Patent Application
20250187026
The present invention concerns systems for dispersing fluid using an agricultural sprayer. More particularly, embodiments of the present invention concern systems for atomizing fluid using a plurality of fluid nozzles and a pair of fans for dispersing atomized fluid.
The present invention concerns a fluid dispersion system for an agricultural sprayer (generally referred to hereafter as “system”), as well as methods of using the same. Some embodiments of the present invention concern a system having a plurality of fluid nozzles disposed within a dispersion chamber for atomizing fluid and a pair of fans for forcing air toward the fluid nozzles and dispersing atomized fluid. The system may be incorporated into agricultural sprayers which may be mounted, or otherwise engaged, to a vehicle, such as a tractor, and may be operatively connected therewith to allow a sprayer to be controlled from the vehicle.
According to some embodiments of the present invention, a system may comprise: (i) a first axial fan and a second axial fan, each configured to force air toward a dispersion chamber; (ii) a shaft for driving each fan; and (iii) a plurality of air vanes disposed within the dispersion chamber, each having at least one nozzle for atomizing a fluid. In some embodiments, each air vane may comprise a fluid inlet through which a pressurized fluid may flow and be directed to each nozzle of the corresponding air vane. A fluid inlet, according to some embodiments, may be connected to a tank for storing the fluid. In some embodiments, each air vane may be disposed near a periphery of the dispersion chamber, with each nozzle thereof directed generally away from a center of the dispersion chamber. According to some embodiments, each pair of adjacent air vanes may be equally spaced (i.e., the distance between a pair of adjacent air vanes may be about the same for all pairs of adjacent air vanes).
In accordance with some embodiments, the first axial fan and the second axial fan may be centrally engaged with the shaft which may be longitudinally oriented from a first end to a second end of the system. In some embodiments, a rotation axis of the shaft may be generally aligned with the center of the dispersion chamber. According to some embodiments, the shaft may be engaged with one or more motors to rotate the shaft and cause the blades of the first axial fan and the second axial fan to rotate and force air toward the dispersion chamber. In some embodiments, the shaft may be power take-off (PTO) driven, or directly driven by an engine.
According to some embodiments, the system may comprise a plurality of guide vanes for maintaining air flow parallel to the shaft, where each guide vane may be centrally aligned with the shaft. A first plurality of guide vanes, in some embodiments, may be disposed adjacent to an outflow side of the first axial fan blades (i.e., the side toward the dispersion chamber). Similarly, a second plurality of guide vanes, in some embodiments, may be disposed adjacent to an outflow side of the second axial fan blades (i.e., the side toward the dispersion chamber). According to some embodiments, the second axial fan blades and the second guide vanes may each be positioned closer to the dispersion chamber, relative to the positions of each of the first axial fan blades and the first guide vanes. During operation, air flow may be directed (by the axial fan blades and guide vanes) toward the dispersion chamber where it may be redirected toward the air vanes to aid in the mixing of atomized fluid dispensed from the air vane nozzles with surrounding air and also in the dispersion of atomized fluid over a given area. In some embodiments, one or more air baffles may be disposed within the dispersion chamber for diverting air entering the dispersion chamber.
As an advantage of the present invention, and according to some embodiments, the first axial fan blades may have a diameter (i.e., the distance from an edge of a blade to a center of the rotation axis) which may be less than a diameter of the second axial fan blades. Likewise, in some embodiments, the first guide vanes may have a diameter which may be less than a diameter of the second guide vanes. In addition, and according to some embodiments, an axial fan may be disposed within a housing which, in some embodiments, may have a circumferential body and a lip circumscribing an opening of the housing. In some embodiments, a body of a housing of a first axial fan may partially extend within an opening of a housing of a second axial fan. A space between a body of a housing of a first axial fan and a body of a housing of a second axial fan, according to some embodiments, may equate approximately to the difference between the diameters of the first axial fan and second axial fan.
