Atomizer disc and method of producing an atomizer disc

Abstract

The invention relates to an atomizing disc for atomizing a fluid with at least one fluid guide disc (11) and at least one spray hole disc (12) arranged on the fluid guide disc (11), which has at least one spray hole (15) offset from the center (Z) of the atomizing disc (10), and to a method for manufacturing an atomizing disc (10), wherein a fluid guide disc (11) and a spray hole disc (12) with at least one spray hole 15 arranged therein and a circumferential geometry 18 are cut out.

Description

[0001] The present invention relates to an atomizer disc for atomizing a fluid, comprising at least one fluid guide disc and at least one spray hole disc arranged on the fluid guide disc, which has at least one spray hole offset from the center of the atomizer disc, and to a method for producing such an atomizer disc.

[0002] Multi-part atomizer discs of this type are known, for example, from European patent application EP 1 186 774 or US patent specification 5 899 390. Modern internal combustion engines require optimal atomization of fluids such as fuels in order to trigger the required reaction effects and thus increase their efficiency. Fluids are also atomized during charge air pretreatment, for example, water, which cools and humidifies the charge air. For optimal atomization, the fluid is often set in rotation by swirl geometries before exiting the at least one atomizer bore of an atomizer disc, or is caused to collide head-on by means of intersecting channels.

[0003] Such channels are typically embossed into single- or multi-part atomizer discs. In other designs, such as the atomizer disc described in EP 1 186 774, a channel geometry is cut out of a fluid guide disc, with the channel base being formed by a disc adjacent to this disc. Depending on the intended channel shape, the desired cross-section is distorted by an anisotropic punch indentation of the material and conically deformed contours. In addition, punch indentations are often accompanied by undesirable material changes and compression, which impair the desired atomization of the fluid emerging from a spray hole. Such an atomizer disc is known, for example, from German Offenlegungsschrift DE 10 2015 225 338 A1.In an atomizer disc known from US patent 5 899 390, a fluid chamber is formed between two discs, from which the fluid emerges through, in particular, several spray hole bores.

[0004] Based on this, the invention is based on the object of providing an improved atomizer disc and an improved method for producing an atomizer disc.

[0005] This is achieved according to the invention by the teaching of the independent claims. Preferred developments of the invention are the subject of the dependent claims.

[0006] To achieve this objective, an atomizer disc for atomizing a fluid is proposed, comprising at least one fluid guide disc and at least one spray hole disc arranged on the fluid guide disc, which has at least one spray hole offset from the center of the atomizer disc. A channel geometry is cut out in the fluid guide disc, forming the side surfaces of a guide channel for the fluid. The bottom surface of the guide channel is formed by the spray hole disc.

[0007] By cutting out the channel geometry in the fluid guide disc, anisotropic punch indentations, particularly on the walls of the guide channel, are prevented, which occur when the channel geometry is simply stamped into a one-piece spray orifice disc. Furthermore, the structure with the cut-out channel geometry can achieve a guide channel for the fluid to be atomized that corresponds exactly to the geometric design. The resulting increased accuracy allows the flow through at least one flow channel to be calculated more precisely. A further advantage of the proposed atomizer disc is that no undesirable turbulence occurs along punch indentations, thus maintaining the defined flow path of the fluid. Accordingly, the precisely manufacturable channel geometry makes it easier to calculate and maintain the desired flow rate.

[0008] The proposed atomizer disc is intended for atomizing one of these fluids, supplied in particular by means of an injection or metering valve. The fluid can be, in particular when the atomizer disc is used in an internal combustion engine, for example, for atomizing fuel, a fluid used for exhaust gas purification, such as urea, or water used for cooling and / or humidifying the charge air. The proposed atomizer disc is designed in at least two parts and has a separately manufactured fluid guide disc. The two-part design makes it possible to precisely cut out the intended channel geometry in the fluid guide disc.

[0009] In principle, the channel geometry can be created using any suitable manufacturing and, in particular, cutting process, such as a punching process, or a laser or waterjet cutting process, which allows for the production of sufficiently precise cut edges. The cut edges of the cut-out channel geometry form the side surfaces of a guide channel for the fluid. The base surface of the guide channel is formed by the spray orifice plate arranged on the fluid guide plate. This enables flexible and precise production of the intended channel geometry of the atomizer plate. This reduces the influences on the fluid flow in the guide channels caused by the manufacturing of the atomizer plate.

