Spray tip with manufactured wear-simulating surface prefabricated prior to use

Abstract

A spray tip (1100) configured to atomize a fluid includes an inlet (1102), an outlet (1106) internal geometry (1109), the inlet (1102) being configured to receive a fluid, and a manufactured wear-simulating geometry (1115); the outlet (1106) defines an outlet of a spray tip; the inner geometry (1109) defines a path from the inlet toward the outlet.

Description

Background Technology

[0001] Fluid applicators, such as fluid jet guns, are commonly used in a variety of applications to apply fluids, such as coatings, to a surface. A fluid jet gun may include a jet tip for breaking up or atomizing the liquid material to deliver it in a desired spray pattern. The jet tip may have a selected geometry to provide the desired spray pattern. With continued use, the jet tip may wear down, and the geometry of the jet tip may change, which in turn can alter the spray characteristics of the jet tip.

[0002] While the examples described herein are in the context of applying fluids (in the form of coatings) to a surface, it should be understood that these concepts are not limited to these specific applications, and fluid jet guns (such as those described herein) can be operated to apply a variety of fluids. As used herein, coatings include substances consisting of coloring agents or pigments suspended in a liquid medium, as well as substances that do not contain coloring agents or pigments. Coatings may also contain a pre-coating (such as a primer) and can be opaque, transparent, or translucent. Some specific examples include, but are not limited to, latex paints, oil-based paints, dyes, varnishes, inks, etc.

[0003] The above discussion is provided for general background information only and is not intended to help determine the scope of the subject matter for which protection is sought. Summary of the Invention

[0004] The jet tip configured to atomize fluid includes: an inlet, an outlet, and an internal geometry; the inlet is configured to receive the fluid; the outlet defines the outlet of the jet tip; the internal geometry defines a path from the inlet toward the outlet; and fabricated wear-like geometry.

[0005] This "Summary" is provided to introduce, in a simplified form, the selection of concepts further described in the "Detailed Description" below. This "Summary" is not intended to identify key or essential features of the claimed subject matter, nor is it intended to aid in determining the scope of the claimed subject matter. The claimed subject matter is not limited to examples addressing any or all of the shortcomings mentioned in the "Background Art". Attached Figure Description

[0006] Figure 1 This is a perspective view showing an example fluid application system.

[0007] Figure 2 This is a side view showing an example fluid applicator.

[0008] Figure 3 This is a perspective view showing an example jet tip assembly.

[0009] Figure 4 This is a partial front view showing an example jet tip assembly.

[0010] Figure 5 This is a cross-sectional view showing an example jet tip assembly.

[0011] Figure 6 This is a cross-sectional view showing an example jet tip.

[0012] Figure 7 This is a cross-sectional view showing an example of an unfinished jet tip.

[0013] Figure 8 This is a top view showing an example jet tip with an outlet produced by grinding.

[0014] Figure 9 This is a top view showing an example jet tip with an outlet produced by laser ablation.

[0015] Figures 10A to 10B (Hereinafter referred to as Figure 10) is a cross-sectional view showing an example jet tip with a fabricated wear-like surface.

[0016] Figure 11 This is a cross-sectional view showing an example of an unfinished jet tip.

[0017] Figure 12 This is a cross-sectional view showing the spray tip of an example finished product.

[0018] Figure 13 This is a graphical view showing an example wear curve.

[0019] Figure 14 This is a flowchart illustrating an example manufacturing operation for producing a jet tip with one or more laser ablation structures.

[0020] Figure 15 This is a flowchart illustrating an example manufacturing operation for producing a jet tip with a wear-like surface.

[0021] Figure 16 This is a flowchart illustrating an example manufacturing operation for producing a jet tip with a wear-like surface.

[0022] Figure 17 This is a flowchart illustrating an example manufacturing operation for producing a jet tip with a wear-like surface. Detailed Implementation

[0023] For the purpose of facilitating an understanding of the principles of this disclosure, reference will now be made to the examples illustrated in the accompanying drawings, and these examples will be described using specific language. However, it should be understood that this is not intended to limit the scope of this disclosure. Any changes and further modifications to the described apparatus, systems, and methods, as well as any further application of the principles of this disclosure, should be fully contemplated, as would normally occur to those skilled in the art to which this disclosure pertains. In particular, it is fully contemplated that features, components, steps, or combinations thereof described with respect to one example may be combined with features, components, steps, or combinations thereof described with respect to other examples of this disclosure.

[0024] In some current systems, the jet tip (or tip element) is made of carbides (e.g., tungsten carbide). Compared to the wear characteristics of some other materials, carbides (e.g., tungsten carbide has a Mohs hardness of 9) provide better wear characteristics in high-pressure fluid application systems. In some current systems, the machining of carbides (e.g., grinding, etc.) is used in the production of the jet tip. For example, in some current systems, grinding is used to produce the jet tip exit. Typically, diamond tools (such as diamond grinding wheels) are used in the grinding of carbides to produce the exit. While this grinding can be used to form the exit, the geometry of such an exit is limited by the profile of the diamond tool used in the grinding.

[0025] The geometry of the jet tip exit affects the jet pattern and the operating parameters of the jetting system, such as the required flow rate and pressure. Furthermore, grinding with diamond tools leaves sharp edges that wear down more quickly. Once these sharp edges are worn away, the jet pattern and flow characteristics of the fluid are altered. For example, a worn jet tip will have a different jet pattern than intended (i.e., as manufactured) and will typically result in more fluid output at the same pressure. This wear necessitates adjustments to the jetting system by the operator or control system; otherwise, it will lead to errors. In some cases, even when adjustments can be made to compensate for wear, these adjustments are often reactive, and therefore, not all errors can be prevented.

