Secure Nozzle Insert Assembly Retention
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Solution Overview
Problem
Conventional spray nozzles fail to retain inserts effectively at extreme temperatures and are prone to high pressure leakage and damage from cleaning brushes, leading to operational disruptions and maintenance costs in applications like steel rolling mills and paper mills.
Innovation Solution
A metallic spray nozzle design featuring a tapered insert shield with an annular shape and an O-ring seal, which allows for smooth fluid flow and enhanced retention of inserts without glues, while protecting fragile inserts from damage using a crimped retaining lip and flared crimp to prevent turbulence and leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the nozzle is located very close to the metal surface to spray hot materials, then the liquid can reach the surface effectively, but the nozzle expansion becomes differential causing inserts to become free floating and potentially leave the nozzle
Solution Approach 1:
The patent applies preliminary action by providing a retaining means (such as a retaining ring or interference fit features) during the nozzle manufacturing process that proactively prevents insert displacement before it can occur. This anticipates the thermal expansion issue and counteracts it in advance, ensuring inserts remain secured even when the nozzle expands differentially at high temperatures.
2Reliability
If a retaining means is used to prevent insert movement by peening over the end of the counter-bore, then insert retention is improved, but turbulence is caused in the fluid flow into the back of the nozzle
Solution Approach 1:
The patent applies local quality by creating a localized retaining feature (such as a retaining ring positioned at a specific location in the counter-bore, or localized interference fit zones) that secures the insert without requiring peening over the entire end of the counter-bore. This localized approach maintains insert retention while preserving smooth fluid flow paths, eliminating the turbulence caused by extensive peening.
3Reliability
If a crimped retaining lip is used to retain the insert, then insert retention is improved, but high pressure leakage occurs and fragile inserts can be damaged during the crimping process
Solution Approach 1:
The patent applies the intermediary principle by introducing a retaining ring or similar intermediate component that acts as a mediator between the nozzle body and the insert. This retaining ring provides the retention function through a controlled interference fit or mechanical features, eliminating the need for direct crimping of the nozzle lip. The intermediary component protects fragile inserts from crimping damage while maintaining secure retention and preventing high pressure leakage through proper sealing.
4Stress or pressure
If the nozzle is used in high pressure applications with ruby or ceramic inserts, then the inserts can withstand the pressure, but they are damaged by cleaning brush bristles due to their fragility in shear
Solution Approach 1:
The patent applies preliminary action by designing and implementing a protective retaining structure (such as a retaining ring with proper clearance and positioning features) during manufacturing that proactively prevents brush bristles from contacting the fragile insert edges. This preliminary protective arrangement ensures that routine cleaning operations do not cause shear damage to the inserts, allowing them to maintain their pressure resistance without vulnerability to mechanical abuse.
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 nozzle design ensures reliable insert retention, reduces turbulence, prevents high pressure leakage, and shields ceramic or ruby inserts from damage, maintaining efficient operation and reducing maintenance costs in high-pressure applications.
Implementation Method 1
An O-ring or other sealing membrane is disposed between a locating shoulder in the nozzle body and the inside edge of the insert
Implementation Method 2
a retaining lip formed by deformation of an outer periphery of the counterbore towards an axis of the nozzle
Data Source
Figure 1~5
AI summary
The invention is a metallic spray nozzle having a counterbore from one side thereof into which an insert to control the spray is located and retained by means of a retaining lip formed by deformation of the outer periphery of the counterbore. This deformation can be towards an axis of the nozzle or alternatively this deformation can subsequently direct the tip of the periphery outwards at its extremity such that flow into the counterbore is smooth. Also provided are an O ring or other sealing membrane between a locating shoulder in the nozzle body and the insert and an insert shield between the insert and the retaining lip.