Patent Application
20090197214
1. Field of the Invention
The present invention is directed to low flow fuel nozzles for use in burners, such as oil burners, and more particularly, to an air assisted simplex fuel nozzle that is adapted for fuel modulation and uses auxiliary assist air to atomize the fuel.
2. Background of the Related Art
Conventional burners used in home heating applications generally include a fuel supply conduit connected at one end to a fuel supply pump and terminating at the other end at a fuel nozzle where the fuel is dispensed as an oil spray. The spray nozzle functions to mix the fuel with air that has been delivered by a motor powered blower. A burner-mounted ignition system is connected to an ignition apparatus that is located adjacent to the fuel nozzle near the exit where it ignites the atomized fuel-air mixture.
Typically, home heating applications require low flow rates (approximately 0.5 gph to 1.0 gph) of finely atomized fuel. Moreover, extremely low fuel flow rates (less than 0.5 gph) are desirable in applications where the volume of air to be heated is small, such as in a trailer home or small office.
Several known techniques exist for atomizing fuel. One conventional method of atomizing fuel is “pressure atomization,” whereby high velocity fuel is injected into relatively low velocity air. The interaction between the fuel and air shreds the fuel into fine droplets and subsequently greatly increases the fuel's surface area. The fine droplets and large surface area-to-volume ratio enhance chemical reaction rates that are beneficial to many processes. The disadvantage of using pressure atomization for low fuel flow rates is that the fluid passage size has to be very small to generate the hydraulic pressure required for atomization. Small fluid passage sizes are difficult to manufacture and are detrimental to product life due to a propensity to plug the fuel passage with contamination. When the passage size is maintained at some minimal value that is deemed acceptable for contamination resistance, the resultant hydraulic pressure associated with such a reduced fueling rate is so low that atomization is poor or nonexistent and fuel distribution is substandard.
An alternative method for atomizing fuel is to inject low velocity fuel into a relatively high velocity air stream. This method is generally referred to as “air blast atomization”. This method overcomes the minimum fluid passage size and low fuel pressure issues associated with “pressure atomization” as long as there is sufficient kinetic energy in the atomizing air stream to properly break up the fuel. In certain applications, the air stream does not have sufficient energy for atomization or there are operating modes where the air stream has limited energy for atomizing the fuel. When the atomizing air energy is low or insufficient, the result is the same as that of the low flow pressure atomizer; poor or nonexistent atomization and poor fuel distribution.
For applications where the required fuel flow rate is too low for effective pressure atomization and where there are no air blast atomizing air streams with sufficient energy across the application's entire operating range; an air assist system can be used. Air assist atomizers typically utilize a relatively high-pressure, high velocity air from an external source to augment the atomization process. Because the air assist atomizer uses an external source (e.g., a compressor), it is important to keep the air flow rate to a minimum in order to minimize the cost of the auxiliary air system. Thus, air assist atomizers are characterized by their use of a relatively small quantity of very high velocity air. The use of kinetic energy from the auxiliary air circuit to break up the fuel droplets provides very good atomization and fuel distribution at very low fuel flow rates. The low fuel pressure and fuel velocities associated with low fuel flow rates are not detrimental in an air assisted atomizer; in fact, a low fuel exit velocity as compared to a high air assist velocity provides the greatest relative velocity between the two fluids and promotes good atomization.
A siphon nozzle, shown in
Another example of a prior art device that uses assist air to atomize the fuel is an “Airo” nozzle, shown in
Therefore, there is a need for a low flow fuel nozzle for use in burners, such as oil burners that is easily modulated and uses assist air to atomize the fuel.
