Swirler with 180-Degree Offset Channels for Uniform Spray
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Solution Overview
Problem
Conventional swirl nozzles with a swirl body require an upstream diaphragm to create a vortex, which can lead to dead areas and clogging due to liquid residues and deposits, especially in full cone nozzles where the liquid distribution is not uniform, causing corrosion and operational issues.
Innovation Solution
A swirl body design with exactly two swirl channels, 180° offset from each other, and a central bore (optional) that ensures uniform liquid distribution and prevents liquid residues from accumulating, eliminating the need for an upstream diaphragm and reducing the risk of clogging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an upstream diaphragm is used to create a vortex in conventional swirl nozzles, then a rotational flow is achieved, but dead areas and dead spaces form where liquid residues accumulate causing corrosion and clogging
Solution Approach 1:
The invention removes the upstream diaphragm component entirely from the nozzle system. Instead of using a diaphragm to create the vortex, the swirl body itself with its specifically designed swirl channels generates the rotational flow. This extraction of the problematic diaphragm component eliminates the dead areas and dead spaces that caused liquid residue accumulation, corrosion, and clogging, while maintaining the essential vortex generation function.
Solution Approach 2:
Conventional designs use a diaphragm upstream of the swirl body to create the vortex. The invention inverts this approach by integrating the vortex-generating functionality directly into the swirl body structure itself through the swirl channels. The rotational flow is now generated by the swirl channels' geometry rather than by a separate upstream component, fundamentally changing where and how the vortex is created.
2Ease of manufacture
If flat end faces are used on the swirl body, then manufacturing is simplified, but liquid residues accumulate on the end faces forming dead areas that lead to corrosion and clogging
Solution Approach 1:
The invention replaces the flat end faces with conically tapering end sections that have curved surfaces. The conical geometry with its sloping surfaces prevents liquid residues from accumulating on horizontal surfaces. Liquid that reaches the end sections naturally drains off along the sloped surfaces back toward the swirl channels, eliminating the dead areas that formed on flat end faces and preventing corrosion and clogging.
3Manufacturing precision
If multiple swirl channels are formed in the cylindrical outer surface, then liquid distribution improves, but the complexity of the swirl body increases
Solution Approach 1:
The invention applies local quality by giving each swirl channel a specific oblique orientation relative to the central longitudinal axis, with channels positioned at different angular locations around the circumference. Each channel is angled to direct liquid flow in a specific direction, creating a coordinated rotational pattern. This localized optimization of channel geometry and orientation achieves uniform liquid distribution across the spray pattern while maintaining a relatively simple overall swirl body structure.
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 achieves a full cone spray pattern with uniform liquid distribution and prevents liquid residues from accumulating, reducing corrosion and clogging risks, while allowing for easy cleaning and maintaining the nozzle's functionality.
Implementation Method 1
a plurality of swirl channels of the same geometry running obliquely to a central axis of the swirl body are formed... the liquid to be sprayed flows through at least one swirl channel... thereby creating a rotational flow
Implementation Method 2
a centrifugal force acts on the rotating fluid... creates a relatively thin, hollow cone-like liquid film that breaks up into individual fine drops
Implementation Method 3
the rotational flow leads to a pressure gradient between the wall of the outlet chamber and the central longitudinal axis of the swirl body
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The present invention relates to a swirler (1), in particular for use in a cone nozzle (19), such as a solid cone nozzle or a hollow cone nozzle, in order to set a fluid flowing through in rotation, with a cylindrical base section (2), which defines a cylindrical exterior surface (3), wherein one end section (8, 9) defining a conically tapering and a conical end face (6, 7) respectively adjoins each end-face end (4, 5) of the base section (2), and wherein, in the cylindrical exterior surface (3) of the swirler (1), a plurality of swirl channels (11) of identical geometry and running at an angle to a central axis (L) of the swirler (1) are formed with a uniform offset around the circumference of the swirler (1) and each swirl channel (11) opens into both conical end faces (6, 7), wherein exactly two swirl channels (11) are formed in the cylindrical exterior surface (3) of the swirler (1) with an offset of 180° in relation to one another, each channel opening into both end faces (6, 7).