Two-Fluid Nozzle Intermediate Chamber for Constant Jet Angle
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Solution Overview
Problem
Existing two-component nozzles for spraying liquid-gas mixtures face challenges in maintaining a constant jet angle when liquid or gas pressure fluctuates, leading to potential defects in cooling processes, such as those in continuous casting plants, where uniform cooling is critical for producing defect-free strands.
Innovation Solution
The nozzle design incorporates a throttle at the downstream end of the mixing chamber and an intermediate chamber before the swirl insert, along with a perforated disk and orifice plate, which maintains a constant jet angle by ensuring even distribution of the liquid-gas mixture, independent of pressure changes, and allows for adjustable liquid distribution by varying pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If pressure of liquid or gas supplied to the nozzle changes, then volume flow and cooling intensity can be adjusted, but jet angle of the spray jet changes leading to defects in cooling processes
Solution Approach 1:
An intermediate chamber is introduced between the mixing chamber and the swirl insert to act as a buffer zone. This intermediary space allows the liquid-gas mixture to stabilize before entering the swirl insert, decoupling the jet angle determination (which occurs at the swirl insert) from upstream pressure fluctuations in the mixing chamber.
Solution Approach 2:
The design changes the physical state and distribution parameters of the liquid-gas mixture by allowing it to travel through the intermediate chamber, where pressure equalization and phase stabilization occur. This parameter transformation ensures that when the mixture enters the swirl insert, it does so with consistent properties regardless of upstream pressure variations.
2Productivity
If volume flow is increased for stronger cooling, then cooling intensity improves, but jet angle changes causing non-uniform cooling and defects
Solution Approach 1:
The intermediate chamber serves as a buffer that decouples the relationship between volume flow adjustments and jet angle changes. By providing this intermediary space, the system can vary volume flow for different cooling intensities while maintaining consistent jet angle geometry, ensuring uniform cooling coverage across the entire strand surface.
3Device complexity
If simple nozzle design is used, then device complexity is reduced, but inability to maintain constant jet angle under pressure fluctuations occurs
Solution Approach 1:
The nozzle is segmented into distinct functional chambers: a mixing chamber for liquid-gas combination, an intermediate chamber for stabilization, and an outlet section with swirl insert for jet formation. This segmentation allows each section to perform its specific function independently, with the intermediate chamber specifically dedicated to pressure stabilization without adding complex control mechanisms.
4Adaptability or versatility
If pressure fluctuations are allowed for control flexibility, then adaptability improves, but segregation of liquid and gas in the mixture occurs
Solution Approach 1:
The intermediate chamber acts as a stabilizing intermediary that prevents pressure fluctuations from causing liquid-gas segregation. By providing this buffer zone, the system maintains mixture homogeneity even when upstream pressure varies for control flexibility, as the intermediate chamber allows pressure equalization before the mixture enters the outlet section.
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
This design ensures a substantially constant jet angle over a wide range of pressures, preventing defects in cooling processes and allowing for controlled cooling adjustments by influencing the liquid distribution within the spray cone, thus ensuring uniform cooling of strands.
Implementation Method 1
Downstream of the throttle there is an even distribution of liquid and gas in the liquid-gas mixture
Implementation Method 2
The liquid-gas mixture can then be set in rotation by means of the twist insert and, for example, a full cone or a hollow cone can be produced downstream of the outlet opening
Implementation Method 3
a throttle at the downstream end of the mixing chamber... provides a substantially constant jet angle, for example when the water pressure changes or fluctuates
Data Source
Figure 1~5
Figure 6~9
Figure 10~13
AI summary
The two-component nozzle (10) has a nozzle housing (12) with a liquid inlet and a gas inlet, where the liquid inlet and the gas inlet are opened in a mixing chamber. An outlet chamber is provided between a swirl insert and an outlet opening (18). A throttle is formed at the downstream seated end of the mixing chamber. An intermediate chamber is formed between the throttle and the swirl insert. The throttle has a perforated disk. An independent claim is included for a method for spraying a liquid-gas mixture with a two-component nozzle.