Tangential pressure atomization tip without feed chamber

Abstract

Embodiments of the present disclosure relate to a tip for a fuel nozzle. The tip includes a tip body having a first end and a second end spatially disposed from the first end along a longitudinal axis of the tip body. A nozzle passage is disposed at the first end. The inlet cavity, the swirl chamber, and the plurality of swirl channels are disposed within the tip body. A plurality of swirl channels connect the inlet cavity and the swirl chamber. Each of the swirl channels has an opening to the inlet cavity and an outlet into the swirl chamber. Fluid communication is provided from the second end to the first end such that fluid flows from the inlet cavity through the swirl passage into the swirl chamber and out through the nozzle passage.

Description

Technical Field

[0001] The present invention generally relates to the tip of a fuel nozzle and, more particularly, to a tip that does not include a feed chamber. Background Art

[0002] Fuel injectors have been applied in many applications related to air-breathing propulsion systems (such as those used in aviation). These systems typically include a section for compressing inlet air, a combustion section for burning the compressed air with fuel, and an expansion section where the energy of the hot gases resulting from the combustion of the fuel is converted into mechanical energy. The exhaust of the expansion section can be used to generate thrust or as a heat and energy source.

[0003] Such injectors typically employ nozzles from which the fuel exits prior to combustion. These nozzles include tips that typically incorporate features for promoting a desired fuel droplet distribution in the fuel spray. Such features can include swirl chambers, tip geometries, atomizers, etc.

[0004] For reliable engine operation, especially under high altitude conditions, an appropriate droplet size distribution is important for sustenance. When swirl is generated in the fuel prior to its exit from the nozzle, one factor related to maintaining an appropriate droplet size distribution is to provide a strong tangential component.

[0005] Figure 8 An example of a state-of-the-art tip 200 of a fuel nozzle is depicted that provides a strong tangential component of the fuel that generates swirl prior to its exit from the nozzle. The tip 200 is shown as having a two-piece construction including a tip body 202 and a swirl body 204. The tip body 202 has an inner wall 206 that defines a lumen 208 leading to a tip orifice 210. A conical wall 212 can be provided between the inner wall 206 and the tip orifice 210. The swirl body 204 is disposed within the lumen 208 of the tip body 204. The swirl body 204 has a first outer surface 214 and a second outer surface 216. The first outer surface 214 defines a first circumference having dimensions sufficient to cause the first outer surface 214 to contact the inner wall 206 of the tip body 202. The second outer surface 216 defines a second circumference that is smaller than the first circumference such that the second outer surface 216 is inserted radially inward from the first outer surface 214.

[0006] When the swirl body 204 is disposed within the lumen 208, a feed chamber 218 is formed between the inner wall 206 and the second outer surface 216. The feed chamber 218 provides fluid communication between a first inner lumen 220 of the swirl body 204 and a second inner lumen 222 of the swirl body 204. In particular, a first flow channel 224 provides fluid communication between the first inner lumen 220 and the chamber 218, and a second flow channel 226 provides fluid communication between the chamber 218 and the second inner lumen 222.

[0007] Fuel entering the tip body flows into the first inner cavity 220 of the swirl body 204, passes through the first flow passage 224, and flows into the feed chamber 218.

[0008] In some cases, such tip designs may be associated with one or more of the following disadvantages. Since the annular feed chamber 218 is formed between two components (the tip body 202 and the swirl body 204), packaging may require more space. Due to the additional features required to form the feed chamber, the tip body 202 and the swirl body 204 are more difficult to machine. Forming a feed chamber between the tip body 202 and the swirl body 204 creates a potential leakage path for fuel entering axially downstream of the swirl chamber. There is a possibility of pressure loss due to the additional chambers through which the fuel must pass. Additionally, the annular feed passage is not easily thermally insulated.

[0009] Accordingly, there is a need in the art for an improved nozzle tip that avoids or eliminates the above disadvantages. The present invention provides such a tip. These and other advantages of the present invention, as well as additional inventive features, will be apparent from the description of the invention provided herein. SUMMARY OF THE INVENTION

[0010] Embodiments of the present disclosure provide a tip for a fuel nozzle that addresses the foregoing problems in existing tip designs. As will be discussed more fully below, the presently disclosed tip is a one-piece or two-piece construction that eliminates the feed chamber. Instead of using a feed chamber, the tip disclosed herein includes a swirl passage through which fuel enters substantially axially and enters a swirl chamber in fluid communication with the nozzle passage substantially tangentially. In one or more embodiments, additive manufacturing techniques are used to fabricate the components of the one-piece tip or two-piece tip, which allows for the formation of complex flow paths. Additionally, in one or more embodiments, the flow area of the swirl passage tapers between the inlet and the outlet to accelerate the fuel flowing through the passage.

[0011] Advantageously, embodiments of the tip disclosed herein provide a more compact design, are easier to machine, provide a seal between the components of a two-piece construction, avoid pressure loss by eliminating the feed chamber, and reduce wall temperature by increasing fuel velocity. These and other advantages of the disclosed tip design, as well as additional inventive features, will be apparent from the description provided herein.

