Patent Application
20090308953
The present invention relates generally to fluid atomizing nozzles. Specifically, the present invention relates to atomizing nozzles that are configured to consistently produce a uniform fine mist.
Atomizing nozzles, also called mist heads, are used in connection with misting systems to produce a fog or fine mist. A fluid, typically water, is forced under pressure through the atomizing nozzles to produce the mist. Desirably, the mist is sufficiently fine so that it rapidly evaporates. As the mist evaporates, the general area around the atomizing nozzles becomes cooler. Rapid evaporation enhances the cooling effect while preventing people and property located in the mist from becoming overly wet. Accordingly, misting systems are often used for cooling and for increasing humidity.
In order to produce a fog or fine mist that quickly evaporates, atomizing nozzles conventionally incorporate a small outlet orifice through which the fluid passes under pressure to produce the desired fog or mist. In addition, a cylindrical or conical impeller, also called a plunger or poppet, is positioned within a fluid chamber from which the orifice provides fluid egress. The action of the impeller within the passage serves to fracture the fluid, resulting in a finer fog or mist.
One of the disadvantages of a cylindrical impeller is that, if the impeller is not perfectly aligned in the chamber, an inconsistent spray pattern and flow rate may result. This problem increases over time as deposits build on the impeller. These deposits create an uneven distribution of weight, resulting in more frequent improper orientations of the impeller within the fluid chamber.
Cylindrical impellers typically have one or more grooves that cause the impeller to vibrate and spin during operation. With the buildup of calcium and other deposits upon internal parts of the nozzle, the grooves on the impeller may catch and hang up on these deposits, stopping the movement of the impeller and interfering with proper nozzle operation.
Another disadvantage of current nozzle designs is that only a single variable, the size of the nozzle orifice, may be used to effect changes to the spray pattern and/or flow rate of the nozzle under a consistent pressure and with a given nozzle body. Changes in the nozzle body itself are often required to effect changes in flow rate. Since, in most circumstances, the nozzle body is the most expensive component of the nozzle to produce, the production of a plurality of different nozzle bodies is simply not cost effective.
What is desirable, therefore, would be an atomizing nozzle configured to eliminate the problems of impeller misalignment, and to allow increased control over the spray pattern and flow rate of a plurality of different nozzle utilizing a common nozzle body.
Accordingly, it is an advantage of one embodiment of the present invention that an atomizing nozzle with a spherical occluder is provided.
It is another advantage of one embodiment of the present invention that an atomizing nozzle is provided that uses a spherical occluder in lieu of a cylindrical impeller to reduce significantly the possibility of impeller misalignment.
It is another advantage of one embodiment of the present invention that an atomizing nozzle is provided that incorporates the use of fixed grooves to control the flow of fluid through the nozzle.
It is another advantage of one embodiment of the present invention that an atomizing nozzle is provided that incorporates an orifice bevel to control a mist spray pattern.
The above and other advantages of the present invention are carried out in one form by an atomizing nozzle for use in a misting system, where the atomizing nozzle includes a nozzle body having an inlet end, having an outlet end, and comprising an occluder chamber, an orifice insert configured to be affixed to the nozzle body proximate the outlet end and comprising a substantially cylindrical insert chamber configured to be contiguous with the occluder chamber, and a substantially spherical occluder configured to reside within the occluder chamber.
The above and other advantages of the present invention are carried out in another form by an atomizing nozzle for use in a misting system, where the atomizing nozzle includes a nozzle body incorporating an occluder chamber formed therein and substantially coaxial with a nozzle axis, an orifice insert made up of a substantially cylindrical insert chamber configured to be substantially coaxial with the nozzle axis, a mating surface formed at a chamber end of the orifice insert, and a flow-control groove formed into the mating surface of the orifice insert and configured to extend from the occluder chamber to the insert chamber, and an occluder configured to reside within the occluder chamber and mate with the mating surface.