[0010] The spray hole disc has at least one spray hole, to which the fluid is guided through the guide channel and through which it then exits, particularly in atomized form, into the area surrounding the atomizer disc. The fact that the spray hole is arranged in a separate component simplifies its geometric design and manufacture, which can be carried out, for example, using a conventional micro-punching process. A spray hole can, of course, have any other suitable contour besides a circular one. In particular, various channel systems with different spray hole arrangements can be easily and simply combined and analyzed for prototype construction.

[0011] In one embodiment of the atomizer disc, the fluid guide disc and the spray hole disc have the same thickness or are constructed with different thicknesses. The fluid guide disc and the spray hole disc can each have a thickness in the low single-digit micrometer range (µm). Furthermore, the machining direction can be varied during production, which also contributes to improved efficiency. The fluid guide disc and the spray hole disc can also be made of the same or different materials.

[0012] In one embodiment of the atomizer disc, the guide channel is designed to guide the fluid to a spray hole with a substantially laminar flow. In particular, this increases the dynamic pressure in the fluid in the area of ​​the spray hole. This design supports effective atomization of the fluid as it flows through the spray hole through a suitable supply of the fluid. An increased dynamic pressure at the end of the guide channel can accelerate the fluid as it flows through the spray hole. In particular, a particularly laminar swirl flow with corresponding acceleration of the fluid can be created through suitable guidance of a laminar fluid.

[0013] In one embodiment of the atomizer disc, the guide channel has a recess formed in the disc in the region of at least one spray hole. Such a recess is typically used to create a desired fluid flow. Depending on the design of the recess, it can serve, for example, to create a swirling flow in the fluid. In particular, the recess formed in the disc can be embossed or manufactured therein or cut out of it using a machining process.

[0014] In one embodiment of the atomizer disc, the spray hole disc is formed in at least two parts in the direction of passage of the at least one spray hole, wherein the inner spray hole disc, which faces the fluid guide disc, has at least one recess. An at least two-part construction of the spray hole disc enables a more flexible design of the recess, in particular with regard to its geometry, arrangement, and manufacture. The at least two parts of the spray hole disc can have the same thickness (= material thickness) or different thicknesses. Likewise, the elements of the spray hole disc can be made of the same or different materials.

[0015] In one embodiment of the atomizer disc, the spray hole disc has multiple spray holes, with the channel geometry being designed to guide fluid to each spray hole via a respective guide channel. Thus, the flow of fluid to each spray hole can be individually configured.

[0016] In one embodiment of the atomizer disc, if there are several spray holes, these are arranged circularly around the center of the channel geometry. Such an arrangement enables individual and, in particular, identical guidance of the fluid to each of the spray holes. In particular, several spray holes can be evenly distributed on a circle arranged around the center of the channel geometry, or in a predetermined arrangement, for example depending on the geometry and / or the flow conditions in the space into which the fluid is introduced, in particular in atomized form. In particular, the number and respective diameter and / or the opening geometry of the spray holes can be selected, in particular depending on the intended volume flow and the atomization properties of the fluid.

[0017] In one embodiment of the atomizer disc, the at least one spray hole is oriented at an oblique angle or at a right angle to the bottom surface of the guide channel. The alignment of the at least one spray hole to the bottom surface of the guide channel can be provided in particular depending on the geometry and / or the flow conditions in the space into which the fluid is introduced, in particular in atomized form, and / or depending on the interaction with the flow formation in the feed channel and / or depending on the atomization properties resulting from the spray hole geometry of the spray hole geometry, in particular associated therewith. In particular, the at least one spray hole can be cylindrical or conically tapering or widening, or can also have a cross-section that changes along the direction of passage of the fluid.

[0018] In one embodiment of the atomizer disc, the fluid guide disc and the spray hole disc are firmly connected to each other. This allows the atomizer disc to be handled as a whole, similar to a one-piece atomizer disc.

