Helical Inlet Fluid Atomizer for Homogeneous Spray
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Solution Overview
Problem
Existing fluid atomizers experience high energy losses and cavitation due to irregular fluid entry into inlet channels, leading to non-homogeneous sprays with larger droplets, which reduces efficiency in applications like combustion and coating processes.
Innovation Solution
A fluid atomizer with helical inlet channels that allows fluid to enter the swirl chamber tangentially or at an angle, reducing energy losses and promoting a homogeneous spray distribution by designing the internal flow helically.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fluid enters inlet channels tangentially or at an angle in standard pressure swirl atomizers, then spray is generated, but fluid becomes irregular causing high energy losses and cavitation
Solution Approach 1:
The patent applies helical curvature to the inlet channel geometry, transforming straight or angled channels into helical paths. This curvature design guides fluid smoothly into the swirl chamber, maintaining flow regularity while generating the necessary swirl motion for spray formation, thereby reducing energy losses and cavitation
Solution Approach 2:
The helical inlet channels perform preliminary swirling action on the fluid before it enters the main swirl chamber. This pre-swirl preparation ensures uniform flow distribution and reduces abrupt flow irregularities, preventing energy losses and cavitation while maintaining spray generation efficiency
2Productivity
If fluid enters inlet channels tangentially or at an angle in standard pressure swirl atomizers, then spray is generated, but non-homogeneous spray with larger drops is formed
Solution Approach 1:
The helical curvature of inlet channels creates uniform rotational flow patterns that distribute fluid evenly throughout the swirl chamber. This curved path design ensures consistent flow velocity and direction, producing homogeneous spray with uniform droplet sizes rather than irregular large drops
Solution Approach 2:
The helical inlet channel design inherently promotes homogeneous flow distribution by maintaining consistent flow characteristics throughout the channel length. This uniform flow entry into the swirl chamber directly results in homogeneous spray patterns with consistent droplet sizes, improving spray quality
3Volume of moving object
If multi-part atomizer designs are used to create swirl, then compact structure is achieved, but very low manufacturing tolerances are required increasing cost
Solution Approach 1:
The patent merges the inlet channels and swirl chamber into a single integrated component with helical geometry. This consolidation eliminates the need for multiple separate parts that must be precisely assembled, significantly reducing manufacturing tolerance requirements and production costs while maintaining the compact atomizer structure
4Volume of moving object
If multi-part atomizer designs are used, then swirl is created in narrow volume, but too much pressure loss is experienced
Solution Approach 1:
The helical curvature of the integrated inlet channels creates smooth flow transitions into the compact swirl chamber. This curved geometry minimizes flow separation and turbulence, reducing pressure losses while maintaining effective swirl generation in a narrow volume
Solution Approach 2:
The helical inlet channels perform preliminary flow conditioning before fluid enters the swirl chamber, creating uniform rotational flow that reduces turbulence and pressure losses. This pre-prepared flow enters the compact chamber efficiently, maintaining swirl quality while minimizing energy loss
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 fluid atomizer achieves lower pressure loss at constant flow rates, improves internal flow, and provides a more homogeneous spray distribution, even at high flow rates and low pressures, enhancing efficiency and reducing the risk of combustion irregularities and non-homogeneous coatings.
Implementation Method 1
a plurality of helical inlet channels (3) that are located on the fluid inlet (2), extends from the fluid inlet (2) towards the swirl chamber (4) helically, allows the fluid accumulated at the fluid inlet (2) to be atomized and transferred to the swirl chamber (4)
Implementation Method 2
Pressure swirl atomizers create a hollow conical fluid film at the exit of the atomizer and then a hollow conical spray with the atomizing of this film by pushing the fluid inside and outside the atomizer from the center outwards with the swirl they create in the swirl chamber
Implementation Method 3
Pressure swirl atomizers create a hollow conical fluid film at the exit of the atomizer and then a hollow conical spray with the atomizing of this film
Implementation Method 4
In case the swirl chamber has a narrowing conical structure or is smaller in diameter than the fluid inlet, the flow and rotation speed of the fluid in the swirl chamber increases
Data Source
AI summary
A fluid atomizer with helical inlet channel which is used to atomize the fluid and convert the same into a spray of droplets, contains fluid inlet which are two independent chambers through which the flow passes and swirl chamber, transforms the fluid into spray dispersion by atomizing the same after the fluid is collected in the center after centrally coming fluid is dispersed by forming a swirl.