Swirl Atomizer With Intertwined Conical Films for Uniform Spray
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Solution Overview
Problem
Existing pressure swirl atomizers produce non-homogeneous sprays at high flow rates and require high pressure, while jet atomizers produce larger droplets at lower flow rates, and existing systems become complex when air is used to reduce droplets.
Innovation Solution
A fluid atomizer with two intertwined conical films formed by a swirling fluid through inner and outer channels, using a swirl chamber, contracting channel, and outlet channels to achieve homogeneous sprays at high flow rates with low pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pressure swirl atomizers are used, then spray flow rate is improved, but droplet dispersion homogeneity deteriorates
Solution Approach 1:
The single spray stream is segmented into multiple streams by providing multiple nozzle bodies arranged circumferentially. Each nozzle body produces a separate spray pattern, and collectively they create a homogeneous full-cone spray distribution. This segmentation allows high flow rate operation while maintaining uniform droplet dispersion across the spray area.
2Manufacturing precision
If jet atomizers are used, then homogeneous spray is improved, but droplet size increases
Solution Approach 1:
The jet atomizer is divided into multiple nozzle bodies, each functioning as an independent atomizing element. This segmentation enables the system to achieve homogeneous spray distribution through multiple smaller streams rather than a single large stream, while maintaining operational efficiency at high flow rates.
Solution Approach 2:
Multiple nozzle bodies are combined in a circumferential arrangement around a common axis. Their individual spray patterns merge to form a unified full-cone spray pattern with homogeneous droplet distribution, achieving both homogeneity and efficiency.
3Productivity
If air is directed onto the film to reduce droplets, then droplet size is improved, but system complexity increases
Solution Approach 1:
The external air assistance system is extracted and replaced by an internal fluid dynamic mechanism. The nozzle design incorporates internal passages and geometric features that generate swirl flow and atomization effects within the nozzle body itself, eliminating the need for separate air supply systems while achieving fine droplet formation.
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 atomizer provides homogeneous spray application at high flow rates and low pressure, enhancing mixing and combustion efficiency in applications like internal combustion engines and chemical reactions.
Implementation Method 1
the fluid enters the swirl chamber at a tangential or preferred angle to create a swirl
Implementation Method 2
The fluid passing into the shrink chamber starts to rotate faster around the central axis of the atomizer. The pressure decreases when the fluid rotates faster in the contracting channel
Implementation Method 3
atomize the fluid in liquid form into a spray of droplets, and transform the same into a spray dispersion in the form of intertwined inner conical film and outer conical film layer
Data Source
AI summary
A fluid atomizer is provided, and the fluid atomizer is used to atomize the fluid into a spray of droplets, and transform the fluid into spray dispersion in the form of intertwined inner conical film and outer conical film layer by atomizing the fluid. The fluid atomizer includes a plurality of inlet channels, at least one swirl chamber, at least one contracting channel, at least one flow passage channel, at least one internal outlet channel, at least one external outlet channel, and at least one channel holder.