[0012] In a first aspect, the present invention provides a tip for a fuel nozzle. The tip includes a tip body having a first end and a second end. The second end is spatially disposed from the first end along a longitudinal axis of the tip body. A nozzle passage is disposed at the first end. An inlet cavity is disposed within the tip body, and a swirl chamber is disposed within the tip body. A plurality of swirl passages are disposed within the tip body, and the plurality of swirl passages connect the inlet cavity and the swirl chamber. Each swirl passage has an opening leading to the inlet cavity and an outlet entering the swirl chamber. Fluid communication is provided from the second end to the first end such that fluid is configured to flow from the inlet cavity through the swirl passages, into the swirl chamber, and out through the nozzle passage.

[0013] In a second aspect of the tip, according to one or more embodiments, each swirl passage at least partially wraps around the longitudinal axis from each respective opening to each respective outlet. Additionally, each swirl passage imparts a flow component tangential to the swirl chamber to at least a portion of the fluid flowing through the swirl passage.

[0014] In one or more embodiments according to the second aspect, each of the plurality of swirl passages wraps around the longitudinal axis from 60° to 120°.

[0015] In one or more embodiments according to the second aspect, each of the plurality of swirl passages wraps around the longitudinal axis by at least 330°.

[0016] In a third aspect of the tip, according to one or more embodiments, the tip has a one-piece construction, and the tip body includes an intermediate separator separating the inlet cavity from the swirl chamber. Additionally, a plurality of swirl passages extend through the intermediate separator.

[0017] In a fourth aspect, according to one or more embodiments of the third aspect, a wall extends from the intermediate separator toward the second end. The wall divides the inlet cavity into a first inlet cavity and a second inlet cavity. The second inlet cavity surrounds the first inlet cavity. The plurality of swirl passages includes a first plurality of inner swirl passages and a second plurality of outer swirl passages. The first plurality of inner swirl passages provides fluid communication between the first inlet cavity and the swirl chamber, and the second plurality of outer flow passages provides fluid communication between the second inlet cavity and the swirl chamber.

[0018] In one or more embodiments according to the fourth aspect, the inner swirl passages wrap around the longitudinal axis from 180° to 360°.

[0019] In one or more embodiments according to the fourth aspect, the outer swirl passages wrap around the longitudinal axis by at least 270°.

[0020] In one or more embodiments according to the fourth aspect, the swirl chamber has a bottom plate and a side wall surrounding the bottom plate. The bottom plate includes a frustoconical surface, and each outlet of the first plurality of inner swirl channels is formed to pass through the frustoconical surface of the bottom plate. In addition, each outlet of the second plurality of outer swirl channels is formed to pass through the side wall.

[0021] In one or more embodiments according to the fourth aspect, the outer swirl channels are connected to a manifold different from the inner swirl channels.

[0022] In one or more embodiments according to the second aspect, the plurality of swirl channels intersect the swirl chamber at an angle of less than 10° with respect to a transverse axis perpendicular to the longitudinal axis.

[0023] In one or more embodiments according to the second aspect, the plurality of swirl channels intersect the swirl chamber at an angle of less than 45° with respect to a transverse axis perpendicular to the longitudinal axis.

[0024] In one or more embodiments according to any of the aspects described herein, each opening of the plurality of swirl channels has a first flow area, and each outlet of the plurality of swirl channels has a second flow area. The second flow area is smaller than the first flow area.

[0025] In one or more embodiments according to the first aspect, the tip has a two-piece construction, and the tip further includes a swirl body disposed within the tip body. The swirl body has a first portion defining a swirl chamber, a second portion defining an inlet cavity, and an intermediate portion disposed between the first portion and the second portion. The plurality of swirl channels extend through the intermediate portion.

[0026] In the fifth aspect, according to one or more embodiments of the first aspect, each of the plurality of swirl channels has a first section and a second section. The first section extends axially toward the swirl chamber and outward from the longitudinal axis at a first angle formed with the longitudinal axis. The second section intersects the swirl chamber and extends toward the longitudinal axis at a second angle formed with the longitudinal axis.

[0027] In one or more embodiments according to the fifth aspect, the first angle is less than 45°.

[0028] In one or more embodiments according to the fifth aspect, the second angle is in the range of 30° to 90°.

[0029] In one or more embodiments according to any of the aspects described herein, fluid communication is provided to directly pass from the inlet cavity through the plurality of swirl channels and into the swirl chamber without an intermediate feed chamber.

[0030] In one or more embodiments according to any of the aspects described herein, the tip body is formed at least in part by additive manufacturing.

[0031] In one or more embodiments of any of the embodiments described herein, the swirl chamber has a bottom plate and a side wall surrounding the bottom plate, and each outlet of the plurality of swirl channels is formed in the side wall.

