Atomizing Nozzle Orifice Insert Design
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Solution Overview
Problem
Conventional atomizing nozzles are expensive to manufacture and prone to clogging due to the high cost and complexity of machining small, cup-shaped orifice inserts, which are difficult to clean and replace, leading to increased material waste and shipping costs.
Innovation Solution
An atomizing nozzle design featuring a nozzle body made of one metal and an orifice insert fabricated from a sheet material of another metal, with a conical bevel design that reduces material thickness and length, allowing for easier manufacturing and minimizing mineral buildup, combined with an impeller for efficient fluid atomization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If cup-shaped orifice insert is used to provide strength during pressing, then orifice insert strength is improved, but manufacturing cost and device complexity increase significantly
Solution Approach 1:
The patent applies preliminary action by forming the orifice in a flat metal sheet before the pressing operation. The orifice is precisely formed in the flat state, then the entire assembly is pressed into the nozzle body. This eliminates the need for complex cup-shaped structures during pressing, reducing manufacturing difficulty while maintaining orifice integrity.
Solution Approach 2:
The patent changes the geometric parameters of the orifice insert from a cup-shaped structure with parallel walls to a flat sheet structure with conical bevels. This parameter change reduces the material thickness and simplifies the forming process, making the insert easier to manufacture while still providing sufficient strength through the conical reinforcement features.
2Stability of the object's composition
If cup-shaped orifice insert is used to resist deformation during pressing, then orifice insert stability is improved, but nozzle body length and material usage increase
Solution Approach 1:
The patent extracts the unnecessary cup-shaped structure from the orifice insert design. By removing the deep cylindrical walls of the cup shape, the nozzle body length is reduced. The essential function of preventing deformation is achieved through localized conical bevels rather than extended cylindrical walls, eliminating excess material while maintaining stability.
Solution Approach 2:
The patent transitions from a three-dimensional cup-shaped structure to a predominantly two-dimensional flat sheet structure with conical features. This dimensional simplification reduces the axial length requirement in the nozzle body while maintaining the structural integrity needed to resist deformation during pressing through the conical bevel geometry.
3Reliability
If orifice insert is pressed into nozzle body with great force to seal, then fluid-tight seal is improved, but orifice insert deformability resistance increases manufacturing difficulty
Solution Approach 1:
The patent applies preliminary action by pre-forming the orifice in the flat metal sheet before pressing. The orifice geometry is established in advance when the material is more formable, avoiding the need for complex three-dimensional structures that would require sophisticated machining or forming operations during the high-force pressing operation into the nozzle body.
4Manufacturing precision
If small-sized orifice insert is used to achieve fine mist, then mist fineness is improved, but machining precision requirements and handling difficulty increase
Solution Approach 1:
The patent replaces traditional mechanical machining operations with a stamping process for forming the orifice in the metal sheet. Stamping allows for precise orifice geometry to be achieved through die formation rather than complex machining, reducing the skill and equipment requirements while maintaining the precision needed for uniform fine mist production.
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 significantly reduces production costs, minimizes material usage, and prevents clogging by using a thinner orifice insert that is easier to produce and maintain, resulting in a more efficient and cost-effective misting system.
Implementation Method 1
The action of impeller 28 within fluid chamber 30 fractures the fluid and produces a finer fog or mist
Implementation Method 2
Desirably, the mist is sufficiently fine so that it rapidly evaporates. As the mist evaporates, the general area around the atomizing nozzles becomes cooler. Rapid evaporation prevents people and property located in the mist from getting wet
Data Source
AI summary
An atomizing nozzle (100) for use in a misting system and a process (300) for manufacturing the atomizing nozzle (100) are provided. The atomizing nozzle (100) is made up of a nozzle body (104), an orifice insert (106), and an impeller. The nozzle body (104) has an inlet end (110), has an outlet end (112), has an insert recess (116) proximate the outlet end (112), and encompasses a first chamber (122). The metallic orifice insert (106) is fabricated from a metallic sheet material (140) and affixed to the nozzle body (104) within the insert recess (116) and encompasses a second chamber (148). The non-metallic impeller (108) is configured to reside within the first and second chambers (122,148) between the metallic orifice insert (106) and the nozzle inlet end (110).