Air Cap Spray Nozzle for Uniform Full Cone Atomization
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Solution Overview
Problem
Existing spray nozzle assemblies are ineffective in generating uniform full cone spray patterns, particularly when spraying slurries and difficult-to-atomize liquids, and are often complex and expensive in construction.
Innovation Solution
A pressurized air assisted spray nozzle assembly with a nozzle body and air cap design featuring circumferentially spaced pressurized air discharge passages oriented at compound angles, which interact with the liquid flow to create a full cone spray pattern with uniform particle distribution, allowing for easy modification and efficient manufacture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional spray nozzle assemblies with separate air cap and spray tip are used, then spray pattern shaping is achieved, but uniform full cone spray patterns cannot be generated effectively
Solution Approach 1:
The invention merges the spray tip and air cap into a single integrated nozzle assembly where the liquid flow passage and air discharge passages are formed as one unified structure. This integration ensures precise spatial relationship between liquid discharge and air impingement points, enabling consistent full cone spray patterns with uniform particle distribution that cannot be achieved with separate components.
Solution Approach 2:
The nozzle assembly features locally optimized air discharge passages positioned at specific locations around the liquid flow passage. The air passages are strategically arranged to direct pressurized air streams at precise angles against the liquid stream, creating localized atomization zones that collectively produce a uniform full cone spray pattern.
2Ease of operation
If multiplicities of parts are used in spray nozzle assemblies, then spray pattern control is improved, but construction complexity and cost increase
Solution Approach 1:
The invention combines multiple functions (liquid delivery, air supply, atomization, and spray pattern formation) into a single integrated nozzle assembly. The unified structure eliminates the need for separate spray tips, air caps, and mounting hardware, reducing part count while maintaining precise spray pattern control through internally optimized flow passages.
Solution Approach 2:
The integrated nozzle assembly performs multiple functions simultaneously: it delivers liquid through the central passage, introduces pressurized air through surrounding passages, atomizes the liquid through air-liquid interaction, and shapes the spray into a full cone pattern. This multi-functionality in a single component simplifies the overall system while maintaining operational effectiveness.
3Reliability
If complex internal air atomization is implemented, then atomization effectiveness improves, but manufacturing complexity and cost increase
Solution Approach 1:
The nozzle features locally optimized air discharge passages positioned at specific locations around the liquid flow passage. Each air passage is configured to deliver pressurized air at precise angles against the liquid stream, creating effective atomization zones. This localized approach achieves reliable atomization without requiring complex internal structures throughout the entire nozzle.
Solution Approach 2:
The invention optimizes atomization effectiveness by controlling key parameters such as air pressure, air flow angle, and the ratio of air to liquid flow. By adjusting these parameters in the integrated design, effective atomization of difficult-to-atomize liquids is achieved while maintaining manufacturing simplicity through standardized passage geometries.
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 design effectively generates full cone spray patterns with uniform particle distribution, suitable for slurries and other difficult-to-atomize liquids, while being simpler and more cost-effective in construction, with the ability to control the conical angle of the spray pattern through adjustments in air discharge passage orientation.
Implementation Method 1
pressurized air streams directed into intersecting relation with a liquid flow stream for atomizing the liquid flow stream and imparting a tangential direction thereto which swirls the outwardly expanding liquid and forms it into a conical spray pattern
Implementation Method 2
pressurized air streams directed into intersecting relation with a liquid flow stream for atomizing the liquid flow stream
Data Source
Figure 1~2
Figure 3~5
Figure 6~6B
AI summary
A spray nozzle assembly having a nozzle body and a downstream air cap. The air cap has a central opening through which liquid is directed and a plurality of circumferentially spaced air passages oriented at a compound angle to the central flow axis of the air cap opening for directing pressurized air flow streams that interact with discharging liquid for atomizing the liquid while imparting a tangential direction to the atomized liquid for enhanced atomization and a swirling movement into a full cone spray pattern. The air cap may have an integrally formed spray tip or a separate spray tip may be associated with the nozzle body. The air cap may be formed with a downstream conical recess into which liquid and air streams are directed, or alternatively, be designed for atomizing liquid internally within the air cap.