[0026] This paper provides a system and method for utilizing laser ablation in the production of jet tips. Compared to grinding, laser ablation of jet tips allows for greater flexibility in the geometry of specific structures of the jet tip, such as the exit of the jet tip. Furthermore, jet tips produced by laser ablation do not require sharp edges (such as those produced by the grinding process described above), and therefore, jet tips produced by laser ablation will have better wear characteristics compared to jet tips produced by the grinding process described above.

[0027] Furthermore, while the use of robust materials (such as carbides, e.g., tungsten carbide) improves the wear characteristics of the injection tip compared to other types of materials, wear still occurs. Typically, known injection tips exhibit a non-linear wear profile. During the initial use cycle of a known injection tip (e.g., during the first (approximately) 25 gallons of fluid), the wear rate is higher than after the initial use cycle. This can be frustrating for the end user because the injection behavior of the tip changes with wear, and is most pronounced from the beginning to the end of the initial use cycle, requiring more frequent adjustments to the injection system (e.g., pressure setting adjustments, motor / pump speed adjustments, injection distance adjustments, etc.), or larger adjustments, or both. During this initial use cycle, the end user may need to make multiple adjustments during the course of a single job. In subsequent use cycles, the wear rate is lower, and the frequency or magnitude of adjustments, or both, are less than in the initial use cycle. Therefore, during subsequent use cycles, the end user can complete one or more jobs without having to make adjustments based on the changing injection characteristics of the tip.

[0028] This paper provides a system and method for manufacturing jet tips with a pre-fabricated simulated wear surface (or geometry) before use. The pre-fabricated wear-mimicking surface (or geometry) provides a geometry that matches or approximates a jet tip that has already undergone its initial service cycle. This provides a more linear wear profile for the manufactured (pre-fabricated) jet tip, thereby improving the end-user experience and reducing the frequency and magnitude of fluid application system adjustments. The manufactured wear-mimicking surface can be provided in various ways, such as by laser ablation, sandblasting, water erosion machining (or grinding), using molds or dies (in metallurgical manufacturing processes), or other methods.

[0029] As used in this article, “wear-simulated” means that the prefabricated wear-simulated surface (or wear-simulated geometry) is manufactured before the end user uses the spray tip (e.g., to spray paint or another fluid) and before the end user uses the wear.

[0030] Figure 1This is a perspective view illustrating an example fluid application system 1. The fluid application system 1 (schematically shown as an airless fluid jet system, e.g., a highly efficient airless jet system) includes a pump 2 mounted on a cart 4 and connected to an applicator 10 via a fluid delivery line 6 (e.g., a hose). The pump 2 includes a fluid inlet 8 disposed within a fluid source (e.g., a five-gallon paint can). The pump 2 pumps fluid from the fluid source through the fluid inlet 8 and delivers the fluid to the applicator 10 at a given pressure via the fluid delivery line 6. In one example, the pump 2 can pressurize the fluid to above 1500 PSI (e.g., between 1500 PSI and 3500 PSI).

[0031] Figure 2 This is a side view illustrating an example applicator 10. Applicator 10 is used in a fluid jetting system (e.g., fluid application system 1) to apply fluid to a surface (e.g., applying paint to a wall). Fluid enters through inlet 20 and exits through outlet 50 after passing through a fluid passage (not explicitly shown) within applicator 10. Fluid inlet 20 may be coupled to a fluid delivery line (such as fluid delivery line 6). Tip assembly 30 is coupled to applicator 10 and has outlet 50. Tip assembly 30 is typically reversible or removable from applicator 10.

[0032] Figure 3 This is a perspective view showing an example jet tip assembly 30. The jet tip assembly 30 includes a mark 32, a tip stem 34, and a receiving channel 36. The mark 32 can be coupled to the tip stem 34 in various ways, including (e.g., but not limited to) pressing the mark onto the tip stem 34, or overmolding the mark 32 onto the tip stem 34. The mark 32 provides a convenient surface for manipulating the jet tip assembly 30, particularly when the jet tip assembly 30 is mounted in an applicator, and can be used to indicate the directionality of the jet tip assembly 30. For example, as previously described, the tip assembly 30 is oriented from conventional operation (e.g., Figure 2 The orientation of the nozzle (as shown) to the cleaning operation can be reversible (e.g., capable of rotating about its longitudinal axis), in which the outlet of the nozzle tip faces away from the spray gun in the conventional operation orientation, and in which the outlet of the nozzle tip faces the spray gun in the cleaning operation orientation. The nozzle 32 can contain various materials (e.g., polymers). The nozzle stem 34 can contain various materials (e.g., metals such as stainless steel). A receiving channel 36 can be provided through the nozzle stem 34 (e.g., by machining, cutting, etc.). The receiving channel 36 extends a distance between the front and rear portions of the nozzle tip assembly 30. In some examples, the receiving channel 36 may extend from the front to the rear of the nozzle tip assembly 30; however, in other examples, the receiving channel 36 may extend some other distance.