[0032] Other embodiments, objects, and advantages of the present invention will become more apparent from the following detailed description in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The drawings incorporated in and forming a part of the specification illustrate several embodiments of the present invention and, together with the description, serve to explain the principles of the invention. In the drawings:

[0034] Figure 1A The tip of a fuel nozzle having a two-piece construction according to an exemplary embodiment is depicted;

[0035] Figure 1B The tip of a fuel nozzle having a one-piece construction according to an exemplary embodiment is depicted;

[0036] Figures 2A to 2C The tip of a fuel nozzle having a one-piece construction according to an exemplary embodiment is depicted, wherein six swirl channels wind around the longitudinal axis of the tip by about 90°;

[0037] Figures 3A to 3C The tip of a fuel nozzle having a two-piece construction according to an exemplary embodiment is depicted, wherein three swirl channels wind around the longitudinal axis of the tip by about 90°;

[0038] Figures 4A to 4C The tip of a fuel nozzle having a one-piece construction according to an exemplary embodiment is depicted, the one-piece construction having three inner swirl channels and three outer swirl channels that wind around the longitudinal axis of the tip by more than 90°;

[0039] Figures 5A to 5C The tip of a fuel nozzle having a one-piece construction according to an exemplary embodiment is depicted, which has three swirl channels that wind around the longitudinal axis of the tip by about 360°;

[0040] Figures 6A to 6C The tip of a fuel nozzle having a two-piece construction according to an exemplary embodiment is depicted, which has three swirl channels that wind around the longitudinal axis of the tip by about 180° and discharge into the swirl chamber at an angle of 30° to the tangent;

[0041] Figure 7 A cross-sectional view of a fuel nozzle having a one-piece construction according to an exemplary embodiment is depicted, which has a plurality of swirl channels that do not wind around the longitudinal axis of the tip; and

[0042] Figure 8 depicts a state-of-the-art tip of a fuel nozzle having a two-piece construction with an annular feed chamber.

[0043] Although the invention will be described in connection with certain preferred embodiments, it is not intended to be limited to those embodiments. On the contrary, it is intended to cover all alternatives, modifications, and equivalents included within the spirit and scope of the invention as defined by the appended claims. Detailed Description

[0044] Various embodiments of the present disclosure relate to tips for fuel nozzles without a feed chamber. The presently disclosed tips include a swirl passage that axially extends through the tip and outputs fuel having a tangential component into a swirl chamber. In one or more embodiments, the swirl passage radially rotates about the longitudinal axis of the tip as it axially extends. In one or more other embodiments, the swirl passage is angled outwardly away from the longitudinal axis and then angled inwardly toward the longitudinal axis as it axially extends through the tip. Such a swirl passage provides axial and tangential acceleration of the fuel within the tip, thereby allowing a tip configuration that avoids the use of an annular feed chamber. Additionally, as will be discussed below, the swirl passage can be formed as a tip having a one-piece or two-piece construction, particularly using additive manufacturing techniques. These and other solutions and advantages will be described more fully below in conjunction with the drawings. The presented embodiments are provided by way of illustration and not limitation.

[0045] Figure 1A depicts an embodiment of a tip 100 of a fuel nozzle. In Figure 1A the embodiment, the tip 100 is a two-piece construction having a tip body 102 and a swirl body 104. The tip body 102 includes a first wall 106 and a second wall 108. The first wall 106 extends between a first outer surface 110 and a first inner surface 112. The second wall 108 extends between a second outer surface 114 and a second inner surface 116. In an embodiment, the first outer surface 110, the first inner surface 112, the second outer surface 114, and the second inner surface 116 can be substantially planar or can have raised or recessed portions, such as a layered surface. For example, the second outer surface 114 is depicted as a layered surface having a raised central region.

[0046] The tip body 102 includes a first end 118 and a second end 120, and a longitudinal axis 122 extends through the first end 118 and the second end 120. The first wall 108 intersects the second wall 108 at the first end 118 of the tip body 100. As shown in FIG. 1, the second wall 108 can be perpendicular to the first wall 108. In one or more embodiments, the first wall 108 is a circumferential wall, and the second wall 110 is a top wall that covers the circumferential wall. In one or more embodiments, the tip body 102 is rotationally symmetric about the longitudinal axis 122. In such an embodiment, the tip body 102 can be cylindrical.

[0047] The first wall 106 and the second wall 108 define a first inner cavity 124 of the tip body 102. The swirl body 104 is disposed within the first inner cavity 124. A nozzle passage 126 is formed through the second wall 110 of the tip body 102. The nozzle passage 126 is in fluid communication with the first inner cavity 124. In Figure 1A the illustrated embodiment, the nozzle passage 126 extends from the second outer surface 114 toward the second inner surface 116.

[0048] The swirl body 104 includes a first portion 128, a second portion 130, and an intermediate portion 132. The intermediate portion 132 is disposed between the first portion 128 and the second portion 130. The intermediate portion 132 has a first side 134 and a second side 136, where the second side 136 is opposite the first side 134. The first portion 128 has a third wall 138 extending from the first side 134 of the intermediate portion 132, and the second portion 130 has a fourth wall 140 extending from the second side 136 of the intermediate portion 132. In particular, the third wall 138 extends from the intermediate portion 132 in a direction opposite to the fourth wall 140. The third wall 138 defines a second cavity 142 (also referred to as the "swirl chamber" 142), and the fourth wall 140 defines a third cavity 144 (or "inlet chamber 144"). Fluid communication is provided between the third cavity 144 and the second cavity 142 through a plurality of swirl channels 146 extending through the intermediate portion 132.