The present invention is directed to an air-assisted simplex spray nozzle assembly for a fuel burner that includes, inter alia, a nozzle body that has opposed upstream and downstream ends, wherein the downstream end of the nozzle body defines a fuel outlet, an adapter member that is engaged with the upstream end of the nozzle body and defines concentrically positioned air and fuel inlets for the nozzle assembly and an air cap that is positioned over the downstream end of the nozzle body. The nozzle assembly further includes a fuel circuit and a first air circuit. The fuel circuit directs fuel from a fuel pump toward the fuel outlet of the nozzle body. The fuel circuit extends from the fuel inlet of the adapter member through the nozzle body to the fuel outlet. The first air circuit directs assist air towards the fuel exiting from the fuel outlet. The first air circuit extends from the air inlet of the adapter member, through a gap defined between the air cap and the nozzle body and merges with the fuel emitted from the fuel outlet of the nozzle body. In certain embodiments, the assist air is provided to the first air circuit by a pump.
The nozzle assembly of the present invention preferably includes a fuel distributor disposed within an interior chamber defined by the nozzle body for receiving fuel from the fuel inlet of the adapter member and directing the fuel radially outward. It is also envisioned that the nozzle assembly can utilize an orifice disc that is disposed within the interior chamber of the nozzle body downstream of the fuel distributor. In such constructions, the fuel circuit extends through a gap formed between the fuel distributor and the orifice disc which terminates in a spin chamber. Preferably, the fuel distributor has a plurality of slots formed in its downstream end that are adapted and configured for imparting a swirl to the fuel traversing the fuel circuit.
In a preferred embodiment, the adapter member includes a plurality of flow ports that are in fluid communication with the air inlet and extend at an angle with respect to a central axis for the nozzle assembly to the exterior of the adapter member. Still further, it is envisioned that the nozzle body can include a plurality of flow ports that are in fluid communication with corresponding flow ports of the adapter member and direct the assist air to a gap defined between the air cap and nozzle body.
It is further envisioned that the downstream surface of the nozzle body can include means for imparting a swirling motion to the assist air passing through the gap defined between the air cap and the nozzle body.
In certain embodiments of the present invention the nozzle assembly can also include a first and second tube members that are engaged with the adapter member. It is envisioned that the first tube member is adapted for supplying auxiliary assist air to the air inlet of the adapter member and the second tube member is positioned within the first tube member and is adapted and configured for supplying fuel to the fuel inlet of the adapter member.
It is envisioned that the nozzle assembly of the present invention can also include an air shroud positioned over the air cap, so as to define a second air circuit between the air shroud and air cap. In a preferred embodiment, system air or fan air is supplied to the second air circuit.
It is presently preferred that the nozzle assembly be capable of accommodating a fuel flow modulation turn down ratio of 5. Preferably, the nozzle assembly is adapted and configured for fuel flow modulation between 0.1 gallons per hour and 0.5 gallons per hour.
The present invention is also directed to an air-assisted spray nozzle assembly that includes, inter alia, an elongated nozzle body, an orifice disc, a fuel distributor, an adapter member and an air cap.
The elongated nozzle body has a peripheral wall that extends between axially opposed upstream and downstream ends. Moreover, the nozzle body defines an interior chamber for the spray nozzle assembly and has a plurality of air passages formed in its peripheral wall which extend radially outward from the interior chamber. In certain constructions, the nozzle body includes a plurality of radial flow ports.
The orifice disc is disposed within the interior chamber of the nozzle body, adjacent the downstream end thereof. A fuel orifice extends from an upstream side of the orifice disc to a downstream side of the disc.
The fuel distributor is disposed within the interior chamber of the nozzle body and is positioned adjacent to and upstream of the orifice disc. The fuel distributor defines a fuel passage which extends axially from its upstream end to a plurality of radially oriented exit ports. In certain embodiments, it is envisioned that a fuel circuit extends through a gap formed between the fuel distributor and the orifice disc. Preferably, the fuel distributor has a plurality of slots formed in its downstream end that are adapted and configured for imparting a swirl to the fuel. In certain embodiments, the slots are formed in planes that are slightly offset from a plane passing through the central axis of the distributor. In alternative embodiments the slots can be formed in arcs similar to swirling vanes.
The adapter member is releasably secured to the upstream end of the nozzle body so as to retain the orifice disc and fuel distributor within the interior chamber. The adapter member defines a fuel inlet passage and an assist air inlet passage for the spray nozzle. The fuel inlet passage extends axially through the adapter member and connects with the fuel passage of the distributor. The air inlet passage extends axially from the upstream end of the adapter to a plurality of flow ports which are formed at an angle with respect to the axis for the spray nozzle and exit the periphery of the adapter member.