[0019] The atomizer disc is provided with at least one connecting element arranged on the circumference of the atomizer disc, which serves to connect the atomizer disc to a fluid valve. The one or more connecting elements are designed such that a particularly positive connection to a fluid valve can be established by means of them.

[0020] In a second aspect, a method for producing an atomizer disk for atomizing a fluid is proposed to achieve the object. The atomizer disk has at least one fluid guide disk in which a channel geometry is formed, and at least one spray hole disk arranged on the fluid guide disk, which has at least one spray hole. The method comprises the following steps: a) Cutting out a fluid guide disc with a channel geometry and a circumferential geometry arranged therein; b) Cutting out a spray hole disc with at least one spray hole arranged therein and a circumferential geometry, wherein at least one connecting element arranged on the circumference of the atomizer disc is formed, which connecting element is provided for connecting the atomizer disc to a fluid valve; c) Arranging the fluid guide disc on the spray hole disc such that the spray hole disc forms the bottom surface of the at least one guide channel for the fluid; and d) Joining the fluid guide disc to the spray hole disc to form the atomizer disc.

[0021] The atomizer disc produced using the proposed method has at least one or more advantages and properties of the previously described atomizer disc. Consequently, the advantages and properties described above apply analogously to a correspondingly designed atomizer disc produced using the proposed manufacturing method, and conversely, the advantages and properties described below, which result from the manufacturing method, also apply to the atomizer disc produced using this method.

[0022] Advantageously, the proposed manufacturing method prevents anisotropic punch indentations, particularly on the walls of the guide channel in the fluid guide disc, by cutting out the channel geometry. This allows a guide channel for the fluid to be atomized to be produced that precisely matches the geometric design. The resulting increased accuracy allows the flow through the at least one flow channel to be calculated more precisely. A further advantage of the proposed manufacturing method is that no undesired turbulence occurs along punch indentations, thus maintaining the defined flow path of the fluid. Accordingly, the precisely manufacturable channel geometry allows the desired fluid flow rate to be achieved.

[0023] The proposed manufacturing process for the atomizer disc provides for an atomizer disc constructed in at least two parts. This allows the intended channel geometry to be precisely cut out in the fluid guide disc, resulting in precisely aligned cut edges. This largely eliminates the influences on fluid flow in the guide channels caused by the manufacturing of the atomizer disc.

[0024] In a first step a), the fluid guide disc is cut out with a channel geometry and a peripheral geometry arranged therein. Any suitable cutting process can be used for this purpose, such as a punching process, a laser cutting process, or a waterjet cutting process.

[0025] In a second step b), the spray hole disc is cut out with at least one spray hole arranged therein and a peripheral geometry. Any suitable cutting method can be used for this purpose, such as a punching process, a laser cutting process, or a waterjet cutting process. In particular, the spray holes can also be produced using a micro-punching process, for example.

[0026] In a further step c), the fluid guide disc is arranged on the spray hole disc such that the spray hole disc forms the bottom surface of the at least one guide channel for the fluid; and in step d), the fluid guide disc is joined to the spray hole disc to form the atomizer disc. The fluid guide disc and the spray hole disc can be firmly connected to one another, in particular by establishing a positive and / or non-positive and / or material connection between the discs.

[0027] An embodiment of the method for producing an atomizer disk, in which the spray hole disk is formed in two parts in the direction of passage of the at least one spray hole, has as a further step step b1), in which an inner spray hole disk with a circumferential geometry and with at least one recess is cut out at the position of the at least one spray hole. Cutting out the recess in an inner spray hole disk provided for this purpose also enables the production of a very precise contour of the recess. Because the recess has a greater extent than the spray hole arranged in an outer spray hole disk, the recess forms a depression of the guide channel after the atomizer disk is joined.A related flow change occurs depending on the geometry of the recess, in particular in conjunction with the geometry of the guide channel formed in the fluid guide disc. In particular, an at least partially rounded recess can cause the formation of a swirling flow in the fluid, in particular to achieve the desired atomization of the fluid after exiting the atomizer disc.

[0028] In one embodiment of the method for producing an atomizer disk, in step b) or in step b1), a recess is embossed into the spray hole disk in at least one area surrounding the spray hole. Such an embossed recess in the guide channel can also be used, in particular, to influence the fluid flow before passing through a spray hole, in particular to achieve a desired atomization of the fluid.