[0033] Figure 4 This is a partial front view showing an example jet tip assembly 30. (See attached image.) Figure 4 As shown, a jet tip (or tip element) 100 (or another jet tip (or tip element), such as jet tip (or tip element) 1100 shown below) can be placed and held within the receiving channel 36. Various other components can be placed and held within the receiving channel of the jet tip assembly, as will be shown in more detail in the accompanying drawings below.

[0034] Figure 5 This is a cross-sectional view of the jet tip assembly 30. (See image.) Figure 5 As shown, the injection tip assembly 30 also includes a pre-orifice element 562, a sealing element 564, and a retaining ring 565, which are disposed together with and upstream of the injection tip 100 (or another injection tip, such as injection tip 1100) within the receiving channel 36. Furthermore, as... Figure 5 As shown, the receiving channel extends between exit 50 and entrance 55. Mark 32 is not shown. Figure 5 As shown in the image. It should be understood that... Figure 5 The example jet tip assembly 30 shown is merely one example. Other example jet tip assemblies, including jet tip 100 (or another jet tip such as jet tip 1100) are contemplated herein.

[0035] It should be understood that Figure 5 The example jet tip assembly 30 shown is merely one example. In other examples, the jet tip assembly may be... Figure 5 The examples shown are different. For example, in one example, the injection tip assembly may include a pre-orifice element as an integrated part of the tip stem body. Alternatively, it may not necessarily include retaining elements (such as 565 and shoulder). Figure 5 In this design, the jet tip is shown as abutting against the shoulder. Conversely, internal components of the jet tip assembly (e.g., the jet tip, sealing element, and one or more pre-orifice elements) may be held within the receiving channel in various other ways, such as friction fit, filler metal (e.g., brazing, solder, etc.), and others. Alternatively, the jet tip assembly may not include... Figure 5 Some of the components shown, for example, some example jet tip assemblies may not include a sealing element or a pre-orifice element, or both.

[0036] Figure 6 This is a cross-sectional view showing an example jet tip 100. (As shown in...) Figure 6As can be seen, the jet tip 100 includes an inlet 102, an internal geometry 104, and an outlet 106. The internal geometry 104 includes a dome 105, a path diameter 107, and may include other components(s) as shown. Fluid enters the jet tip 100 through the inlet 102 and exits the jet tip 100 through the outlet 106. Although in Figure 1 The given internal geometry 104 is shown, but it should be understood that in other examples, the jet tip 100 may include other internal geometries. For example... Figures 4 to 6 As shown, Exit 106 is sometimes referred to as the "cat's eye".

[0037] In some examples, Figure 6 The jet tip 100 shown may be an unfinished jet tip that is further processed to create a wear-like surface (or geometry).

[0038] Figure 7 This is a cross-sectional view showing an example unfinished jet tip 110 (jet tip blank). Figure 7 As shown, the unfinished jet tip 110 includes an inlet 102 and an internal geometry 104, but does not include an outlet (such as outlet 106). The unfinished jet tip 110 can be produced by pressing carbide powder (e.g., tungsten carbide powder). Typically, the carbide powder is placed (e.g., poured) into a press chamber (e.g., a die), and then a punch (or press) is positioned in the press chamber and the powder is compressed to form the unfinished jet tip 110. Once the powder is completely pressed, the punch is withdrawn from the chamber. The formed unfinished jet tip 110 can then be removed from the press chamber. In some current systems, the unfinished jet tip 110 is then ground with a diamond grinding wheel to cut an outlet in the unfinished jet tip 110 as part of the production of the finished jet tip.

[0039] Figure 8 This is a top view showing an example of a jet tip 1000. (As shown in...) Figure 8As can be seen, the jet tip 1000 is conical. The jet tip 1000 is produced by grinding the unfinished jet tip 110 at approximately its center (or the top of the conical body) to form an outlet 1006. The outlet 1006 is a "cat's eye" outlet. It can be seen that the grinding process creates traces 1010 in the portion of the jet tip 1000 surrounding the outlet 1006. These traces 1010 represent the path of the grinding wheel and also indicate any additional material removed by the grinding wheel. The grinding process further produces a sharp edge 1008 for the outlet 1006. Additionally, it can be seen that the outlet 1006 has a geometry corresponding to and is constrained by the cross-section of the grinding wheel used to produce the outlet 1006.

[0040] Figure 9 This is a top view of the jet tip 100. In one example, the jet tip 100 is produced by laser ablation of the unfinished jet tip 110 to form the exit 106. It can be seen that the jet tip 100 does not have a mark similar to the mark 1010 of the jet tip 1000. Furthermore, the exit 106 does not have a sharp edge similar to the sharp edge 1008 of the exit 1006. Instead, in Figure 9 In the example shown, outlet 106 has a greater curvature than outlet 1006. Outlets formed by laser ablation are not geometrically restricted, unlike outlets formed by grinding. Laser ablation allows for greater flexibility regarding the geometry of the outlet compared to the geometries allowed by grinding. For example, in… Figure 9 Beyond the examples shown, various geometries can be selected and produced using laser ablation, which is impossible with grinding. For instance, various arbitrary additional exit features can be provided through laser ablation. Geometries with different angles can be provided by changing the tilt angle of the laser. Furthermore, laser ablation can be used to form shapes different from those shown. Figure 9 The cat's eye shaped exit is shown.

