Multi-Dimple Orifice Disc for Split Spray Atomization
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Solution Overview
Problem
Existing fluid injectors are limited in producing diverse fluid spray patterns, as they often rely on a single large dimple or uniform orifice design, which restricts their applicability across various fluid injection applications.
Innovation Solution
An orifice disc with multiple asymmetrical dimples and orifices, where each dimple has an oblique angle and offset dimensions, and orifices are positioned at an angle relative to the radial and longitudinal axes, allowing for a split spray pattern with improved atomization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single large dimple or uniform orifice design is used, then the device complexity is reduced, but the adaptability or versatility is limited
Solution Approach 1:
The single large dimple is segmented into multiple smaller dimples arranged in a specific pattern. Each dimple contains an orifice, and the segmented configuration enables diverse spray patterns while maintaining a manageable structural complexity through systematic arrangement.
Solution Approach 2:
The dimples are configured with asymmetrical characteristics including offset positions from the center axis and varying orientations. The orifices within dimples are angled relative to the disc axis, creating asymmetrical flow paths that enable customizable spray patterns including split stream patterns.
2Adaptability or versatility
If multiple asymmetrical dimples with offset dimensions are used, then the spray pattern customization is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The dimples and orifices are pre-configured in specific asymmetrical positions and orientations during the disc manufacturing process. The punch operations are designed to create dimples at predetermined offset locations with specific angular orientations, establishing the spray pattern characteristics before the injector is assembled or used.
Solution Approach 2:
The manufacturing process incorporates variable parameters including dimple radius, offset distance from center axis, angular orientation of orifices within dimples, and depth variations. By systematically varying these parameters across multiple dimples, diverse spray patterns are achieved while maintaining controllable manufacturing precision through standardized production methods.
3Reliability
If orifices are positioned at an oblique angle relative to radial and longitudinal axes, then the atomization quality is improved, but the device complexity increases
Solution Approach 1:
Each orifice within a dimple is oriented at a specific oblique angle relative to the disc's longitudinal axis and radial direction. This local angular orientation creates asymmetric flow patterns that enhance atomization quality by promoting fluid turbulence and droplet breakup, while the overall device complexity is managed through consistent angular configurations across multiple orifices.
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 fluid atomization and allows for customizable spray patterns, enabling the fluid injector to be suitable for a range of applications, from fuel injection to reductant delivery in vehicles, by creating a split stream with appreciable atomization.
Implementation Method 1
Breakup of the fluid stream is enhanced by keeping the fluid turbulent as it exits the fluid injector
Data Source
AI summary
A fluid injector for injecting fluid is disclosed, including a body; a fluid passageway defined in the body and extending from an inlet to an outlet of the fluid injector; a valve seat disposed internally of the body and forming part of the passageway; a valve element that is selectively reciprocated relative to the valve seat to close and open the passageway to fluid flow by seating and unseating the valve element on and from the valve seat, respectively; and an orifice disc disposed in the passageway downstream of the valve seat in a direction of the fluid flow through the fluid injector, the orifice disc including a plurality of dimples and a plurality of orifices defined through the orifice disc, each dimple including at least one orifice located thereon and each dimple having an asymmetrical cross-section.