[0029] In one embodiment of the method for producing an atomizer disk, at least one joining element is formed on the circumference of the fluid guide disk and / or on the circumference of the spray hole disk, in particular in steps a) and / or b).

[0030] At least one joining element is formed on the circumference of the fluid guide disc, which is intended for joining the fluid guide disc to the spray orifice disc. In the same way, at least one joining element can also be formed on the circumference of the spray orifice disc, which is intended for joining the spray orifice disc to the fluid guide disc. Such joining elements are designed in particular to produce a joining connection, for example by engaging with the circumferential contour of the other disc, as can be provided in particular with clamps or the like. Likewise, one or more such joining elements can engage with one or more joining elements arranged on the respective other disc element of the atomizer disc.In particular, a particularly positive and / or non-positive connection between the spray hole disc and the fluid guide disc can be formed by means of the joining elements on the circumference of the fluid guide disc and / or the spray hole disc.

[0031] In one embodiment of the method for producing an atomizer disk, a joining element arranged on the spray orifice disk is designed as a tab with a recess, and a joining element arranged on the fluid guide disk is designed as a tab that can be arranged in the recess of the tab on the spray orifice disk. Accordingly, in this embodiment, the fluid guide disk and the spray orifice disk are positively connected to one another after the fluid guide disk has been arranged on the spray orifice disk in step c). The tab arranged on the fluid guide disk is arranged positively in the recess of the tab on the spray orifice disk.

[0032] In one embodiment of the method for producing an atomizer disk, in step d), the fluid guide disk is arranged on the spray orifice disk and the at least one joining element arranged on the fluid guide disk and / or the at least one joining element arranged on the spray orifice disk is / are deformed, in particular caulked, thereby establishing a connection between the fluid guide disk and the spray orifice disk. By deforming the at least one joining element, the fluid guide disk and the spray orifice disk are firmly connected to one another. In particular, a positive and / or non-positive connection is established in this way between the elements of the atomizer disk. The joining element can be designed such that it forms a connecting element for connecting the atomizer disk to a fluid valve.

[0033] Further advantages, features and possible applications of the present invention will become apparent from the following description in conjunction with the figures.

[0034] They show: Fig. 1: a three-dimensional view of an exemplary atomizer disk according to the invention in a view of the fluid guide disk; Fig. 2: a three-dimensional view of the exemplary atomizer disk according to the invention in a view of the spray hole disk; Figs. 3a and 3b: each a sectional view of a detail of two further exemplary atomizer disks according to the invention; Fig. 4: a schematic representation of a flow diagram of the method according to the invention; Fig. 5: a further three-dimensional view of the exemplary atomizer disk according to the invention from Fig. 1 after arranging the fluid guide disc on the spray hole disc; and Fig. 6: a three-dimensional detailed view of the atomizer disc according to the invention from Fig. 1 with joined joining elements.

[0035] Fig. 1 shows a three-dimensional view of an exemplary atomizer disk 10 according to the invention in a view of the fluid guide disk 11. In addition to the fluid guide disk 11, the atomizer disk 10 has a spray hole disk 12, which in Fig. 1 is arranged below the fluid guide disk 11 and has four spray holes 15 offset from the center Z of the atomizer disk 12. A channel geometry 21 is cut out in the fluid guide disk 11, which forms the side surfaces 22 of a guide channel 25 for the fluid, and the bottom surface 24 of the guide channel 25 is formed by the spray hole disk 12. Each guide channel 25 of the exemplary atomizer disk 10 is designed to guide the fluid with a substantially laminar flow to a spray hole 15 and is further designed such that the back pressure in the fluid increases in the region of the spray hole 15. The fluid guide disk 11 has a circumferential geometry 17 and the spray hole disk 12 has a circumferential geometry 18, which in the exemplary embodiment are also produced by a cutting process.

[0036] Fig. 2 shows a three-dimensional view of the exemplary atomizer disk 10 according to the invention in a view of the spray hole disk 12. As in Fig. 2 As can be seen, the four spray holes 15 of the atomizer disc 10 are arranged circularly around the center Z of the atomizer disc 10 and thus, in the exemplary embodiment, also around the center of the channel geometry 21. The atomizer disc 10 also has connecting elements 30 arranged on its circumference, which are provided for connecting the atomizer disc 10 to a fluid valve (not shown).