[0041] Additionally, it should be noted that in some cases, the grinding process may cause minute parts to detach from the sharp edge of the outlet 1006. This can lead to unexpected and undesirable hydrodynamics (e.g., unexpected and undesirable jetting patterns), or may require the complete scrapping of the jetting tip 1000. Laser ablation has zero cutting force and is therefore less likely to cause minute parts to detach from the edge of the outlet 106. Consequently, laser ablation results in less waste and more consistent production of the jetting tip as desired.

[0042] Furthermore, during the formation of the outlet, the laser can strike the jet tip from the upstream end of the jet tip, or from the downstream end of the jet tip, or both.

[0043] Figures 10A to 10B (Collected herein referred to herein as Figure 10) is a cross-sectional view showing an example jet tip 1100. As can be seen in Figure 10, the jet tip 1100 includes an inlet 1102, an internal geometry 1104, an outlet 1106, and a wear-simulating surface (or wear-simulating geometry feature) 1115. The internal geometry 1104 itself includes a dome 1105 and a path diameter 1107, and also includes other components, as shown. The jet tip 1100 can be manufactured in a variety of ways.

[0044] For example, an unfinished jet tip can be ground or laser-ablated (such as unfinished jet tip 110) to form an outlet 1106. The wear-like surface 1115 can then be formed by laser ablation, sandblasting, water erosion machining (or grinding), or other methods. In another example, an unfinished jet tip (such as an example where jet tip 100 is an unfinished jet tip) can be generated (e.g., by pressing), and the wear-like surface 1115 can then be formed by laser ablation, sandblasting, water erosion machining (or grinding), or other methods.

[0045] In another example, the jet tip 1100 can be produced by pressing as described above (e.g., pressing carbide powder, such as tungsten carbide powder).

[0046] In one example, the jet tip 1100, manufactured by pressing, may include an outlet 1006 and an abrasion-simulating surface 1115. Thus, in one example, as shown in FIG10, the jet tip 1100 can be formed entirely by pressing. In this example, the die may include the geometry used to form the abrasion-simulating surface 1115 (and other features of the jet tip 1100).

[0047] In another example, the jet tip 1100, manufactured by pressing, may include an outlet 1006 (and other components of the jet tip 1100), but not the wear-resistant surface 1115. Figure 11 An example is shown. In this example, the wear-like surface 1115 can be formed by laser ablation, sandblasting, water erosion machining (or grinding) or other methods. In the case of laser ablation, the laser can be struck onto the jet tip 1100 from the upstream end (i.e., the end including the inlet 1102) opposite to the downstream end (i.e., the end including the outlet 1106).

[0048] Laser ablation may be superior to sandblasting, water erosion machining (or grinding), and other manufacturing techniques used to produce simulated wear surfaces 1115 because laser ablation allows for more precise control and is therefore less prone to errors.

[0049] As can be seen, the wear-simulating surface 1115 is a geometric feature of the interior of the injection tip 1100. The wear-simulating surface 1115 extends around the inner circumference 1117 of the outlet 1106 (opposite to the outer circumference 1119 of the outlet 1106) and extends radially away from the inner circumference 1117 of the outlet 1106 in multiple directions. The wear-simulating surface 1115 extends between the inner circumference 1117 of the outlet 1106 and the dome 1105. It can be seen that the wear-simulating surface 1115 has a varying width (the distance from the inner circumference 1117 of the wear-simulating surface 1115 to the circumference 1121). It can be seen that the wear-simulating surface 1115 is generally thinner or narrower (i.e., has a smaller width) at the corners of the outlet 1106 (e.g., at each corner of the cat's-eye outlet) compared to its width at other parts of the inner circumference 1117 of the outlet 1106 (such as the width at the middle of the inner circumference 1117 of the outlet 1106). Therefore, the wear-simulating surface 1115 is asymmetrical and cannot be produced by machining tools (such as large equipment). It can also be seen that the wear-simulating surface 1115 has a slope that causes the circumference 1121 to be offset from the inner circumference 1117 (e.g., laterally). Furthermore, it can be seen that the area of ​​the wear-simulating surface 1115 is smaller than the area of ​​the dome 1105.

[0050] Figure 11 This is a cross-sectional view showing an exemplary unfinished jet tip 1110. (See attached image.) Figure 11 As shown, the unfinished jet tip 1110 includes an inlet 1102, an internal geometry 1104, and an outlet 1106, but does not include the wear-simulating surface 1115. The unfinished jet tip 1110 can be produced by a pressing process (such as a pressing process using carbide powder, e.g., tungsten carbide powder). Typically, carbide powder is placed (e.g., poured) into a press chamber (e.g., a die), then a punch (or press) is positioned in the press chamber and the powder is compressed to form a compact of the unfinished jet tip 1110. Once the powder is completely compressed, the punch is withdrawn from the chamber. The compact formed of the unfinished jet tip 1110 can then be removed from the press chamber and sintered to form the shaped unfinished jet tip 1110. The unfinished jet tip 1110 can then be further processed to form a wear-like surface 1115 (e.g., by laser ablation, water erosion machining (or grinding), sandblasting, etc.) and to generate the jet tip 1100.

[0051] Figure 12 This is a cross-sectional view showing an example jet tip 1100. (See example...) Figure 12 As shown, the finished product's jet tip 1100 includes an inlet 1102, an internal geometry 1104, an outlet 1106, and a wear-simulating surface 1115.

