive manufacturing methods may also be useful.

[0073] References to coupling in this disclosure should be understood to include any conventional means used in the art. This can take the form of a snap or forced fit of components, although threaded connections, bead and groove, and bayonet / slot and flange assemblies can be employed. Adhesives and fasteners can also be used, although these must be chosen judiciously, taking into account the design factors discussed above.

[0074] In the same way, joining may include a connection or an abutment relationship.These terms, as well as any implicit or explicit reference to connection, should be considered in the context in which they are used, and any perceived ambiguity may potentially be resolved by reference to the drawings.

[0075] Although the present embodiment has been shown in the drawings and described in the above detailed description, it should be understood that the present invention is not limited to the embodiments of the present disclosure and that various rearrangements, modifications and substitutions are possible. Although the exemplary embodiments have been described with reference to the preferred embodiments, the above detailed description also involves further modifications and variations. These modifications and variations also fall within the scope of the attached claims or their equivalents.

Claims

1. A fluid insert for producing an oscillating spray pattern at relatively low temperatures, the insert comprising: a body defining an inlet positioned within an upper portion of the body and an outlet positioned at a lower edge of the body such that fluid flows from the inlet to the outlet along a major face of the body in a common spatial plane; a primary island and a secondary island, each formed on the primary face symmetrically about a centerline axis of the body, and wherein the primary island: i) is located closer to the inlet than the secondary island, ii) includes a lower edge spaced from an upper edge of the secondary island to define an exchange channel, and iii) has a greater maximum lateral width than the secondary island; an interaction chamber positioned between the inlet and the outlet and having: i) an upper face defined by a lower edge of the secondary island, and ii) a lower face including a pair of straight-sided wall segments diverging in opposite directions from an opening defining the outlet, the straight-sided wall segments extending a certain wall distance perpendicular to the centerline axis and then curving axially upward to define opposed protrusions; and opposing power nozzles, the opposing power nozzles being defined by opposing protrusions and opposing lateral ends of the main island; and Wherein, each of the power nozzles directs a fluid jet toward opposite lateral ends of the secondary island.

2. The fluid insert of claim 1, wherein: The secondary island is in a crescent shape, a C shape or a speed bump shape.

3. The fluid insert of claim 1, wherein: The opposite lateral ends of the secondary island include thickened portions to impart a serif-like C-shape.

4. The fluid insert of claim 1, wherein: The lower edge of the primary island is spaced apart from the upper edge of the secondary island at a substantially constant distance along the entire exchange channel.

5. The fluid insert of claim 1, wherein: The interaction chamber has an inverted mushroom configuration.

6. The fluid insert of claim 1, wherein: The wall distance is equal to or at most three times the outlet distance defined by the narrowest point between the pair of straight-sided wall sections defining the outlet.

7. The fluid insert of claim 1, wherein: The opposite lateral ends of the main island are located axially closer to the lower edge of the body than the opposite protrusions.

8. The fluid insert of claim 1, wherein: The power nozzle width is defined as the narrowest point between the relative protrusion of each power nozzle and the relative lateral ends of the main island, wherein the sub-island spacing is defined as the shortest distance between the relative lateral ends of the sub-island and the power nozzle associated therewith, and wherein the sub-island spacing is less than twice the power nozzle width.

9. The fluid insert of claim 1, wherein: A bottom plate formed on the main surface includes a stepped section between the inlet and the main island.

10. The fluid insert of claim 1, wherein: Fluid from the inlet flows around two opposing lateral ends of the main island to generate a pair of vortices in the interaction chamber, and wherein the intensity of the vortices alternates to generate an oscillating spray in the fluid ejected from the outlet.

11. The fluid insert of claim 1 , wherein: The exchange channel acts as an inertia circuit that is alternately fed by only one of the motive nozzles to maintain an oscillating spray in the fluid ejected from the outlet.

12. The fluid insert of claim 1, wherein: A spherical recess is interposed between each straight-sided wall section and the projection associated therewith.

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