The air cap is positioned over the downstream end of the nozzle body for directing the assist air received from the air inlet passage of the adapter member to the fuel orifice of the orifice disc where the assist air merges with the fuel. In a preferred construction, the assist air is provided to the air inlet passage of the adapter member by an auxiliary pump.
It is also envisioned that the downstream surface of the nozzle body includes structure (e.g., vane elements) for imparting a swirling motion to assist air passing through a gap defined between the air cap and the nozzle body.
In certain embodiments of the present invention the nozzle assembly can also include a first and second tube members that are engaged with the adapter member. It is envisioned that the first tube member is adapted for supplying assist air to the air inlet of the adapter member and the second tube member is positioned within the first tube member and is adapted and configured for supplying fuel to the fuel inlet of the adapter member.
It is envisioned that the nozzle assembly of the present invention can also include an air shroud positioned over the air cap, so as to define a second air circuit between the air shroud and air cap. Preferably, the air supplied to the second air circuit is provided by a blower or motor/fan assembly.
In a presently preferred embodiment of the present invention the nozzle assembly including an air shroud is capable of accommodating a fuel flow modulation turn down ratio of 5. Preferably, the nozzle assembly including air shroud is adapted and configured for fuel flow modulation between 0.1 gallons per hour and 0.5 gallons per hour.
The present invention is also directed to an oil burner for home heating that includes, among other elements, an air pump or compressor for providing assist air, a motor driven blower for providing system air, a fuel pump for supplying fuel and an air assisted spray nozzle that has been constructed in accordance with the teachings of the present invention.
So that those having ordinary skill in the art will better understand how to make and use the nozzles of the subject invention, embodiments thereof will be described below with reference to the drawings wherein:
a is an elevational view of a prior art system for atomizing fuel;
b provides an elevational view (taken in cross-section) and upstream and downstream end views of a siphon nozzle used in the prior art system shown in
a is an elevational view of a second prior art system for atomizing fuel;
b provides an elevational view (taken in cross-section) and upstream and downstream end views of an Airo nozzle;
These and other aspects of the subject invention will become more readily apparent to those having ordinary skill in the art from the following detailed description of the preferred embodiments of the invention taken in conjunction with the figures.
In the description which follows, as is common in the art to which the subject invention appertains, the term “upstream” shall refer to a direction with respect to the air-assisted nozzle that faces the fuel and air inlet/supply, while the term “downstream” shall refer to a direction with respect to the air-assisted nozzle that faces the fuel and air exit, as identified in
Referring now to the drawings wherein like reference numerals identify similar features of the nozzle of the subject invention, there is illustrated in
An adapter member 30 is engaged with the upstream end 22 of the nozzle body 20 and includes a series of male threads 32 that engage with corresponding female threads 27 formed on the nozzle body 20. A pair of 0-rings 33/35 are used to seal the connection between the adapter member 30 and the nozzle body 20, so as to prevent fluid and air leakage. Those skilled in the art will readily appreciate that a variety of connections can be used to releasably secure the adapter member 30 to the nozzle body 20 without departing from the inventive aspects of the present disclosure.
The adapter member 30 also includes a plurality of flow ports 36 that are in fluid communication with an air inlet 38 and extend at an angle with respect to a central axis 12 for the nozzle 10. The nozzle body 20 includes a plurality of circumferentially spaced apart flow ports 29 that are in fluid communication with corresponding flow ports 36 of the adapter member 30.
An air cap 40 is positioned over the downstream end 24 of the nozzle body 20. The air cap 40 has an outer circumferential wall 44 with an inner diameter that is dimensioned for insertion over a portion of the upstream end 22 of the nozzle body 20. The air cap 40 also includes an inwardly projecting frustoconical surface 46 that encloses the downstream end 24 of the nozzle body 20.
