Air-Assisted Spray Nozzle for Uniform Full Cone Patterns
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Solution Overview
Problem
Existing spray nozzle assemblies that generate conical spray patterns face issues with uniform distribution and control due to the intermixing of pressurized liquid and air, leading to streaking and clogging, especially when handling viscous liquids, and are limited in varying spray angles and pressures.
Innovation Solution
A pressurized air assisted liquid spray nozzle assembly with a combination of transverse and tangential air passages that atomize and shape the liquid spray outside the nozzle, allowing for uniform distribution and control of full cone spray patterns across a wide range of angles and pressures, preventing clogging with viscous liquids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If internal mix design is used to pre-atomize liquid in a mixing chamber, then conical spray pattern is generated, but streaking occurs and uniform distribution is impeded
Solution Approach 1:
The invention extracts the atomization process from the internal mixing chamber and moves it to an external location. The liquid flows through a discharge orifice while air streams act upon it externally to atomize the liquid, eliminating the internal mixing chamber that caused streaking and uniform distribution problems.
Solution Approach 2:
The invention introduces air streams as an intermediary substance that mediates between the liquid flow and the spray pattern formation. The air streams act upon the liquid externally to atomize it, serving as a mediator that enables conical spray pattern generation without direct internal mixing.
2Shape
If internal mixing chamber is used for pre-atomization, then conical spray pattern is formed, but control of spray pattern is limited due to pressure requirements
Solution Approach 1:
The invention extracts the pressure mixing requirement from the system by moving atomization externally. This eliminates the constraint that liquid and air pressures must be substantially similar, enabling independent control of liquid flow rate and air pressure to achieve versatile spray pattern control.
Solution Approach 2:
The invention makes the spray pattern dynamically controllable by allowing independent adjustment of air pressure and liquid flow rate. The air streams can be dynamically adjusted to vary spray angle and particle distribution without being constrained by pressure equilibrium requirements.
3Shape
If internal mixing chamber is used for pre-atomization, then conical spray pattern is generated, but clogging occurs when spraying viscous liquids
Solution Approach 1:
The invention extracts the atomization process from the internal mixing chamber and performs it externally. This eliminates the enclosed mixing chamber where viscous liquids could set up and clog, allowing continuous operation with viscous liquids by atomizing them outside the nozzle body.
Solution Approach 2:
The invention performs preliminary atomization of the liquid externally before the liquid enters any enclosed chamber. By atomizing the liquid with air streams at or immediately following discharge from the liquid discharge orifice, the liquid is broken into small particles that are less prone to clogging and can flow continuously.
4Reliability
If external mix spray nozzle is used, then clogging is prevented, but ability to control spray particle distribution and vary spray angle is limited
Solution Approach 1:
The invention segments the air delivery system into multiple independent air streams with different functions. Some air streams are directed to control spray particle distribution while others control spray angle, enabling versatile spray control while maintaining external mix design that prevents clogging.
Solution Approach 2:
The invention applies air streams to different locations and at different angles to achieve localized control of spray characteristics. By directing air streams at specific locations around the liquid discharge orifice, the invention can independently control spray particle distribution and spray angle, enhancing adaptability while preventing clogging.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively produces uniform full cone spray patterns with enhanced control over spray angles and pressures, preventing clogging and ensuring efficient operation with viscous liquids, while maintaining simplicity and economical manufacturing.
Implementation Method 1
a liquid flow stream is atomized by pressurized air at or immediately following discharge from a liquid discharge orifice of the nozzle
Implementation Method 2
external mix air atomizing spray nozzle assemblies in which a liquid flow stream is atomized by pressurized air at or immediately following discharge from a liquid discharge orifice
Data Source
Figure 1
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AI summary
A pressurized air assisted liquid spray nozzle assembly having a liquid spray nozzle having a downstream discharge orifice for discharging a solid stream of liquid, an air guide mounted in surrounding relation to a downstream end of said liquid spray nozzle, and an outer nozzle body disposed in surrounding relation to said air guide. The air guide defines a first plurality of air passages for directing pressurized atomizing air transversely to liquid discharging from said liquid spray nozzle for atomizing the discharging liquid and a second plurality of air passages for directing shaping air tangentially to liquid discharging from said liquid spray nozzle for shaping the atomized liquid particles into a predetermined conical spray pattern.