A more complete understanding of the present invention may be derived by referring to the detailed description and claims when considered in connection with the Figures, wherein like reference numbers refer to similar items throughout the Figures, and:
In accordance with a preferred embodiment of the present invention,
Atomizing nozzle 20 forms a misting nozzle or head for use in a misting system (not shown) well known to those of ordinary skill in the art. Atomizing nozzle 20 is made up of a nozzle body 22, an orifice insert 24, an occluder 26, and an o-ring 28.
In the preferred embodiment, nozzle body 22 is formed of a series of substantially cylindrical shapes having a common axis 30, which serves as axis 30 for the entirety of atomizing nozzle 20.
Nozzle body 22 has a substantially cylindrical shank 32. Upon shank 32 are formed threads 34, with which atomizing nozzle 20 may be secured to piping or fittings in the misting system (not shown). Above shank 32, nozzle body 22 desirably has a substantially cylindrical seat 36, which is larger than shank 32. Seat 36 prohibits atomizing nozzle 20 from being screwed into the pipe or fitting of the misting system too far. Within seat 36 is an o-ring seat 38. O-ring 28 sits in o-ring seat 38, and allows a tight seal to be formed between atomizing nozzle 20 and the pipe or fitting of the misting system into which it is screwed without undue pressure. Above seat 36, nozzle body 22 desirably expands into a knob 40. Knob 40 is desirably knurled to increase friction, allowing atomizing nozzle 20 to be screwed into or out of the pipe or fitting of the misting system using hand-pressure alone.
Those skilled in the art will appreciate that these external features of atomizing nozzle 20 are not requirements of the present invention. Alternative embodiments of these features may be incorporated without departing from the spirit of the present invention.
Nozzle body 22, i.e., atomizing nozzle 20, has an inlet end 42 and an outlet end 44. An inlet channel 46 is formed into nozzle body 22 from inlet end 42. In the preferred embodiment, inlet channel 46 is desirably substantially cylindrical and substantially coaxial with nozzle axis 30. It will be appreciated, however, that this is not a requirement of the present invention. Alternative embodiments of inlet channel 46 may be used without departing from the spirit of the present invention.
Similarly, an insert recess 48 is formed into nozzle body 22 from outlet end 44. In the preferred embodiment, insert recess 48 is desirably substantially cylindrical and substantially coaxial with nozzle axis 30. It will be appreciated, however, that this is not a requirement of the present invention. Alternative embodiments of insert recess 48 may be used without departing from the spirit of the present invention.
An occluder chamber 50 is formed within nozzle body 22. Desirably, occluder chamber 50 is substantially coaxial with nozzle axis 30 and contiguous with inlet channel 46 and insert recess 48. In the preferred embodiment, occluder chamber 50 is desirably substantially cylindrical. It will be appreciated, however, that this is not a requirement of the present invention. Alternative embodiments of occluder chamber 50 may be used without departing from the spirit of the present invention.
Inlet channel 46, occluder chamber 50, and insert recess 48 together form a passage through nozzle body 22 along nozzle axis 30. Inlet channel 46 and insert recess 48 extend through nozzle body 22 from occluder chamber 50 to inlet end 42 and body outlet end 44, respectively.
Inlet channel 46 has an inlet channel diameter 52. Occluder chamber 50 has an occluder chamber diameter 54 greater than inlet channel diameter 52. Insert recess 48 has a recess diameter 56 greater than occluder chamber diameter 54.
Occluder 26 is substantially spherical and configured to reside within occluder chamber 50. Occluder 26 has an occluder diameter 58 which is greater than inlet channel diameter 52 and less than occluder chamber diameter 54. The operation and functionality of occluder 26 is discussed in greater detail hereinafter.
Orifice insert 24 is configured to be affixed to nozzle body 22 proximate outlet end 44. An insert flange 62 is formed upon orifice insert 24 and configured to mate with insert recess 48 formed within nozzle body 22.
In the preferred embodiment, insert recess 48 and insert flange 62 are substantially cylindrical and substantially coaxial with nozzle axis 30. Those skilled in the art will appreciate, however, that this is not a requirement of the present invention and that other mating forms of insert recess 48 and insert flange 62 may be used without departing from the spirit of the present invention.