During operation, the configuration of the fans and housings may create a Venturi effect which causes the entrainment of surrounding air which mixes with the induced air by each fan, thereby increasing the amount of air forced into the dispersion chamber, relative to a conventional fluid dispersion system. As a result of this enhanced air flow (i.e., induced and entrained air) into the dispersion chamber, atomized fluid dispensed from the fluid nozzles may be mixed more effectively with surrounding air and dispersed over a relatively greater area compared to conventional fluid dispersion systems.
According to some embodiments, upon activation of the system, atmospheric air may be drawn into the first axial fan which, in some aspects, may be a 30″ HPR (high performance reverse) steel axial flow fan. In some embodiments, the first axial fan may be a 34″ HPR steel axial flow fan. The first axial fan may force air through the housing of the first axial fan (with guide vanes) to supercharge air delivery to the second axial fan which, in some aspects, may be a 36-inch HPR steel axial flow fan. In some embodiments, the second axial fan may be a 40″ HPR steel axial flow fan. It is to be appreciated that, in some embodiments, the first axial fan and the second axial fan may be aligned so that the blades of each fan may be picketed to cover the gap between the blades if aligned down the shaft. The second axial fan may consume forced air from the first axial fan, as well as draw atmospheric air from around the housing of the first axial fan. This creates a forced air induction Venturi effect which in turn multiplies air production through the housing of the second axial fan to positively charge the air discharge throat exit of the fan housing which, in some aspects, may have a diameter of 9 and ¾ inches. Upon the air passing through the housing of the second axial fan, according to some embodiments, there may be a series of two air baffles to divert air flow which may create more air turbulence (relative to conventional systems) before the discharge air will compress in the dispersion chamber and exit the system. Lastly, pressurized fluid may pass through one or more manifolds to a plurality of pressure hoses which, in some aspects, may each be ⅜ inch hoses each attached with an SAE (Society of Automotive Engineers) swivel fitting to a plurality of 3-port composite nylon air vanes. The introduction of fluid at the dispersion chamber combined with high air volume, extreme air turbulence, and the ability to manipulate where the discharge air and spray are directed to target a crop make the present invention advantageous over conventional systems.
According to some implementations, the axial fans of the system may be installed according to the following steps. First, the rear leading plate of the system may be removed to expose a plurality of second guide vanes within a second housing of a second axial fan. Next, the second guide vanes may be removed from the second housing of the second axial fan. Following, the shaft and bearings may be dialed to a plurality of bearing stands and tightened according to final specifications, then the shaft may be removed, leaving the bearings in place. Next, a first axial fan may be set in place, followed by setting the second axial fan in place. Following, the second guide vanes may be set back in place and loosely secured with or more fasteners (e.g., bolt(s)). Then, the shaft, with taper-locks and keys, in some embodiments, may be slid back through the bearings and axial fans. Next, the shaft may be set in place and the bearing housings may be secured to the fan shaft. Next, the taper-locks of the axial fans may be aligned and the axial fans may be set in place loosely to the guide vanes. Following, the final position of the guide vanes may be set and tightened completely. Next, the axial fans may be adjusted and set in their final position and tightened completely. Then, the rear leading-edge plate may be secured according to final specifications. Following, one or more air vanes (in some embodiments, eighteen 3-port composite nylon air vanes) may be installed into the dispersion chamber and one or connections (in some embodiments, SAE swivel connections) may be attached to one or more pressure manifold hoses which connect to the one or more air vanes. Lastly, the air baffles (which may be galvanized steel, in some embodiments) may be installed, preferably, at the bottom right and left sides of the dispersion chamber. The system may now be complete and ready for final installation to a chassis of an agricultural sprayer.