A fuel distributor 50 and an orifice disc 60 are disposed within the interior chamber 25 of the nozzle body 20. The fuel distributor 50 receives fuel from the fuel inlet of the nozzle 10 and directs the fuel radially outward through a plurality of exit ports 54.
First and second tube members 70/80 are engaged with the upstream end of the adapter member 30. As will be discussed in more detail below, the first tube member 70 receives auxiliary assist air and supplies the assist air to the air inlet 38 of the adapter member 30. The second tube member 80 is coaxially positioned within the first tube member 70 and is adapted and configured for receiving fuel from a fuel pump and directs the fuel to the adapter member 30.
The assembled nozzle 10 defines a fuel circuit and a first air circuit. In operation, the second tube member 80 of the nozzle assembly is fluidly connected to a fuel source. The second tube member 80 or fuel supply tube receives the fuel and directs it axially to an inlet port 56 formed in the distributor 50. The distributor 50 redirects the fuel radially outward through flow ports 54 into a void space formed within interior chamber 25. The distributor 50 has a series of flow channels 58 formed on its downstream surface which allow the fuel to proceed between the distributor 50 and the orifice disc 60 into spin chamber 80. As shown in
The first tube member 70 (air supply tube) receives assist air from an auxiliary pump, for example, and directs the air towards the air inlet 38 of the adapter member 30. The assist air then proceeds through flow ports 36 and 29 of the adapter member 30 and nozzle body 20, respectively. The nozzle body 20 has a plurality of flow channels 86 formed on its downstream end 24 that are defined by a plurality of vane elements 88. The assist air flows from within gap 42, through the flow channels 86, which impart a swirling motion to the air, and then the swirling air merges with the fuel exiting orifice 65 in mixing chamber 85. In the embodiment shown in
In home heating applications, the auxiliary assist air is provided to the first air circuit and the air supply tube at a pressure that is considered relatively high compared to the pressure of the system air provided by a blower assembly that includes a motor and a fan. For example, the presently disclosed nozzle performed well during testing when the auxiliary pump provided assist air at about between 2 psig to about 4 psig and the blower assembly provided system air to the nozzle at between about 5 inches to 10 inches of water delta pressure (0.1805 psig to 0.3610 psig).
Nozzle 10 is adapted for use in home heating applications that require a particularly low fuel flow rate. For example, in small homes or offices, it is desirable to provide the fuel at an extremely low flow rate (i.e., less than 0.5 gallons per hour). Traditionally, such low flow rates have not been achievable due to the inability to provide a fuel nozzle that can support a flow rate below 0.5 GPH without clogging.
Nozzle 10 is capable of accommodating a fuel flow modulation turn down ratio of 5 and is adapted and configured for fuel flow modulation between about 0.1 gallons per hour and about 0.5 gallons per hour. At very low flow rates, such as 0.1 GPH, the distributor is ineffective and the fuel exits orifice 65 with very little momentum. The air assist circuit picks up the fuel as it exits and creates the desired conic spray. At higher fuel flow rates (e.g. 0.5 GPH) the distributor imparts a swirling motion that causes the fuel to spread out into a conic spray or an onion shape as it exits orifice 65. The fuel spray is again merged with the assist air and creates the desired conic spray. The use of a distributor 50 with angled flow channel 58 imparts a swirling motion on the fuel and avoids the narrow spray angle of a plain orifice.
The assist air circuit is positioned concentrically outboard of the fuel exit orifice. If additional air is required for process mixing or for combustion, additional swirlers can be added concentrically outboard of the air assist circuit.
Referring now to
Since the mixing of the fuel and assist air occurs external to the nozzle body, there is little feedback between the fuel and the air assist circuits. As a result, the fuel can be modulated without impacting the flow of the assist air and vice verse. Through experimentation, nozzle 10 performs optimally when the assist air pressure is between about 2 and about 4 psig for fuel flow rates of 0.1 to 0.6 GPH.
While the present invention has been described in terms of specific embodiments thereof, it will be understood that no limitations are intended thereby to the details of construction or design, the present invention contemplating and including any novel feature or novel combination of features which are herein disclosed.
