Stacked Spray Disc Assembly for Off-Axis Fluid Injection
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Solution Overview
Problem
Existing fluid injectors are limited in directing fluid spray patterns off-axis relative to the longitudinal axis, and they often result in non-atomized sprays, which restricts the flexibility and efficiency of fluid distribution.
Innovation Solution
A fluid injector design featuring a stack of disc members with dimples and channels, where the first disc member has a centrally located orifice and the second disc member has multiple orifices along its dimple, allowing fluid to flow through channels before exiting, creating an off-axis and highly atomized spray pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If channels are formed in a disc to direct fluid flow at the exit orifice, then fluid spray patterns are created, but the spray patterns are limited to being parallel to the fluid injector's longitudinal axis
Solution Approach 1:
The disc is segmented into multiple stacked disc members, each with specific channel configurations and orientations. This segmentation allows each disc member to contribute to different aspects of spray direction control, enabling off-axis spray patterns while maintaining manageable structural complexity
Solution Approach 2:
The invention introduces a stacked dimensional arrangement of multiple disc members instead of using a single planar disc. This adds a vertical dimension to the channel flow paths, enabling fluid to traverse through multiple disc layers and achieve off-axis spray directions that cannot be obtained with conventional single-disc designs
2Adaptability or versatility
If existing off-axis disc designs are used, then spray patterns are directed off-axis, but the spray is not highly atomized
Solution Approach 1:
The fluid flow path is segmented across multiple disc members with progressively configured channels and orifices. This segmentation creates multiple stages of flow direction changes and turbulence generation, which enhances atomization quality while maintaining off-axis spray capability
Solution Approach 2:
The stacked disc members create preliminary turbulence and flow disruption before the fluid exits the final orifices. This preliminary action of chaotifying the flow path through multiple disc layers ensures highly atomized spray patterns are achieved before the fluid is directed off-axis
3Adaptability or versatility
If a single disc with off-axis orifice is used, then off-axis spray is achieved, but spray atomization is insufficient
Solution Approach 1:
The single off-axis orifice is segmented into multiple orifices distributed across multiple stacked disc members. This segmentation increases the total quantity of fluid that can be sprayed off-axis while maintaining effective atomization, thereby improving overall fluid distribution efficiency
Solution Approach 2:
Multiple disc members with multiple orifices are merged into a stacked assembly that functions as a unified off-axis spray system. This merging combines the off-axis direction control capability with enhanced atomization and increased fluid distribution capacity
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 enables the creation of off-axis, highly atomized spray patterns, providing improved fluid distribution and flexibility in directing fluid streams, suitable for various applications such as fuel injection and reductant delivery systems.
Implementation Method 1
the fluid is directed by channels to impinge fluid flows and create a higher turbulence at the exit orifices
Data Source
AI summary
A spray disc arrangement for a fluid injector includes a first disc having a dimple with an orifice defined through the dimple. A second disc includes a dimple and a plurality of orifices defined through the dimple. The first disc dimple is received in the second disc dimple. The second disc includes a plurality of channels defined along a concave surface of the dimple, with the plurality of orifices located in the channels. The first disc and the second disc are coupled together such that a convex surface of the dimple of the first disc contacts a concave surface of the dimple of the second disc. The first disc is disposed along a downstream side of a valve seat of the fluid injector.