Spray Orifice Disk Swirl Geometry for Uniform Atomization
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Solution Overview
Problem
Conventional spray orifice disks in metering or injection valves for internal combustion engines and exhaust gas aftertreatment systems produce non-uniform jet distributions and large droplet sizes at low pressures, which is undesirable for many applications.
Innovation Solution
A spray orifice disk with a swirl geometry configuration that forms an oval cross-sectional pattern in the atomization cone by interacting jets from multiple orifices, reducing droplet size and achieving uniform distribution, particularly effective at pressures between 3 and 10 bar.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional spray orifice disks are used with turbulence atomization, then the structure is simple, but the droplet distribution is non-uniform and droplet size is large at low pressures
Solution Approach 1:
The patent changes the geometric parameters of the spray orifice system by introducing swirl geometry with specific angles (alpha between 10-45 degrees, beta between 0-30 degrees) and dimensional relationships (L1/L2 ratios, R1/R2 ratios). This parameter optimization enables uniform droplet distribution and reduced droplet size at low pressures without requiring complex additional components
Solution Approach 2:
The patent employs curved surfaces and rotational symmetry in the swirl geometry design, where the conical surfaces with specific angles create rotational flow patterns. This curvature-based design generates centrifugal forces that enhance atomization uniformity while maintaining a relatively simple overall structure
2Use of energy by moving object
If low pressure operation is used, then energy consumption is reduced, but atomization quality deteriorates with large droplet sizes
Solution Approach 1:
The patent optimizes geometric parameters including cone angles (alpha, beta), dimensional ratios (L1/L2, R1/R2), and orifice dimensions to maximize atomization efficiency at low pressures. The swirl geometry parameters are specifically tuned to generate sufficient centrifugal forces for fine atomization without requiring high pressure input
Solution Approach 2:
The swirl geometry creates rotational motion and centrifugal forces that enhance the atomization process. The rotating flow patterns generate dynamic effects that improve droplet breakup and distribution uniformity, achieving fine atomization equivalent to higher pressure systems but with lower energy input
3Manufacturing precision
If single jet spray is used, then the device structure is simple, but the spray distribution uniformity is poor
Solution Approach 1:
The patent divides the single jet into multiple jets by providing multiple spray orifices (first spray orifice and second spray orifice) with different orientations. Each orifice produces a jet at a specific angle, and the combined effect creates a uniform oval-shaped spray distribution pattern that would be difficult to achieve with a single orifice
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 solution achieves a uniform and finely atomized spray with reduced droplet size, improving atomization efficiency and reducing wall wetting in engines and exhaust systems, suitable for applications like AdBlue metering and fuel injection.
Implementation Method 1
the spray orifice, the channel and/or the transition between the channel and spray orifice being configured to form a swirl geometry of the spray orifice disk in such a manner, that during operation, due to interaction of one or more jets of the fluid emerging from the spray orifice in atomization, an oval cross-sectional pattern of the spray is formed
Implementation Method 2
the spray orifice, the channel and/or the transition between the channel and spray orifice being configured to form a swirl geometry of the spray orifice disk in such a manner, that during operation, due to interaction of one or more jets of the fluid emerging from the spray orifice in atomization
Data Source
AI summary
A spray orifice disk for a valve for a flowing fluid and, in particular, for a metering or injection valve for an internal combustion engine, including a disk body and a spray orifice set-up, which is formed in the disk body and is configured with at least one spray orifice for dispensing supplied fluid, and including at least one channel for supplying the fluid to the spray orifice. The spray orifice, the channel and/or the transition between the channel and the spray orifice being configured to form a swirl geometry of the spray orifice disk in such a manner, that during operation, due to interaction of one or more jets of the fluid emerging from the spray orifice in turbulence atomization, an oval cross-sectional pattern of the spray is formed, in particular, in the form of a flat spray.