Dry Fog Nozzle Head With Triangular Channels for Stable Fine Atomization
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Solution Overview
Problem
Existing hydraulic nozzles for dry fog formation suffer from ceramic tip cracking, assembly issues, and inefficiencies in producing uniform and small particle sizes, particularly under high pressure conditions.
Innovation Solution
A hydraulic nozzle head design featuring a ceramic tip with triangular flow outlet channels, a plastic outer body with internal flange, and a movable piston mechanism, ensuring the nozzle produces a high percentage of particles smaller than 10 µm, even at pressures above 7 MPa, while protecting the ceramic tip from stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the ceramic tip is fixed using a threaded joint and conical sleeve, then the assembly is secure, but the ceramic tip cracks due to material stresses or is pulled out under high pressure
Solution Approach 1:
A protective sleeve is introduced as an intermediary element between the ceramic tip and the threaded joint. This sleeve absorbs the mechanical stresses and prevents direct transmission of loads to the ceramic tip, eliminating cracking while maintaining secure fixation through the threaded connection.
Solution Approach 2:
The protective sleeve is installed beforehand to cushion and absorb potential stress concentrations before they can reach the ceramic tip. This preemptive protection prevents both cracking and pull-out failures under high pressure conditions.
2Manufacturing precision
If the jet orifice diameter is reduced to produce smaller particles, then the particle size decreases, but the nozzle becomes more sensitive to pressure fluctuations and less stable
Solution Approach 1:
The flow outlet channels are designed with specific geometric characteristics (triangular cross-section, optimized angles) to create localized flow patterns that promote stable atomization. This local geometric optimization ensures consistent particle formation even with small orifice diameters and pressure variations.
Solution Approach 2:
The triangular cross-section of the flow outlet channels creates a specific flow regime that changes the fluid dynamics characteristics. This geometric parameter change optimizes the balance between atomization efficiency and stability, allowing small particle production without excessive sensitivity to pressure fluctuations.
3Quantity of substance
If the flow outlet channels have a large cross-section, then the liquid flow is sufficient, but the liquid does not split into non-condensable fog under high pressure
Solution Approach 1:
The single large flow outlet is segmented into multiple smaller outlet channels with triangular cross-sections. This segmentation creates multiple atomization zones that work simultaneously, maintaining sufficient total liquid flow while effectively splitting the liquid into fine non-condensable fog particles under high pressure conditions.
Solution Approach 2:
The flow outlet channels are designed with a triangular cross-section instead of a circular one, utilizing the geometric properties of triangles to optimize flow distribution and atomization. This dimensional change in the outlet geometry enhances the splitting of liquid into fine particles while maintaining adequate flow rate.
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 enhances the nozzle's durability and efficiency, producing a high percentage of dry fog particles smaller than 10 µm with improved atomization and resistance to bursting, ensuring reliable operation under high pressure.
Implementation Method 1
The flow outlet channels in the conical surface of the open cavity and in the face of the open cavity of the ceramic tip are flat and are preferably shaped like an inequilateral triangle... The atomizing integrity and uniformity of the individual droplets is maximized
Implementation Method 2
The jet orifice has the inner diameter φ2 and the outer diameter φ1, which is preferably between 140 µm and 160 µm preferably with the taper ratio 1:8 to 1:12. With thus chosen jet orifice diameters and taper ratio, the atomizing integrity and uniformity of the individual droplets is maximized
Implementation Method 3
The notched pin is the moving member of the system which, at the start of atomizing, if the pin is pushed against the nozzle orifice due to liquid pressure, the nozzle produces a condensing fog
Data Source
Figure 1
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Figure 3
AI summary
The head of the hydraulic nozzle for dry fog formation comprises the outer hollow cylindrical body (1) of the head made of plastic, the face (2) of which has the inner flange (3). In the face (2) of the outer hollow cylindrical body (1) of the head is arranged the ceramic tip (4) having the spherical cap (5) and the jet orifice (6) in its centre, wherein the ceramic tip (4) has the outer rim (7) which abuts against the inner flange (3) of the outer hollow cylindrical body (1). The ceramic tip (4) has the truncated cone-shaped open cavity (8) on one side with at least two flow outlet channels (9) in the conical surface (10) of the open cavity (8) and in the face (11) of the open cavity (8), wherein the flow outlet channels (9) are in the shape of an inequilateral triangle and are terminated by the outlet orifice (34) which leads into the cavity (35) of the jet orifice (6).