In the preferred embodiment, insert recess 48 is formed with recess diameter 56 and a recess depth 60. Insert flange 62 is formed with a flange diameter 64 and a flange depth 66. Recess diameter 56 is substantially equal to flange diameter 64 and recess depth 60 is equal to or greater than flange depth 66. Insert flange 62 is configured to fit within insert recess 48, thereby affixing orifice insert 24 to nozzle body 22. Desirably, orifice insert 24 is press fit into nozzle body 22 using conventional techniques well known to those of ordinary skill in the art. It will be appreciated, however, that this is not a requirement of the present invention, and other methods of affixing orifice insert 24 to nozzle body 22 may be utilized without departing from the spirit of the present invention.
Orifice insert 24 has an orifice end 68, in which is found an orifice 70, and a chamber end 72 opposite orifice end 68. A substantially cylindrical insert chamber 74 is formed into orifice insert 24 from chamber end 72. Desirably, insert chamber 74 is substantially coaxial with nozzle axis 30. Ignoring occluder 26, insert chamber 74 is contiguous with occluder chamber 50 when orifice insert 24 is affixed to nozzle body 22.
A substantially conical chamber bevel 76 is formed into orifice insert 24. Desirably, chamber bevel 76 is substantially coaxial with nozzle axis 30, and forms an outlet end 78 of insert chamber 74.
A substantially cylindrical orifice channel 80 is formed through orifice insert 24 from insert chamber 74 to orifice end 68 of orifice insert 24. Orifice channel 80 is substantially coaxial with nozzle axis 30 and contiguous with insert chamber 74. An outer end of orifice channel 80 forms orifice 70.
A mating surface 82 is formed at chamber end 72 of orifice insert 24. Mating surface 82 is configured to mate with occluder 26. Insert chamber 74 has an insert chamber diameter 84. Insert chamber diameter 84 is less than occluder diameter 58, preventing occluder 26 from fully entering insert chamber 74.
In the preferred embodiment of the Figures, mating surface 82 is substantially perpendicular to nozzle axis 30. In this embodiment, a surface of occluder 26 mates with an inner edge of mating surface 82, where mating surface 82 encounters insert chamber 74. Those skilled in the art will appreciate, however, that this is not a requirement of the present invention. Other embodiments of mating surface 82 may be realized without departing from the spirit of the present invention.
In accordance with preferred embodiments of the present invention,
At least one flow-control groove 86 is formed into mating surface 82 of orifice insert 24. In the preferred embodiments, a plurality of substantially identical flow-control grooves is formed into mating surface 82. It will be appreciated that the number of flow-control grooves 86 formed into mating surface 82 is not germane to the present invention.
During operation, a fluid 88, typically water, passes through a fluid passage 90 through atomizing nozzle 20 to emerge as a mist 92. Fluid passage 90 consists of inlet channel 46, occluder chamber 50, flow-control grooves 86, insert chamber 74, and orifice channel 80.
Fluid 88 enters inlet end 42 of atomizing nozzle 20 under pressure. Fluid 88 flows through inlet channel 46 and into occluder chamber 50.
Because fluid 88 is under pressure, fluid 88 drives occluder 26 towards outlet end 44. Occluder 26 meets and mates with mating surface 82 of orifice insert 24. The pressure of fluid 88 holds occluder 26 against mating surface 82 as long as atomizing nozzle 20 is in use.
Unlike the substantially cylindrical impeller, also known as a poppet or plunger, of the prior art, occluder 26 does not vibrate, spin, or move during the operation of atomizing nozzle 20. The pressure of fluid 88 holds occluder firmly against mating surface 82, preventing occluder from moving. Occluder 26 effectively occludes the free passage of fluid 88 between occluder chamber 50 and insert chamber 74.
Because occluder 26 is substantially spherical, occluder 26 cannot misalign with orifice insert 24 and insert chamber 74 therein. It will be appreciated that were occluder 26 to perfectly mate with mating surface 82, occluder 26 would effectively inhibit atomizing nozzle 20 from operating. It is therefore neither necessary nor desirable that the sphericity of occluder 26 be perfect. Occluder 26 need only be substantially spherical.