According to some embodiments of the present invention, a system for dispersing a fluid may comprise: a) a first axial fan which may have a plurality of blades and may be disposed within a first housing and centrally engaged with a shaft, where the first housing may have a first end, a second end having an outwardly protruding lip, and a circumferential body therebetween; b) a second axial fan which may have a plurality of blades and disposed within a second housing and centrally engaged with the shaft, where the second housing may have a first end, a second end having outwardly protruding lip, and a circumferential body therebetween; and c) a dispersion chamber which may comprise a central opening, a plurality of air vanes, and a plurality of fluid nozzles which may be configured to atomize the fluid, wherein each of the fluid nozzles may be engaged with one of the plurality of air vanes. In some embodiments, the first end of the second housing may be engaged to a wall of the dispersion chamber around the central opening. In some embodiments, the first end of the first housing may be positioned within the second housing between the first end of the second housing and the lip of the second housing. In some embodiments, a diameter of the body of the first housing may be less than a diameter of the body of the second housing. In some embodiments, the dispersion chamber may further comprise at least one baffle which may comprise a body and a lip. In some embodiments, the at least one baffle may comprise a first baffle and a second baffle, wherein the body of the first baffle may have a diameter greater than a diameter of the body of the second baffle. In some embodiments, the system may further comprise at least one guide vane disposed within at least one of the first housing and the second housing. In some embodiments, the at least one guide vane may comprise a first guide vane disposed within the first housing and a second guide vane disposed within the second housing, wherein the first guide vane may be positioned between the first axial fan and the second axial fan, and wherein the second guide vane may be positioned between the second axial fan and a wall of the dispersion chamber. In some embodiments, the first guide vane may have a diameter that may be less than a diameter of the second guide vane. In some embodiments, the system may further comprise a guard disposed around a portion of the first housing, where the guard may have a plurality of openings therein. In some embodiments, the plurality of blades of the first axial fan may have a diameter that is less than a diameter of the plurality of blades of the second axial fan. In some embodiments, the first axial fan may be configured to have a rotational speed that may be about the same as a rotational speed of the second axial fan. In some embodiments, at least one of the first axial fan and the second axial fan may be engaged to the shaft through a gear. In some embodiments, the system may further comprise an engine engaged with the shaft. In some embodiments, the system may further comprise a power take-off, wherein the shaft may be engaged to the engine through the power take-off. In some embodiments, the system may further comprise a tank for storing the fluid to be dispersed and a fluid line engaged to the tank and each the plurality of fluid nozzles.
According to some embodiments of the present invention, a system for dispersing a fluid, may comprise: a) an engine engaged with a shaft; b) a tank for storing the fluid to be dispersed; c) a dispersion chamber which may comprise a wall with a central opening, a plurality of air vanes, at least one baffle, and a plurality of fluid nozzles for atomizing the fluid, wherein each fluid nozzle may be engaged to the tank through a fluid line; d) a first axial fan which may comprise a plurality of blades and may be centrally engaged with the shaft, a first guide vane, and a first housing; and c) a second axial fan which may comprise a plurality of blades and may be centrally engaged with the shaft, a second guide vane, and a second housing, wherein the second axial fan may be positioned between the first axial fan and the wall of the dispersion chamber; wherein the second housing may be engaged with the wall of the dispersion chamber around the central opening, wherein a diameter of the plurality of blades of the first axial fan may be smaller than a diameter of the plurality of blades of the second fan, wherein a diameter of the first housing may be smaller than a diameter of the second housing, wherein the first guide vane may be positioned between the first axial fan and the second axial fan, and wherein the second guide vane may be positioned between the second axial fan and the wall of the dispersion chamber. In some embodiments, the second axial fan may be positioned between the first axial fan and the wall of the dispersion chamber. In some embodiments, the first guide vane may be positioned between the first axial fan and the second axial fan, and the second guide vane may be positioned between the second axial fan and the wall of the dispersion chamber.
