Integrated Swirl Seat Nozzle for Simpler Injector Atomization
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Solution Overview
Problem
Existing fluid injectors require complex machining, alignment of multiple components, and increased costs due to the separation of components with different materials and manufacturing processes, which complicates the formation of swirl passages for imparting rotational energy to the fluid.
Innovation Solution
A simplified design for fluid injectors that integrates swirl channels directly into the valve seat or nozzle plate, eliminating the need for multiple swirl plates and reducing component complexity by using a single body with integrated swirl channels and a unified machining process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If multiple swirl plates are used to form swirl passages, then rotational energy is imparted to the fluid, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the swirl passage formation into a single integrated component (nozzle body or valve seat) rather than using multiple separate swirl plates. The swirl passages are formed directly in the nozzle body through curved fluid passages that wrap around the metering orifice, eliminating the need for multiple stacked plates and reducing assembly complexity while maintaining the ability to impart rotational energy to the fluid.
Solution Approach 2:
The nozzle body serves multiple functions simultaneously: it contains the metering orifice for flow control, provides the swirl passages for rotational energy imparting, and acts as the structural housing for the entire assembly. This multi-functional design eliminates the need for separate components dedicated to each function, reducing overall device complexity.
2Use of energy by moving object
If multiple components are used for swirl passages, then rotational energy can be imparted to fluid, but machining complexity and alignment requirements increase
Solution Approach 1:
By consolidating the swirl passage formation into a single nozzle body component, the patent eliminates the need for alignment between multiple plates. The curved fluid passages are machined directly in the nozzle body as a monolithic structure, significantly simplifying the manufacturing process and eliminating alignment complexity while maintaining the swirl function.
3Manufacturing precision
If multiple plates are used for swirl channels, then fluid atomization is improved, but assembly time and cost increase
Solution Approach 1:
The patent integrates the swirl channels directly into the nozzle body as a single molded or machined component, eliminating the need for assembly of multiple separate plates. This integration maintains the atomization quality through properly designed curved fluid passages while dramatically reducing assembly time and operational complexity.
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
Enhances atomization efficiency by imparting rotational energy to the fluid without multiple plates, reducing machining complexity and costs, and enabling faster assembly with improved flatness and surface finish.
Implementation Method 1
the curved shape of the passages impart rotational energy into the fluid, improving atomization of the fluid
Implementation Method 2
the lower end of the valve needle forms a seal with a seating surface in valve seat to prevent liquid from flowing out of the at least one liquid passage
Implementation Method 3
The basic function of such atomizers is to increase shear forces between the fluid and ambient gas
Data Source
AI summary
An injector is provided, comprising: a valve seat having a needle opening extending from an upper surface along a longitudinal axis and terminating at a seating surface configured to mate with a valve needle to control flow of fluid through the injector, and a nozzle plate. The valve seat further comprises a plurality of drillings and a corresponding plurality of swirl channels, each of the plurality of drillings being in flow communication with the needle opening and a swirl channel. Each of the swirl channels directs flow of fluid from one of the drillings toward the longitudinal axis into a central swirl chamber. The nozzle plate includes a substantially flat upper surface that engages the valve seat lower surface and includes an opening in flow communication with a metering orifice, the opening being aligned with the central swirl chamber when the nozzle plate is attached to the valve seat.