Multi-Lip Nozzle Uniform Spray High Viscosity Fluids
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Solution Overview
Problem
Traditional flat fan spray nozzles fail to provide a uniform spray distribution for high viscosity liquids, especially at lower pressures, resulting in excessive fluid volume at the edges of the spray fan, making it difficult to achieve a uniform coating.
Innovation Solution
A new nozzle configuration with a crenellated exit orifice featuring multiple distinct, discontinuous shear inducing lip segments, each with its own convergence angle and width, is designed to control the spray volume distribution, allowing for a uniform spray pattern across the fan width.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional flat fan spray nozzles are used for high viscosity liquids, then the nozzle structure is simple, but the spray distribution is non-uniform with excessive volume at the edges
Solution Approach 1:
The exit orifice is segmented into multiple discrete lips (first lip, second lip, third lip) instead of a single continuous opening. Each lip has a different convergence angle (β1, β2, β3) and edge length (Fw1, Fw2, Fw3), allowing independent control of spray characteristics. This segmentation enables precise adjustment of spray distribution to achieve uniformity across the fan width while managing high viscosity liquid flow.
2Manufacturing precision
If multiple lip segments with different convergence angles are used, then uniform spray distribution is achieved, but the nozzle manufacturing complexity increases
Solution Approach 1:
Different regions of the nozzle interior surface are given different convergence angles (β1, β2, β3) and lip configurations to optimize local spray characteristics. The first lip region, second lip region, and third lip region each have tailored geometry to control fluid flow and shear forces in their respective zones, achieving uniform overall spray distribution through localized optimization.
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 multi-lip nozzle design ensures a significantly more uniform spray distribution for high viscosity liquids, providing a reliable and uniform coating without excessive volume at the edges, suitable for pressures up to 60 PSI in trigger spray applications and up to 140 PSI in aerosol applications.
Implementation Method 1
converging fluid feed channel wall segments... to define first, second and third exit orifice lips or lip segments... which shear the liquid into droplets
Data Source
AI summary
A nozzle and spray dispenser for generating a uniform substantially flat fan spray pattern when spraying high viscosity fluids (i.e., oils, lotions, cleaning liquids, shear-thinning liquids and gels and similar Newtonian and non-Newtonian fluids having viscosities of 10-100 cP) is configured with an exit orifice 134 defining multiple lip segments 150A, 150B, 150C. Cup-shaped nozzle member 100 has a cylindrical side wall 102 surrounding a central longitudinal axis and has a circular closed end wall with at least one exit aperture passing through the end wall 112. At least one enhanced exit orifice structure is formed in an inner surface of the end wall, and includes two to five lip segments of selected width defining edges at the orifice 134, where each edge segment is defined at the distal edge of a separate and distinct interior wall segment 160A, 160B, 160C which has a selected wall convergence angle β.