[0049] In particular, each swirl passage 146 has an opening 148 disposed on a second side 136 of the intermediate portion 132 and an outlet 150 disposed on a first side 134 of the intermediate portion 132. In one or more embodiments, the opening 148 may be formed through the inner surface of the fourth wall 140 or through the second side 136 of the intermediate portion 132. In one or more embodiments, the outlet 150 may be formed through the inner surface of the third wall 138 or through the first side 134 of the intermediate portion 132. In the depicted embodiment, between the opening 148 and the outlet 150 of each swirl passage 146, the swirl passage 146 extends longitudinally and is at least partially wound around the longitudinal axis 122. In one or more embodiments, a first flow area of the opening 148 is greater than a second flow area of the outlet 150. For example, the opening 148 may have a maximum cross-sectional dimension and / or cross-sectional area that is greater than the maximum cross-sectional dimension and / or cross-sectional area of the outlet 150. In one or more embodiments, the cross-sectional flow area of the swirl passage 146 tapers between the differently sized opening 148 and outlet 150. As described above, the swirl passage 146 axially accelerates the fuel flowing from the third chamber 144 to the second chamber 142, and in addition, the swirl passage 146 imparts a tangential component to the fuel flow. In particular, the outlet 150 that enters the second chamber 142 opens in such a way that at least a portion of the fuel flows tangentially to the circumference of the second chamber 142.

[0050] The swirl body 104 is inserted into the tip body 102. The third wall 138 of the first portion 128 of the swirl body 104 abuts the second inner surface 116 of the tip body 102. In addition, the outer surface of the swirl body 104 (at least in the first portion 128 and the intermediate portion 132) contacts the first inner surface 112 of the tip body 102. In this way, compared with some conventional designs, no fluid chamber is formed between the swirl passage 146 and the swirl chamber 142 immediately before the nozzle passage 126, and between the tip body 102 and the swirl body 104.

[0051] Fuel enters the second end 120 of the tip body 102 and enters the third chamber 144 of the swirl body 104. The fuel flows from the third chamber 144 through the swirl passage 146 and into the swirl chamber 142. The swirl chamber 142 is in fluid communication with the nozzle passage 126, and the fuel is ejected from the tip 100 through the nozzle passage 126. Due to the flow path defined by the swirl passage 146, the fuel enters the swirl passage 146 from the third chamber 144 substantially axially (i.e., in a direction within 30° parallel to the longitudinal axis 122), and (at least a portion of the fuel) leaves the swirl passage 146 and enters the swirl chamber 142 substantially tangentially to the circumferential wall of the swirl chamber 142. The strong tangential component provided by the swirl passage 146 helps to ensure an appropriate droplet size distribution during fuel spraying.

[0052] Figure 1B depicts an embodiment of a tip 100 of a fuel nozzle having a one-piece construction including only a tip body 102. As Figure 1B labeled therein, the tip body 102 includes many of the same features included in the Figure 1A embodiment. However, in the Figure 1B embodiment of the tip 100, a swirl body 104 is not provided to define a second chamber 142 and a third chamber 144. Instead, the tip body 102 includes an intermediate separator 152 that divides a first internal chamber 124 into a second chamber 142 (or swirl chamber 142) and a third chamber 144. A swirl passage 146 extends through the intermediate separator 152 to connect the third chamber 144 to the second chamber 142.

[0053] As with the previous embodiments, the swirl passage 146 can be configured such that fuel enters the third chamber 144 substantially axially and exits the swirl passage 146 into the second chamber 142 in a manner such that at least a portion of the fuel has a tangential component relative to the circumference of the second chamber 142. Additionally, as described above, the swirl passage 146 in the depicted embodiment extends longitudinally and at least partially winds around the longitudinal axis 122. Further, the flow area of the swirl passage 146 can taper between an opening 148 of a first flow area and an outlet 150 of a second flow area that is less than the first flow area.

[0054] Because Figure 1B the tip 100 is of a one-piece construction, there is no fluid chamber between the swirl passage and the nozzle passage 126 as compared to some conventional designs.

[0055] In operation, fuel enters the third chamber 144 through the second end 120 of the tip body 102, and the fuel flows from the third chamber 144 through the swirl passage 146 into the swirl chamber 142. The swirl chamber 142 is in fluid communication with the nozzle passage 126, and the fuel is ejected from the tip through the nozzle passage 126.

[0056] Figures 2A to 2C depicts an embodiment of a tip 100 (particularly the Figure 1B tip 100) having a one-piece construction including only a tip body 102. Figure 2A depicts a view of the flow path of the swirl passage 146 shown in dashed lines. In the depicted embodiment, there are six swirl passages 146, but the tip body 102 can include more or fewer swirl passages 146. As Figure 2B visible therein, the openings 148 are evenly spaced around the perimeter of the third chamber 144; however, in other embodiments, the openings 148 need not be evenly spaced around the perimeter of the third chamber 144. Additionally, as Figure 2BAs shown, the opening 148 of each swirl passage 146 is in a first angular position, and as Figure 2C shown, the corresponding outlet 150 of the swirl passage 146 is in a second angular position. Regarding Figure 2B and Figure 2C , the first angular position of each opening 148 is represented by θ A1 , θ B1 ,... θ F1 , and the second angular position of each corresponding outlet 150 is represented by θ A2 , θ B2 , … θ F2 . In one or more embodiments, the second angular position is rotated 60° to 120°, particularly 75° to 105°, from the first angular position. In the Figures 2A to 2C shown embodiment, the outlet 150 of each swirl passage 146 is rotated approximately 90° relative to the corresponding opening 148 of the swirl passage 146. As visible in Figure 2C , the outlet 150 intersects the wall of the swirl chamber 142 in such a way as to introduce a tangential component to at least a portion of the fuel entering the swirl chamber 142.