[0052] Figure 13 This is a graphical illustration of an example wear profile 500. Wear profile 500 includes a Y-axis 502, an X-axis 504, lines 506 and 508, portions 510 and 512, line 514, and line 516. Y-axis 502 plots the tip orifice size in inches (thousandths of an inch). X-axis 504 plots the amount of fluid (e.g., paint) ejected through the jet tip in gallons. Therefore, the wear profile (or wear rate) typically tracks the change in tip orifice size as the volume of ejected fluid changes, or in other words, the change (e.g., increase) in tip orifice size per unit volume. Line 506 shows the projected wear profile of the jet tip, and thus its projected wear rate, excluding factory-made wear-simulating surfaces (such as the manufactured wear-simulating surface 1115). It can be seen that the projected wear profile indicated by line 506 is typically non-linear (or at least less linear than the wear profile indicated by line 508). Furthermore, it can be seen that the projected wear curve indicated by line 506 includes a first portion 510 corresponding to the initial use cycle. The initial use cycle is indicated by line 514 and is approximately the cycle in which the end user sprays the first 25 gallons of material through the spray tip corresponding to line 506. Additionally, it can be seen that line 506 includes a second portion corresponding to subsequent use cycles after the initial use cycle. While Figure 13 The example shown is extended to only one hundred gallons, but it should be understood that this is for illustrative purposes only. It should be understood that the use of the jet tip can exceed one hundred gallons.

[0053] Line 508 shows the expected wear profile of the jet tip, and thus the expected wear rate of the jet tip, which includes a factory-designed wear-simulating surface (such as the manufactured wear-simulating surface 1115). It can be seen that the jet tip corresponding to line 506 wears faster than the jet tip corresponding to line 508, especially during the initial use phase (e.g., the first 25 gallons). It can be seen that after the initial use phase, the expected wear rate of the jet tip corresponding to line 506 flattens out (becomes more linear). It can be seen that the expected wear rate of the jet tip corresponding to line 508 is approximately linear during its use. Therefore, the wear profile indicated by line 508 is more linear than the wear profile indicated by line 506, and thus, the manufactured jet tip with a factory-designed wear-simulating surface (such as the manufactured wear-simulating surface 1115) has a more linear wear profile than a jet tip without a factory-designed wear-simulating surface (such as the manufactured wear-simulating surface 1115).

[0054] It should be understood that, with reference to the expected wear profile or expected wear rate, the term "expected" is used to indicate that it is an estimated wear profile or expected wear rate at the time of manufacture and before the end user uses or operates it.

[0055] Figure 14 This is a flowchart illustrating an example of the fabrication of an ejector tip according to one embodiment. Method 900 begins at block 902, where an unfinished ejector tip (such as unfinished ejector tip 110) is placed in a laser ablation environment. Typically, the laser ablation environment includes a laser ablation system (e.g., a laser and associated components), a housing, and a platform on which the unfinished ejector tip 110 is placed and secured. One example laser ablation system is sold by TRUMPF Corporation of Farmington, CT, under the trade name TruLaser Cell 3000. Another example laser ablation system may be manufactured by Precision MicroFab LLC of Curtis Bay, MD.

[0056] At box 904, design data is provided to the laser ablation system. The design data defines (or describes) the dimensions of the unfinished jet tip and the finished jet tip, as indicated in box 906. It should be understood that the dimensional information defines (or describes) not only the size of the individual components of the jet tip, but also their position on the jet tip or their position relative to other components of the jet tip. The design data further defines (or describes) the geometry of the unfinished jet tip and the geometry of the finished jet tip, including the internal geometry (e.g., 104) and the geometry of the exit (e.g., 106), as indicated in box 908. The design data may also define (or describe) various other information, as indicated in box 909.

[0057] At box 910, the laser ablation system is controlled based on design data to laser ablate the unfinished jet tip and remove material from the unfinished jet tip to generate a structure for the jet tip. This structure may include an outlet (such as outlet 106), as indicated in box 912. Alternatively, the structure may include various other components (such as other holes, apertures, or geometries), as shown in box 913. At box 910, the position of the laser pulse generated by the laser ablation system, the tilt angle of the laser pulse, the intensity of the laser pulse, the duration of the laser pulse, and the duration of the laser pulse at a given position, as well as other operating parameters of the laser or laser ablation system, can be controlled based on design data.

[0058] At frame 914, the jet tip with the laser ablation structure is removed from the laser ablation environment.

[0059] It should be noted that the jet tip may be further processed before or after the production of one or more structures by laser ablation.

[0060] Figure 15 This is a flowchart illustrating an example of the manufacture of an injection tip according to one embodiment. Manufacturing method 600 begins at block 602, where an unfinished injection tip is formed. In one example, forming the unfinished injection tip may include a pressing process, as indicated by block 604. For example, carbide powder (e.g., tungsten carbide powder) may be provided and placed into a press cavity (e.g., a die, etc.), after which a punch (or press or stamping head) is positioned in the press cavity to compress the powder to form a compact of the unfinished injection tip. The compact of the unfinished injection tip may then be sintered to form the unfinished injection tip. The unfinished injection tip may be formed in various other ways, as indicated by block 604.

[0061] As previously described, the unfinished jet tip formed at box 602 may include various features, including an inlet (e.g., 1102, etc.), internal geometry (e.g., 1104, etc.), and an outlet (e.g., 1106, etc.). In some examples, the unfinished jet tip formed at box 602 does indeed include an outlet (as shown in box 608), in which case method 600 proceeds to box 620. In some examples, the unfinished jet tip formed at box 602 does not include an outlet (as shown in box 610), in which case method 600 proceeds to box 612.