[0037] Fig. 3a shows a sectional view of a detail of another exemplary atomizer disk 10 according to the invention, the spray hole disk 12 of which is formed in two parts in the passage direction D of the at least one spray hole 15. The inner spray hole disk 12a, which faces the fluid guide disk 11, has a recess 27, which widens the guide channel 25 in the area of ​​the spray hole 15 in the passage direction D. The spray hole 15 is in the Fig. 3a shown version is aligned at an oblique angle to the bottom surface 24 of the guide channel 25.

[0038] Fig. 3b shows a sectional view of a detail of another exemplary atomizer disk 10 according to the invention, the spray hole disk 12 of which is formed as a single piece in the direction of passage of the at least one spray hole 15. In this embodiment, the single-piece spray hole disk 12 has a recess 27 in the direction of passage D of a spray hole 15, which widens the guide channel 25 in the region of the spray hole 15. As in the embodiment in Fig. 3a is the spray hole 15 at the in Fig. 3b shown version is aligned at an oblique angle to the bottom surface 24 of the guide channel 25.

[0039] Fig. 4 shows a schematic representation of a flow diagram of the method according to the invention for producing an atomizer disk 10 for atomizing a fluid with at least one fluid guide disk 11 in which a channel geometry 21 is formed and at least one spray hole disk 12 arranged on the fluid guide disk 11, which has at least one spray hole 15.

[0040] In the method, in a step a), a fluid guide disk 11 with a channel geometry 21 and a circumferential geometry 17 arranged therein is cut out, and in a second step b), a spray hole disk 12 with at least one spray hole 15 and a circumferential geometry 18 arranged therein is cut out. In addition, in step b), a recess 27 can be embossed into the spray hole disk 12 in at least one area surrounding a spray hole 15. In step c), the fluid guide disk 11 is arranged on the spray hole disk 12 such that the spray hole disk 12 forms the bottom surface 24 of the at least one guide channel 25 for the fluid. In a further step d), the fluid guide disk 11 is joined to the spray hole disk 12 to form the atomizer disk 10.

[0041] In an alternative embodiment of the method, which is used to produce an atomizer disk 10, in which the spray hole disk 12 is formed in two parts in the direction of passage of the at least one spray hole 15, the method has an additional step b1), in which an inner spray hole disk 12a with a circumferential geometry 18 and with at least one recess 27 is cut out at the position of the at least one spray hole 15. The recess 27 has a greater extent than the spray hole 15 arranged in the outer spray hole disk 12b. Alternatively, the recess 27 introduced into the spray hole disk 12a in step b1) can be embossed in at least one area surrounding a spray hole 15.

[0042] Fig. 5 shows a further three-dimensional view of the exemplary atomizer disk 10 according to the invention from Fig. 1 after arranging the fluid guide disc 11 on the spray hole disc 12. Four joining elements 31, 32 are formed on both the circumference 17 of the fluid guide disc 11 and the circumference 18 of the spray hole disc 12, which are provided with an upward bend for joining the fluid guide disc 11 and the spray hole disc 12. The joining elements 32 arranged on the spray hole disc 12 are designed as a tab with a recess 33 (cf. Fig. 6 ) and the joining elements 31 arranged on the fluid guide disc 11 as a tab, which in Fig. 5 is arranged in the recess 33 of the joining element 32 on the spray hole disc 12.

[0043] In Fig. 6 is a three-dimensional detailed view of the atomizing disc according to the invention from Fig. 1 with joined joining elements 31, 32. The joining elements arranged on the fluid guide disc 11 and on the spray hole disc 12 were shown in Fig. 5deformed or caulked together, thereby establishing a connection between the fluid guide disc 11 and the spray hole disc 12. The joining elements 31 and 32 together form connecting elements 30, which are provided for connecting the atomizer disc 10 to a fluid valve (not shown).