[0057] Figures 3A to 3C depicts an embodiment having a tip 100 with a two-piece construction including a tip body 102 and a swirl body 104 (particularly similar to the tip 100 of the embodiment depicted in Figure 1A ). Figure 3A depicts a partial cross-sectional view of the tip 100, in which the swirl passages 146 are shown in dashed lines. As visible in Figure 3B , the depicted embodiment has three swirl passages 146, but in one or more other embodiments, the swirl body 104 may include more or fewer swirl passages 146. Additionally, in the depicted embodiment, the openings 148 are evenly spaced around the perimeter of the third chamber 144; however, in other embodiments, the openings 148 need not be evenly spaced around the perimeter of the third chamber 144. As Figure 3B shown, the opening 148 of each swirl passage 146 is in a first angular position, and as Figure 3C shown, the corresponding outlet 150 of the swirl passage 146 is in a second angular position. Regarding Figure 3B and Figure 3C , the first angular position of each opening 148 is represented by θ A1 , θ B1 , θ C1 , and the second angular position of each corresponding outlet 150 is represented by θ A2 , θ B2 , θ C2 . In one or more embodiments, the second angular position is rotated 60° to 120°, particularly 75° to 105°, from the first angular position. In the Figures 3A to 3CIn the illustrated embodiment, the outlet 150 of each swirl passage 146 is rotated approximately 90° relative to the corresponding opening 148 of the swirl passage 146. Further, as visible in Figure 3C the outlet 150 intersects the wall of the swirl chamber 142 in a manner that introduces a tangential component to at least a portion of the fuel entering the swirl chamber 142.

[0058] Figures 4A to 4C Another embodiment depicts a tip 100 having a one-piece construction that includes only the tip body 102. In Figures 4A to 4C the illustrated embodiment, an inner swirl passage 146a and an outer swirl passage 146b are formed in the tip body 102. As visible in Figure 4A the inner swirl passage 146a has an opening 148 that opens from the third chamber 144 and an outlet 150 that leads to the second chamber 142. In one or more embodiments including the depicted embodiment, an intermediate separator 152 defines a recess that has a first surface 154 at the end of the third chamber 144. In one or more such embodiments, the opening 148a of the inner swirl passage 146a opens through the first surface 154 of the recess. Further, in one or more embodiments including the depicted embodiment, the intermediate separator 152 defines a protrusion that has a second surface 156 at the end of the second chamber 142. The outlet 150a of the inner swirl passage 146a opens through the second surface 156 of the protrusion. Although Figure 4A the first surface 154 is depicted as a conical surface and the second surface 156 is depicted as a frustoconical surface, either surface shape may be formed on the intermediate separator 152, and other surface shapes may also be formed, such as cylindrical, rectangular, cubic, hemispherical, pyramidal, and tetrahedral, etc.

[0059] As Figure 4A visible, a fifth wall 158 extends from the intermediate separator 152 and the fifth wall 158 is radially inserted from the first inner surface 112 of the first wall 106. In this way, the intermediate separator 152, the fifth wall 158, and the first inner surface 112 define a fourth chamber 160 surrounding the third chamber 144. The outer swirl passage 146b provides fluid communication between the fourth chamber 160 and the second chamber 142. The outer swirl passage 146b has an opening 148b and an outlet 150b, the opening 148b opens through the intermediate separator 152 into the fourth chamber 160, and the outlet 150b leads to the second chamber 142. As visible in Figure 4C the outlet 150b intersects the wall of the swirl chamber 142 in a manner that introduces a tangential component to at least a portion of the fluid entering the swirl chamber 142.

[0060] As Figure 4B and 4CAs shown, the tip body 102 includes three inner swirl channels 146a and three outer swirl channels 146b. However, in other embodiments, the tip body 102 may include more or fewer inner swirl channels 146a and outer swirl channels 146b, and / or the tip body 102 may include different numbers of inner swirl channels 146a and outer swirl channels 146b (e.g., may include more outer swirl channels 146b than inner swirl channels 146a).

[0061] In addition, as Figure 4B shown, the opening 148a of each inner swirl channel 146a is at a first angular position, and as Figure 4C shown, the corresponding outlet 150a of the inner swirl channel 146a is at a second angular position. With respect to Figure 4B and Figure 4C , the first angular position of each opening 148a is represented by θ A1 , θ B1 , θ C1 , and the second angular position of each corresponding outlet 150a is represented by θ A2 , θ B2 , θ C2 . In one or more embodiments, the second angular position is rotated from the first angular position by at least 90°, at least 135°, at least 180°, at least 225°, or at least 270°. In one or more embodiments, the second angular position is rotated from the first angular position by up to 360°. In the Figures 4A to 4C shown embodiment, the outlet 150a of each inner swirl channel 146a is rotated approximately 270° relative to the corresponding opening 148a of the inner swirl channel 146a.