[0062] At box 612, an exit (e.g., 1106, etc.) is formed in the jet tip of the unfinished product from box 610. In one example, the exit is formed by grinding, as shown in box 614. Grinding may include grinding with a grinding wheel (e.g., a diamond grinding wheel) to cut the exit into the jet tip of the unfinished product. In one example, the exit is formed by laser ablation, as shown in box 616. Figure 14 The image depicts an example of forming an exit by laser ablation. Exits can be formed in various other ways in the jet tip of the unfinished product, as indicated in box 618.

[0063] Method 600 proceeds from box 608 or box 612 to box 620. At box 620, a wear-simulating surface (or geometry), such as wear-simulating surface (or geometry) 1115, is formed by removing material from the provided unfinished spray tip.

[0064] In one example, the simulated wear surface (or geometry) is formed by laser ablation, as indicated by box 622. This can include: applying laser ablation to a laser ablation system (such as...) Figure 14The laser ablation system described herein provides an unfinished jet tip and controls the laser ablation system to laser ablate the unfinished jet tip and remove material from the unfinished jet tip to generate a wear-like surface (or geometry). Design data describing the dimensions and geometry of the wear-like surface (or geometry) can be provided to the laser ablation system for controlling the laser ablation system to generate the wear-like surface (or geometry).

[0065] In one example, the simulated wear surface (or geometry) is formed by water erosion machining (or grinding), as indicated by box 624. This can include pumping an abrasive fluid under pressure, causing it to impact and pass through the internal geometry and outlet of an unfinished jet tip. The abrasive fluid is a slurry mixture containing a carrier (e.g., an oil or aqueous medium) and finely distributed abrasive particles within the carrier. Therefore, the abrasive fluid is a suspension. The abrasive fluid differs from the fluid ejected by the end user through the jet tip.

[0066] In one example, the simulated abrasion surface (or geometry) is formed by blasting, as indicated by box 626. This can include the forced propulsion (e.g., with pressurized (e.g., compressed) air) of abrasive solid particles, causing them to impact and pass through the internal geometry and exit of the unfinished jet tip. The abrasive solid particles are distinct from the fluid ejected by the end user through the jet tip.

[0067] Wear-like surfaces (or geometric features) can be formed in various other ways, as indicated in box 628.

[0068] The treatment at box 620 results in the finished spray tip having a wear-resistant surface (or geometry) pre-fabricated (before use by the end user) and manufactured (formed during the manufacturing process), such as wear-resistant surface (or geometry) 1115, as well as other components (e.g., inlet, outlet, internal geometry, etc.), as indicated by box 630.

[0069] Figure 16 This is a flowchart illustrating an example of the manufacture of a jet tip according to one embodiment. Manufacturing method 700 describes a pressing process. Manufacturing method 700 begins at block 702, where a mold having a structure and geometry is formed and provided to produce a jet tip having a wear-simulating surface (or geometry) (such as wear-simulating surface (or geometry) 1115) and other components (e.g., inlet, outlet, internal geometry, etc.).

[0070] At frame 704, carbide (e.g., tungsten carbide) powder is placed (e.g., poured) into a mold from frame 702.

[0071] At frame 706, the powder in the mold is compressed using a punch (also known as a press or stamping head).

[0072] At frame 708, another punch (or press or stamping head) removes the compressed powder (also known as the compact) from the die. Typically, the punch (or press or stamping head) in frame 706 is a top punch, while the punch (or press or stamping head) in frame 708 is a bottom punch.

[0073] At frame 710, compressed powder (or compact) undergoes a sintering process to form an injection tip of the finished product, which has a wear-simulating surface (or geometry) (such as wear-simulating surface (or geometry) 1115) and other components (such as an inlet (e.g., 1102, etc.), an outlet (e.g., 1106), an internal geometry (e.g., 1104), and other components in some examples).

[0074] Those skilled in the art will understand that, Figure 16 The powder pressing metallurgical manufacturing method described herein may include additional steps and various sub-steps of the described steps.

[0075] Figure 17 This is a flowchart illustrating an example of the manufacture of a jet tip according to one embodiment. The manufacturing method 800 begins at block 802, where an unfinished jet tip is formed. At block 800, the unfinished jet tip does not include a manufactured wear-simulating surface (such as manufactured wear-simulating surface 1115). At block 800, the unfinished jet tip has a corresponding non-linear expected wear curve (or expected wear rate). This corresponding expected wear curve (or expected wear rate) can be or may be similar to that of... Figure 13 The expected wear curve (or expected wear rate) is represented by line 506. The corresponding expected wear curve (or expected wear rate) has a first portion (e.g., such as first portion 510 or another similar first portion) that corresponds to an initial usage cycle (e.g., such as the initial usage cycle represented by line 514 or another initial usage cycle). The corresponding expected wear curve (or expected wear rate) has a second portion (e.g., such as second portion 512 or another similar second portion) that corresponds to subsequent usage cycles (e.g., such as the subsequent usage cycle represented by line 516 or another subsequent usage cycle). The second portion is more linear than the first portion.

