Additive Powertrain Fluid Sprayers for Fan-Shaped Oil Distribution
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Solution Overview
Problem
Traditional fluid sprayers for powertrains face limitations in design and manufacturability, leading to inadequate fluid distribution to powertrain components, with cylindrical jetted nozzles often focusing oil on localized areas and other solutions failing to provide effective distribution.
Innovation Solution
The development of unitary body fluid sprayers with additively manufactured bends and orifices, allowing for a fluid passage from a mounting portion to a nozzle with multiple orifices that produce different fluid outputs, enabling efficient distribution of oil or other fluids to powertrain components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional assembly brazing of multiple individual parts is used to manufacture fluid sprayers, then the manufacturing process is well-established and reliable, but the design flexibility is limited and fluid distribution is inadequate
Solution Approach 1:
The patent merges multiple individual parts (body, bends, nozzles, orifices) into a single unitary structure manufactured by additive manufacturing. This integration eliminates the need for assembly brazing while enabling complex geometries and optimized fluid distribution paths that were previously impossible to achieve with traditional manufacturing methods.
Solution Approach 2:
The patent changes the manufacturing parameter from traditional subtractive or assembly-based methods to additive manufacturing. This parameter change enables the creation of unitary structures with complex internal fluid passages and integrated nozzle systems, fundamentally improving both design flexibility and manufacturing efficiency.
2Ease of manufacture
If cylindrical jetted nozzles are used, then the nozzle structure is simple and easy to manufacture, but the fluid distribution is focused on localized areas and inadequate for effective cooling and lubrication
Solution Approach 1:
The patent segments the fluid output into multiple nozzles and orifices with different configurations (cylindrical, conical, flat, angled) arranged in specific patterns. Each nozzle type serves a specific function for different cooling and lubrication needs, enabling comprehensive fluid distribution across various powertrain components simultaneously.
Solution Approach 2:
The patent applies different nozzle geometries and orientations at different locations on the sprayer body to optimize fluid distribution for specific target areas. Each nozzle is designed with local quality characteristics (angle, shape, size) tailored to the specific cooling or lubrication requirements of the adjacent powertrain components.
3Reliability
If multiple individual parts are assembled through brazing, then the manufacturing process is traditional and reliable, but the fluid sprayer cannot achieve optimized fluid distribution patterns
Solution Approach 1:
The patent combines multiple functional elements (fluid passages, bends, nozzles, orifices) into a single unitary structure that is manufactured as one integrated component using additive manufacturing. This merging eliminates assembly steps while enabling optimized fluid flow paths and distribution patterns that significantly improve cooling and lubrication efficiency.
Solution Approach 2:
The patent utilizes the third dimension in additive manufacturing to create complex internal fluid passages and three-dimensional nozzle arrangements that cannot be achieved with traditional two-dimensional manufacturing methods. This dimensional freedom enables optimized fluid distribution in multiple directions simultaneously.
Data Source
AI summary
Fluid sprayers for powertrains are disclosed along with methods of manufacturing the fluid sprayers. The fluid sprayers include a unitary body forming a fluid passage therein extending from an inlet at a first end of the body to a nozzle at or near a second end of the body opposite the first end. The fluid sprayers include a mounting portion formed at the first end of the body opposite the second end for connection with a fluid system of the powertrain.