[0062] Also as Figure 4B shown, the opening 148b of each outer swirl channel 146b is at a first angular position, and as Figure 4C shown, the corresponding outlet 150b of the outer swirl channel 146b is at a second angular position. With respect to Figure 4B and Figure 4C , the first angular position of each opening 148b is represented by θ D1 , θ E1 , θ F1 , and the second angular position of each corresponding outlet 150b is represented by θ D2 , θ E2 , θ F2 . In one or more embodiments, the second angular position is rotated from the first angular position by at least 90°, at least 135°, at least 180°, at least 225°, or at least 270°. In one or more embodiments, the second angular position is rotated from the first angular position by up to 360°. In the Figures 4A to 4CIn the illustrated embodiment, the outlet 150b of each outer swirl passage 146b is rotated approximately 360° relative to the corresponding opening 148b of the outer swirl passage 146b.

[0063] In one or more embodiments, the inner swirl passage 146a and the outer swirl passage 146b are connected to different manifolds. In one or more embodiments, the inner swirl passage 146a and the outer swirl passage 146b convey the same or different fluids. For example, the inner swirl passage 146a may be connected to a primary fuel manifold, e.g., for engine ignition and low flow conditions, and the outer swirl passage 146b may be connected to a secondary fuel manifold, e.g., for high flow (i.e., high power) conditions. In this way, during engine operation, flow can be provided to either or both of the inner swirl passage 146a and the outer swirl passage 146b. In another exemplary embodiment, one of the inner swirl passage 146a or the outer swirl passage 146b is connected to a fuel manifold, and the other of the inner swirl passage 146a or the outer swirl passage 146b is connected to a manifold that provides air or water.

[0064] Figures 5A to 5C Another embodiment of the tip 100 having a one-piece construction including only the tip body 102 is depicted. Figure 5A A view of the flow path of the swirl passage 146 shown in dashed lines is depicted. In the depicted embodiment, there are three swirl passages 146, but the tip body 102 may include more or fewer swirl passages 146. As Figure 5B can be seen, the openings 148 are evenly spaced around the perimeter of the third chamber 144; however, in other embodiments, the openings 148 need not be evenly spaced around the perimeter of the third chamber 144. Additionally, as Figure 5B shown, the opening 148 of each swirl passage 146 is in a first angular position, and as Figure 5C shown, the corresponding outlet 150 of the swirl passage 146 is in a second angular position. With respect to Figure 5B and Figure 5C , the first angular position of each opening 148 is represented by θ A1 , θ B1 , θ C1 , and the second angular position of each corresponding outlet 150 is represented by θ A2 , θ B2 , θ C2 . In one or more embodiments, the second angular position is rotated approximately 360° from the first angular position, e.g., 330° to 390°. Thus, each swirl passage 146 forms a complete helical loop around the longitudinal axis 122. As can be seen in Figure 5C , the outlet 150 intersects the wall of the swirl chamber 142 in such a way as to introduce a tangential component to at least a portion of the fuel entering the swirl chamber 142.

[0065] In each of the foregoing embodiments, the outlet 150 of each swirl passage (or the outlets 150a, 150b of the inner swirl passage 146a and the outer swirl passage 146b) is substantially tangent to the cross-sectional plane of the swirl chamber 142 that is perpendicular to the longitudinal axis 122. That is, as the swirl passage 146 leads into the swirl chamber 142, the path of the swirl passage 146 flattens as it winds around the longitudinal axis 122. In this regard, in an embodiment, as the swirl passage 146 traverses between the opening 148 and the outlet 150, the rate of rotation of the swirl passage 146 about the longitudinal axis 122 increases. As shown in the foregoing figures, this is consistent with the decrease in the flow area within the swirl passage 146. Thus, as described above, the flow rate increases and a strong tangential component of the flow is provided, which helps to form a desired droplet size distribution in the nozzle spray.

[0066] However, in one or more other embodiments, the swirl passage 146 leads into the swirl chamber 142 at an angle transverse to the cross-sectional plane. Figures 6A to 6C An embodiment depicting a tip 100 having a two-piece construction is shown, the two-piece construction having a tip body 102 and a swirl body 104. As Figure 6A can be seen, the swirl passage 146 is oriented at an angle α with respect to the cross-sectional plane 162 that is perpendicular to the longitudinal axis 122. For the previously described embodiments, the swirl passage 146 leads into the swirl chamber 142 at an angle α of approximately 0°. In one or more embodiments including the Figures 6A to 6C embodiment shown, the angle α at which the swirl passage 146 leads into the swirl chamber 142 is less than 45°, specifically in the range of 15° to 45°. In one or more embodiments including the depicted embodiment, the swirl passage 126 leads into the swirl chamber 142 at an angle α of approximately 30°.