[0076] In one example, as indicated by box 804, forming an unfinished jet tip may include pressing and sintering to produce an unfinished jet tip including an inlet (e.g., 1102, etc.), an internal geometry (e.g., 1104, etc.), an outlet (e.g., 1106, etc.), and other components. For example, a press chamber (e.g., a mold, etc.) with a geometry for producing the inlet, outlet, and internal geometry can be provided. Carbide powder (e.g., tungsten carbide powder) can be provided and placed into the press chamber (e.g., a mold, etc.), and then a punch (or press or stamping head) can be positioned in the press chamber to compress the powder to form a compact with an inlet, outlet, and internal geometry. The compact is then removed from the press chamber, for example, by another punch (or press or stamping head). The compact is then sintered to obtain an unfinished jet tip including the inlet, internal geometry, and outlet.

[0077] In another example, as indicated by box 806, forming an unfinished jet tip may include pressing and sintering to produce a jet tip blank including an inlet (e.g., 1102, etc.) and an internal geometry (e.g., 1104), as well as other components. For example, a press cavity (e.g., a mold, etc.) may be provided, having a geometry to produce the inlet and internal geometry. Carbide powder (e.g., tungsten carbide powder) may be provided and placed into a press cavity (e.g., a mold, etc.), and then a punch (or press or stamping head) may be positioned in the press cavity to compress the powder to form a compact with an inlet and an internal geometry. The compact may then be removed from the press cavity, for example by another punch (or press or stamping head). The compact is then sintered to obtain a jet tip blank including an inlet and an outlet. The jet tip blank is then further processed to produce an outlet (e.g., 1106, etc.), thereby forming an unfinished jet tip with an inlet, an internal geometry, and an outlet. Processing the jetting tip blank to form an outlet may include: grinding the jetting tip blank to form an outlet, laser melting the jetting tip blank to form an outlet, or another processing method.

[0078] As indicated in box 808, the formation of the unfinished jet tip can be accomplished in a variety of other ways.

[0079] Method 800 proceeds to frame 810. At frame 810, a wear-simulating surface (or geometry), such as wear-simulating surface (or geometry) 1115, is formed by removing material from the provided unfinished spray tip.

[0080] In one example, the simulated wear surface (or geometry) is formed by laser ablation, as indicated by box 812. This can include applying laser ablation to a laser ablation system (such as...) Figure 14The laser ablation system described herein provides an unfinished jet tip and controls the laser ablation system to laser ablate the unfinished jet tip and remove material from the unfinished jet tip to generate a wear-like surface (or geometry). Design data describing the dimensions and geometry of the wear-like surface (or geometry) can be provided to the laser ablation system for controlling the laser ablation system to generate the wear-like surface (or geometry).

[0081] In one example, the simulated wear surface (or geometry) is formed by water erosion machining (or grinding), as indicated by box 814. This can include pumping an abrasive fluid under pressure, causing it to impact and pass through the internal geometry of the unfinished jet tip and outlet. The abrasive fluid is a slurry mixture containing a carrier (e.g., an oil or aqueous medium) and finely distributed abrasive particles within the carrier. Therefore, the abrasive fluid is a suspension. Abrasive fluid differs from fluids ejected by an end user through a jet tip.

[0082] In one example, the simulated wear surface (or geometry) is formed by blasting, as indicated by box 816. This can include the forced propulsion (e.g., with pressurized (e.g., compressed) air) of abrasive solid particles, causing them to impact and pass through the internal geometry and exit of the unfinished jet tip. The abrasive solid particles are distinct from the fluid ejected by the end user through the jet tip.

[0083] Wear-like surfaces (or geometric features) can be formed in various other ways, as indicated in box 818.

[0084] The finished jet tip produced at box 610 has a wear-simulating surface (or geometry) prefabricated (before use by the end user) and manufactured (formed during the manufacturing process), such as wear-simulating surface (or geometry) 1115, as well as other components (e.g., inlet, outlet, internal geometry, etc.), as indicated in box 820. Furthermore, the finished jet tip has a corresponding expected wear curve (or expected wear rate) that differs from the expected wear curve (or expected wear rate) of the unfinished jet tip, as indicated in box 820. The corresponding expected wear curve (or expected wear rate) of the finished jet tip at box 820 is more linear than the expected wear curve (or expected wear rate) of the unfinished jet tip formed at box 802.

[0085] Furthermore, although the specific order of the steps has been described for ease of explanation, it should be understood that some or all of these steps can be performed in any number of orders.

[0086] It should also be noted that the different examples described in this article can be combined in different ways. That is to say, components of one or more examples can be combined with components of one or more other examples. All of these are envisioned in this article.

Claims

1. A method for manufacturing a jet tip with wear-simulating geometry, the method comprising: Carbide powder is pressed into a mold to form the unfinished jet tip; as well as The material is removed from the jet tip of the unfinished product to form the wear-simulating geometry.

2. The method as described in claim 1, wherein, Pressing carbide powder in a mold to form the jet tip of the unfinished product includes: pressing carbide powder in a mold to form the jet tip of the unfinished product, which includes an inlet, an internal geometry, and an outlet.

3. The method as described in claim 1, wherein, Pressing carbide powder in a mold to form the jet tip of the unfinished product includes: pressing carbide powder in a mold to form the jet tip of the unfinished product, including an inlet and an internal geometry.

4. The method of claim 3, further comprising removing material from the jet tip of the unfinished product to form an outlet in the jet tip of the unfinished product.

5. The method of claim 4, wherein, Removing material from the spray tip of the unfinished product to form the outlet includes: removing material from the spray tip of the unfinished product to form a cat's eye outlet as the outlet.

