High-Pressure Nozzle with Coreless Jet Straightener
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Solution Overview
Problem
High-pressure nozzles for descaling steel products face challenges with flow resistance and mechanical stability due to extreme operating pressures and pressure surges, which conventional manufacturing methods struggle to address effectively.
Innovation Solution
The method involves metal powder injection molding to create a combined filter and jet straightener component, where individual parts are sintered together, allowing for complex geometric shapes and enhanced mechanical stability, and a coreless jet straightener design with a free flow cross-section surrounding the central axis to reduce flow resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional manufacturing methods are used to produce high-pressure nozzles, then the structural simplicity is maintained, but the flow resistance is high and mechanical stability is insufficient under extreme pressures
Solution Approach 1:
The patent combines the filter and jet straightener into a single integrated component manufactured via metal powder injection molding. This merging of functions into one complex part simultaneously improves mechanical stability under high pressure while managing flow resistance through optimized internal geometry, directly resolving the contradiction between reliability and device complexity.
Solution Approach 2:
The patent employs metal powder injection molding to create a sintered metal component with composite microstructure. This composite material approach enables the nozzle to withstand extreme pressures and pressure surges while maintaining the complex geometric shapes needed for low flow resistance, addressing both mechanical stability and flow characteristics.
2Loss of energy
If a filter and jet straightener are used as separate components, then the manufacturing simplicity is maintained, but the flow resistance increases and the jet alignment is compromised
Solution Approach 1:
The filter and jet straightener are merged into a single monolithic component manufactured by metal powder injection molding. This integration eliminates the need for separate components and assembly operations, while the unified design optimizes flow paths to reduce flow resistance and improve jet alignment, directly addressing the contradiction between energy loss and manufacturing ease.
3Loss of energy
If the jet straightener has a conventional design with central part and radial flow guide surfaces, then the structural stability is maintained, but the flow resistance is high
Solution Approach 1:
The patent inverts the conventional jet straightener design by eliminating the central cylindrical part and instead creating a star-like cross-section with flow guide surfaces extending radially from a central axis. This inverted geometry reduces flow resistance by allowing more direct flow paths while the sintered metal construction maintains structural stability under high pressure, resolving the contradiction between energy loss and strength.
4Shape
If sintered components are used, then the complex geometric shapes are achievable, but the brittleness increases making them unsuitable for extreme pressure peaks
Solution Approach 1:
The patent uses metal powder injection molding to create a sintered metal component with optimized microstructure. The sintering process creates a composite material structure that achieves complex geometric shapes including internal flow channels and star-like cross-sections, while the metal matrix provides the strength and toughness needed to withstand extreme pressure peaks, resolving the contradiction between shape complexity and pressure resistance.
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
This approach results in high-pressure nozzles that are both stable and streamlined, capable of withstanding extreme pressures and pressure surges, with a significantly reduced flow resistance and improved jet alignment, leading to enhanced performance and longevity.
Implementation Method 1
sintering of the preliminary product obtained after removing the binder, the high-pressure nozzle having at least one filter and one jet straightener in a combined filter and jet straightener component which is composed of at least two individual parts, the individual parts being permanently connected to one another by sintering together
Data Source
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AI summary
The nozzle (10) has a feed channel with a beam directing device (26) formed with a discharge opening (22). A neck of the feed channel is provided downstream to the beam directing device. The beam directing device comprises a free flow section in a proximate region that encloses a center longitudinal axis (30) of the feed channel. The nozzle fastens a section with constant width at the neck of feed channel, where the section is crossed over a tapered discharge chamber. The section includes length that is twice the length of the neck of the feed channel. An independent claim is also included for a method for manufacturing a high pressure nozzle.