[0067] In addition to the changed angle of the outlet leading into the swirl chamber 142, the swirl passage 146 can be as described in the previous embodiments. In particular, the swirl body 104 can include a plurality of swirl passages 146 that wind around the longitudinal axis 122 of the tip 100 from an opening 148 at a first angular position to an outlet 150 at a second angular position. As Figure 6B and 6CAs shown, the depicted embodiment includes three swirl channels having an opening 148 at a first angular position represented by θA1, θB1, θC1 and an outlet 150 at a second angular position represented by θA2, θB2, θC2. In one or more embodiments, the second angular position is rotated at least 90°, particularly at least 135°, from the first angular position. In one or more embodiments, the second angular position is rotated at most 360° from the first angular position. In the depicted embodiment, each second angular position is rotated approximately 180° from each respective first angular position.

[0068] Figure 7 An embodiment of the tip 100 is depicted where the swirl channels 146 do not wrap (or do not substantially wrap) around the longitudinal axis 122 of the tip 100. Instead, the swirl channels 146 are inclined outwardly from the longitudinal axis 122 and then inclined back inwardly toward the longitudinal axis 122. As Figure 7 shown, the swirl channels 146 having an opening 148 in fluid communication with the inlet chamber 144, and each swirl channel 146 includes a first section that extends axially toward the swirl chamber 142 and extends outwardly away from the longitudinal axis 122 at a first angle α1. Thereafter, a second section of each swirl channel 146 intersects the swirl chamber 142 such that the outlet 150 of the swirl channel opens into the swirl chamber 142, particularly in a manner that introduces a tangential component into at least a portion of the fuel. Thus, the second section of the swirl channel 146 is inclined back inwardly toward the longitudinal axis 122 at a second angle α2 until the swirl channel 146. As Figure 7 shown, the flow area of the swirl channels 146 tapers from the opening 148 to the outlet 150. In one or more embodiments, the tip 100 includes two to eight swirl channels 146. In one or more embodiments, each swirl channel 146 extends outwardly away from the longitudinal axis 122 at a first angle α1 within a range below 45° (such as within a range of 10° to 45°) with respect to the longitudinal axis 122. In one or more embodiments, each swirl channel 146 extends inwardly toward the longitudinal axis 122 at a second angle α2 within a range of 30° to 90°. Additionally, although Figure 7 this embodiment of the swirl channels 146 that do not wrap around the longitudinal axis 122 is depicted as a one-piece construction, such swirl channels 146 can also be used in a two-piece construction as described herein.

[0069] The foregoing embodiments are merely exemplary and should not be considered restrictive. Generally, embodiments of the present disclosure relate to a tip 100 having a one-piece (single-piece) or two-piece construction, wherein fluid flows from a second end 120 to a first end 118 along a longitudinal axis 122. The fluid flows into the oral cavity 144, through a plurality of swirl channels 146, into a swirl chamber 142, and exits through a nozzle channel 126. The plurality of swirl channels 146 can be from two to eight swirl channels 146, particularly three to six swirl channels 146. In one or more embodiments, the swirl channels 146 are at least partially wound around the longitudinal axis 122 such that the outlet 150 rotates from the opening 148. In an embodiment, the outlet 150 rotates from the opening 148 by at least 60° and / or up to about 360°. Additionally, the swirl channels 146 open into the swirl chamber 142 at various angles α relative to a cross-sectional plane 162 perpendicular to the longitudinal axis 122, from substantially planar (i.e., an angle α below 10°, particularly about 0°) to an angle α of up to 45°.

[0070] In one or more other embodiments, the swirl channels 146 are substantially not wound around the longitudinal axis 122 (i.e., wound around the longitudinal axis 122 by less than 90°, particularly below 30°). In such embodiments, the swirl channels 146 extend axially towards the swirl chamber 142 and extend outwardly away from the longitudinal axis 122 at a first angle α1, and along the length of the swirl channels 146, the swirl channels 146 extend inwardly back towards the longitudinal axis 122 to form a second angle α2. Further, in any of the foregoing embodiments, the flow area of the swirl channels 146 can decrease from the opening 148 to the outlet 150.

[0071] Although the embodiments of the tip 100 described herein are described as being formed by additive manufacturing, particularly for the purpose of creating the complex geometries of the swirl channels 146, it should not be construed to imply that such embodiments are formed only by additive manufacturing techniques. For example, the tip 100 can be at least partially formed by additive manufacturing techniques and then completed using subtractive forming techniques (such as machining, drilling, grinding, boring, or cutting) as needed.

[0072] All references cited herein (including publications, patent applications, and patents) are incorporated herein by reference to the extent that each reference is individually and specifically indicated to be incorporated by reference and the full content thereof is set forth herein.