Claims

1. Spray disc for atomizing a fluid, comprising at least one fluid guide disc (11) and at least one spray hole disc (12) arranged at the fluid guide disc (11), which spray hole disc has at least one spray hole (15) offset relative to the center (Z) of the spray disc (10), wherein a channel geometry (21) is cut out in the fluid guide disc (11), which forms the side surfaces (22) of a guide channel (25) for the fluid, and the bottom surface (24) of the guide channel (25) is formed by the spray hole disc (12), characterized by at least one connecting element (30) arranged on the circumference (17, 18) of the spray disc (10), which is provided for connecting the spray disc (10) to a fluid valve.

2. Spray disc according to claim 1, characterized in that the guide channel (25) is designed to guide the fluid to a spray hole (15) with a substantially laminar flow.

3. Spray disc according to at least one of the preceding claims, characterized in that the guide channel (25) has a recess (27) in the region of at least one spray hole bore, which recess is formed in the spray hole disc (12).

4. Spray disc according to claim 3, characterized in that the spray hole disc (12) is designed in two parts in the direction of passage of the at least one spray hole (15), wherein the inner spray hole disc (12a), which faces the fluid guide disc (11), has the at least one recess (27).

5. Spray disc according to at least one of the preceding claims, characterized in that the spray hole disc (12) has several spray holes (15) and the channel geometry (21) is designed to guide fluid through a respective guide channel (25) to a respective spray hole (15).

6. Spray disc according to at least one of the preceding claims, characterized in that, if there are multiple spray holes (15), these are arranged circularly around the center of the channel geometry (21).

7. Spray disc according to at least one of the preceding claims, characterized in that the at least one spray hole (15) is aligned at an oblique angle or at a right angle to the base surface (24) of the guide channel (25).

8. Spray disc according to at least one of the preceding claims, characterized in that the fluid guide disc (11) and the spray hole disc (12) are firmly connected to each other.

9. Method for manufacturing an spray disc (10) for atomizing a fluid, comprising at least one fluid guide disc (11) in which a channel geometry (21) is formed, and at least one spray hole disc (12) arranged at the fluid guide disc (11), which has at least one spray hole (15), comprising the steps of: a) cutting out a fluid guide disc (11) with a channel geometry (21) arranged therein and a peripheral geometry (17); b) cutting out a spray hole disc (12) with at least one spray hole (15) arranged therein and a peripheral geometry (18), wherein at least one connecting element (30) is formed on the periphery (17, 18) of the spray disc (10), which is intended for connecting the spray disc (10) to a fluid valve; c) Arranging the fluid guide disc (11) at the spray hole disc (12) in such a way that the spray hole disc (12) forms the bottom surface (24) of the at least one guide channel (25) for the fluid; and d) Joining the fluid guide disc (11) to the spray hole disc (12) to form the spray disc (10).

10. Method for manufacturing a spray disc (10) according to claim 9, wherein the spray hole disc (11) is designed in two parts in the direction of passage of the at least one spray hole (15), characterized by the further step: b1) cutting out an inner spray hole disc (12a) with a peripheral geometry and with at least one recess at the position of the at least one spray hole (15), which has a greater extension than the spray hole (15) arranged in an outer spray hole disc (12b).

11. Method for manufacturing a spray disc (10) according to one of claims 9 or 10, characterized in that in step b) or in step b1), a recess (27) is embossed into the spray hole disc (12) in at least one area surrounding the spray hole (15).

12. Method for manufacturing a spray disc (10) according to one of claims 9 to 11, characterized in that at least one joining element (31, 32) is formed on the periphery (17) of the fluid guide disc (11) and / or on the periphery (18) of the spray hole disc (12).

13. Method for manufacturing a spray disc (10) according to claim 12, characterized in that the at least one joining element (32) arranged at the spray hole disc (12) is designed as a flap with a recess (33) and the at least one joining element (31) arranged on the fluid guide disc (11) is designed as a flap which can be arranged in the recess (33) of the flap on the spray hole disc (12).

14. Method for manufacturing a spray disc (10) according to one of claims 9 to 13, characterized in that in step d) the fluid guide disc (11) is arranged on the spray hole disc (12) and that the at least one joining element (32) arranged on the fluid guide disc (11) and / or the at least one joining element (32) arranged on the spray hole disc (12) is deformed or are deformed, thereby establishing a connection between the fluid guide disc (11) and the spray hole disc (12).

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