6. The method of claim 5, wherein, Removing material from the nozzle tip of the unfinished product to form the wear-simulating geometry includes: removing material from the nozzle tip of the unfinished product in a region extending radially around the inner circumference of the cat's-eye outlet and away from the inner circumference of the cat's-eye outlet; The removal of material from the region of the unfinished jet tip, surrounding the inner periphery of the cat's eye outlet and extending radially away from the inner periphery of the cat's eye outlet, includes: removing a first amount of material from a first sub-region of the region of the unfinished jet tip, surrounding the inner periphery of the cat's eye outlet and extending radially away from the inner periphery of the cat's eye outlet, the first sub-region being associated with a first canthus of the cat's eye outlet; removing a second amount of material from a second sub-region of the region of the unfinished jet tip, surrounding the inner periphery of the outlet and extending radially away from the inner periphery of the outlet, the second sub-region being associated with a second canthus of the cat's eye outlet; and removing a third amount of material from a third sub-region of the region of the unfinished jet tip, surrounding the inner periphery of the cat's eye outlet and extending radially away from the inner periphery of the cat's eye outlet, the third sub-region being between the first sub-region and the second sub-region to form the wear-simulating geometry with a variable width.

7. The method of claim 4, wherein, Removing material from the jet tip of the unfinished product to form the outlet includes: laser ablation of the jet tip of the unfinished product to form the outlet.

8. The method of claim 1, wherein, Removing material from the jet tip of the unfinished product to form the wear-simulating geometry includes: laser ablation of the jet tip of the unfinished product to form the wear-simulating geometry.

9. The method of claim 1, wherein, Removing material from the jet tip of the unfinished product to form the wear-simulating geometry includes: performing water erosion machining on the jet tip of the unfinished product to form the wear-simulating geometry.

10. The method of claim 1, wherein, Removing material from the jet tip of the unfinished product to form the wear-simulating geometry includes: sandblasting the jet tip of the unfinished product to form the wear-simulating geometry.

11. The method of claim 1, wherein, Removing material from the nozzle tip of the unfinished product to form the wear-simulating geometry includes removing material from the nozzle tip of the unfinished product in a region surrounding the inner periphery of the outlet and extending radially away from the inner periphery of the outlet.

12. The method of claim 11, wherein, Removing material from the region of the unfinished jet tip that extends radially around and away from the inner circumference of the outlet includes: removing a first amount of material from a first sub-region of the region of the unfinished jet tip that extends radially around and away from the inner circumference of the outlet; and removing a second amount of material from a second sub-region of the region of the unfinished jet tip that extends radially around and away from the inner circumference of the outlet, to form the wear-simulating geometry having a variable width.

13. A jet tip configured to atomize a fluid, the jet tip comprising: Inlet, which is configured to receive fluid; An outlet, wherein the outlet defines the exit of the jet tip; An internal geometry that defines a path from the inlet toward the outlet; as well as The manufactured wear-resistant geometry.

14. The jet tip as claimed in claim 13, wherein, The manufactured wear-resistant geometry surrounds the outlet.

15. The jet tip as claimed in claim 14, wherein, The manufactured wear-resistant geometry extends radially from the inner circumference of the outlet to multiple points of the internal geometry.

16. The jet tip as claimed in claim 15, wherein, The manufactured wear-simulating geometry has a variable width, which at any given point of the manufactured wear-simulating geometry includes the distance from the inner periphery of the outlet to the point of the internal geometry to which the manufactured wear-simulating geometry extends.

17. The jet tip as claimed in claim 16, wherein, The outlet includes a cat's eye outlet, and wherein the width of the manufactured wear-resistant geometry at each corner of the cat's eye outlet is smaller than the width of the manufactured wear-resistant geometry at the center of the cat's eye outlet.

18. A method for manufacturing a jet tip, the method comprising: A mold is formed having a geometry for forming a jet tip, the jet tip having an inlet, an internal geometry, an outlet, and wear-resistant geometry features; Place the carbide powder in the mold; Carbide powder is pressed in the mold to form a compact; Remove the compact from the mold; as well as The compact is sintered to form the jet tip having the inlet, the internal geometry, the outlet, and the wear-simulating geometry.

19. The method of claim 18, wherein, Forming the mold having a geometry to form the jet tip having an inlet, an internal geometry, an outlet, and an abrasion-like geometry includes: forming the mold having a geometry to form the jet tip having the inlet, the internal geometry, the outlet, and the abrasion-like geometry extending radially around the outlet and away from the outlet's inner circumference.

20. The method of claim 18, wherein, Forming the mold having the geometry to form the jet tip having the inlet, internal geometry, outlet, and the wear-simulating geometry extending radially around and away from the outlet's inner circumference includes: forming the mold having the geometry to form the jet tip having the inlet, internal geometry, outlet, and the wear-simulating geometry extending radially around and away from the outlet's inner circumference and having a variable width.

21. A method for manufacturing a jet tip, the method comprising: Generate an unfinished jet tip with a first expected wear curve, the first expected wear curve including a first part and a second part, the first part corresponding to the initial use cycle and the second part corresponding to subsequent use cycles, the linearity of the first part being less than the linearity of the second part; The unfinished jet tip is finished by providing wear-simulating geometry to generate the jet tip, which has a second predicted wear curve that is more linear than the first predicted wear curve.

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