[0073] The terms "a", "an", and "the" and similar referents used in the context of describing the present invention (especially in the context of the following claims) shall be construed to cover both the singular and the plural unless otherwise indicated herein or clearly contradicted by the context. Unless otherwise indicated, the terms "comprising", "having", "including", and "containing" shall be construed as open-ended terms (i.e., meaning "including but not limited to"). Unless otherwise stated herein, the recitation of numerical ranges herein is merely intended to be a shorthand method of referring individually to each separate numerical value falling within the range, and each separate numerical value is incorporated into the specification as if it were individually recited herein. All methods described herein may be performed in any suitable order unless otherwise indicated herein or clearly contradicted by the context. Unless otherwise stated, the use of any and all examples or exemplary language (e.g., "such as") provided herein is merely intended to better illustrate the invention and does not limit the scope of the invention. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

[0074] Preferred embodiments of the invention are described herein, including the best mode known to the inventors for practicing the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations appropriately, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, the invention includes all modifications and equivalents of the subject matter recited in the appended claims as permitted by applicable law. In addition, unless otherwise indicated herein or clearly contradicted by the context, the invention covers any combination of the above elements in all possible variations thereof.

Claims

1. A tip for a fuel nozzle, comprising: A tip body having a first end and a second end, the second end being spatially arranged from the first end along a longitudinal axis of the tip body; A nozzle passage arranged at the first end; An inlet cavity arranged within the tip body; A swirl chamber arranged within the tip body; A plurality of swirl passages arranged within the tip body, the plurality of swirl passages connecting the inlet cavity and the swirl chamber, each of the swirl passages having an opening leading to the inlet cavity and an outlet entering the swirl chamber; Wherein fluid communication is provided from the second end to the first end such that fluid is configured to flow from the inlet cavity through the swirl passages, into the swirl chamber, and out through the nozzle passage.

2. The tip according to claim 1, wherein each swirl passage at least partially wraps around the longitudinal axis from each respective opening to each respective outlet, and wherein each swirl passage imparts a flow component tangential to the swirl chamber to at least a portion of the fluid flowing through the swirl passage.

3. The tip according to claim 2, wherein each of the plurality of swirl passages wraps around the longitudinal axis from 60° to 120°.

4. The tip according to claim 2, wherein each of the plurality of swirl passages wraps around the longitudinal axis by at least 330°.

5. The tip according to claim 1, wherein the tip has a one-piece construction, and the tip body includes an intermediate separator separating the inlet cavity from the swirl chamber, and wherein the plurality of swirl passages extend through the intermediate separator.

6. The tip according to claim 5, further comprising a wall extending from the intermediate separator towards the second end, the wall separating the inlet cavity into a first inlet cavity and a second inlet cavity, the second inlet cavity being arranged around the first inlet cavity, wherein the plurality of swirl passages include a first plurality of inner swirl passages and a second plurality of outer swirl passages, wherein the first plurality of inner swirl passages provide fluid communication between the first inlet cavity and the swirl chamber, and wherein the second plurality of outer swirl passages provide fluid communication between the second inlet cavity and the swirl chamber.

7. The tip according to claim 6, wherein the inner swirl passages wrap around the longitudinal axis from 180° to 360°.

8. The tip according to claim 6, wherein the outer swirl passages wrap around the longitudinal axis by at least 270°.

9. The tip according to claim 6, wherein the swirl chamber includes a bottom plate and a side wall surrounding the bottom plate, wherein the bottom plate includes a frustoconical surface, wherein each outlet of the first plurality of the inner swirl passages is formed to pass through the frustoconical surface of the bottom plate, and wherein each outlet of the second plurality of outer swirl passages is formed to pass through the side wall.

10. The tip according to claim 6, wherein the outer swirl passages are connected to a manifold different from the inner swirl passages.

11. The tip according to claim 2, wherein the plurality of swirl channels intersect the swirl chamber at an angle of less than 10° with respect to a cross-sectional plane perpendicular to the longitudinal axis.

12. The tip according to claim 2, wherein the plurality of swirl channels intersect the swirl chamber at an angle of 45° or less with respect to a transverse axis perpendicular to the longitudinal axis.

13. The tip according to claim 1, wherein each opening of the plurality of swirl channels has a first flow area, and each outlet of the plurality of swirl channels has a second flow area, and wherein the second flow area is less than the first flow area.

14. The tip according to claim 1, wherein the tip has a two-piece construction, and the tip further includes a swirl body disposed within the tip body, wherein the swirl body includes a first portion defining the swirl chamber, a second portion defining the inlet cavity, and an intermediate portion disposed between the first portion and the second portion, and wherein the plurality of swirl channels extend through the intermediate portion.

15. The tip according to claim 1, wherein each of the plurality of swirl channels includes a first section and a second section, the first section extending axially toward the swirl chamber and outwardly from the longitudinal axis at a first angle formed with the longitudinal axis, and the second section intersecting the swirl chamber and extending toward the longitudinal axis at a second angle formed with the longitudinal axis.

16. The tip according to claim 15, wherein the first angle is 45° or less.

17. The tip according to claim 15, wherein the second angle is in the range of 30° to 90°.

18. The tip according to claim 1, wherein fluid communication is provided to pass directly from the inlet cavity through the plurality of swirl channels and into the swirl chamber without an intermediate feed chamber.

19. The tip according to claim 1, wherein the tip body is formed at least in part by additive manufacturing.

20. The tip according to claim 1, wherein the swirl chamber includes a bottom plate and a side wall surrounding the bottom plate, and wherein each outlet of the plurality of swirl channels is formed in the side wall.

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