Since occluder 26 effectively occludes the free passage of fluid 88 between occluder chamber 50 and insert chamber 74, it is desirable that some means other than leakage be provided to allow fluid 88 to pass into insert chamber 74. In order to pass into insert chamber 74, fluid 88 passes through flow control grooves 86. Flow control grooves 86 therefore extend from occluder chamber 50 to insert chamber 74, allowing the passage of fluid 88. Fluid 88 is forced around occluder 26 and through flow-control grooves 86 into insert chamber 74.
Desirably, each flow-control groove 86 is formed into mating surface 82 so a groove axis 94 of that flow-control groove 86 forms a groove angle 96 of approximately 90°±45° relative to an axis radius 98 emanating from nozzle axis 30. When flow-control grooves 86 are thus angularly formed into mating surface 82, fluid 88 passing through flow-control grooves 86 will spin inside insert chamber 74. This spinning begins the process of fractionating fluid 88 to form mist 92. Those skilled in the art will appreciate that this is not a requirement of the present invention. Other methods of forming flow-control grooves 86 and/or causing fluid 88 to spin within insert chamber 74 may be used without departing from the spirit of the present invention.
Chamber bevel 76 at outlet end 78 of insert chamber 74 causes the spin of fluid 88 to increase as fluid 88 approaches orifice channel 80. Fluid 88 passes through orifice channel 80 and emerges from orifice 70 as mist 92.
Control of fluid 88 through atomizing nozzle 20 is achievable in several different ways, which may be utilized severally or in conjunction.
Flow-control grooves 86 have a groove width 100 and a groove depth 102, demonstrated in
The flow of fluid 88 through flow-control grooves 86 is a function of groove width 100, groove depth 102, and groove shape 104. Varying any of these properties directly affects the flow of fluid 88 through atomizing nozzle 20.
The spin of fluid 88 within insert chamber 74 is a function of groove axis 94, i.e., of groove angle 96 of groove axis 94 relative to axis radius 98 of nozzle axis 30. Varying groove angle 96 and/or a length of axis radius 98 controls the spin of fluid 88 within insert chamber 74, hence the degree of fractionation of fluid 88 and the fineness of mist 92.
Occluder 26 mates with mating surface 82, which forms the chamber end 72 of insert chamber 74. Occluder 26 has occluder diameter 58. Insert chamber 74 has an insert chamber diameter 84 which is less than occluder diameter 58. Occluder 26 therefore can fit only partway into insert chamber 74. The relationship between occluder diameter 58 and insert chamber diameter 84 determines how far occluder 26 fits into insert chamber 74 when occluder 26 is mated with mating surface 82. The flow of fluid 88 from occluder chamber 50 to insert chamber 74 is a function of how far occluder 26 fits into insert chamber 74. Varying insert chamber diameter 84 relative to occluder diameter 58 controls the flow of fluid 88 between occluder chamber 50 and insert chamber 74, i.e., through atomizing nozzle 20.
Chamber bevel 76 forming outlet end 78 of insert chamber 74 has a bevel angle 106. Mist 92 emanates from atomizing nozzle 20 as a cloud having a mist output angle 108. Mist output angle 108 is a function of bevel angle 106. Varying bevel angle 106 will vary mist output angle 108.
In summary, the present invention teaches an atomizing nozzle 20 with a spherical occluder 26. Spherical occluder 26 is used in lieu of the conventional cylindrical impeller of the prior art, thereby significantly reducing the possibility of impeller misalignment. Flow-control grooves 86 are used in conjunction with spherical occluder 26 to control the flow of fluid 88 through atomizing nozzle 20. An insert chamber 74 having a chamber bevel 76 at its outlet end 78 serve to control a mist output angle 108.
Although the preferred embodiments of the invention have been illustrated and described in detail, it will be readily apparent to those skilled in the art that various modifications may be made therein without departing from the spirit of the invention or from the scope of the appended claims.