According to some embodiments of the present invention, a method of dispersing a fluid may comprise the steps of: a) engaging a system to a tractor, where the system may comprise: 1) a dispersion chamber with a wall which may have a central opening and plurality of fluid nozzles; 2) a first axial fan which may be disposed in a first housing, where the first housing may have a first end and a second end; and 3) a second axial fan which may be disposed in a second housing, where the second housing may have a first end and a second end, wherein the second end may be engaged to the wall of the dispersion chamber around the central opening, wherein the second housing may surround a portion of the second end of the first housing; b) rotating the first axial fan to direct airflow towards the second axial fan; c) rotating the second axial fan to direct the airflow through the central opening in the wall of the dispersion chamber; and d) ejecting the fluid through the plurality of fluid nozzles to atomize the fluid in the dispersion chamber. In some embodiments, the system may further comprise a first air vane and the step of directing the airflow towards the second axial fan may comprise the step of directing the airflow through the first air vane. In some embodiments, the system may further comprise a second air vane and the step of directing the airflow through the central opening in the wall of the dispersion chamber may comprise the step of directing the airflow through the second air vane. In some embodiments, the dispersion chamber may further comprise at least one baffle and the method may further comprise the step of: c) directing the airflow through the at least one baffle towards the atomized fluid.
The invention, in its various aspects, will be explained in greater detail below. While the invention will be described in conjunction with several exemplary embodiments, the exemplary embodiments themselves do not limit the scope of the invention. Similarly, the exemplary illustrations in the accompanying drawings, where like elements have like numerals, do not limit the scope of the exemplary embodiments and/or invention, including any length, angles, or other measurements provided. Rather the invention, as defined by the claims, may cover alternatives, modifications, and/or equivalents of the exemplary embodiments.
According to some embodiments of the present invention, a fluid dispersion system may generally comprise a fan system and a fluid dispensing system, where the fan system is configured to force air generally in the direction of a plurality of nozzles configured to atomize a fluid. In some embodiments, the fan system may draw in air from a first side of the system and direct the air to a second side of the system. For example, and with reference, generally, to
In some embodiments, an axial fan may comprise one or more guide vanes. For example, and with reference to
According to some embodiments, and with reference to
According to some embodiments, a fluid dispensing system may comprise one or more air vanes having one or more nozzles engaged therewith. In some embodiments, a nozzle may comprise a single tip or multiple tips (i.e., a nozzle which dispenses fluid out of multiple tips from a single inlet fluid stream). For example, and with further reference to
In some embodiments, a wall of a dispersion chamber may have a fluid inlet which may be aligned with an opening in an air vane to allow a pressurized fluid to flow through the air vane opening and into a nozzle. For example, and with further reference to
In some embodiments, a second axial fan may be positioned such that a first side thereof is adjacent to a dispersion chamber and a second side thereof is adjacent to a first axial fan. For example, and with further reference to
According to some embodiments, a first axial fan and/or a second axial fan may be disposed within a housing. For example, and with reference to
According to some embodiments, a first axial fan and a second axial fan may be similarly shaped and/or sized. In other embodiments, a first axial fan may be differently shaped and/or sized relative to a second axial fan. For example, and with reference to
In some embodiments, a diameter of an opening of a housing may be slightly greater than that of an axial fan housed therein. As further illustrated in
According to some embodiments of the present invention, a fluid dispersion system may comprise one or more air baffles for diverting air outflow. For example, and with reference, generally, to
It is to be appreciated that an air baffle, as well as the walls of a dispersion chamber, may direct air flow entering the dispersion chamber from the fan system, with the shape and placement of the baffle affecting how the outflow air is distributed. For example, and with reference to
According to some implementations of the present invention, during operation, actuation of the first axial fan and the second axial fan may draw air in from the inflow side (i.e., the side opposite to dispersion chamber 60), forcing air through guard 40 (if attached) and into housing 25. While air is drawn into housing 25, air is also entrained into housing 26 toward second axial fan 22, bypassing the first axial fan blades 21 and guide vanes 23, but amplifying the air flow exiting the first axial fan. After air passes through second axial fan blades 22 and guide vanes 24, the air enters dispersion chamber 60 and interacts with first baffle 63 and second baffle 64. Within dispersion chamber 60, first baffle 63 and second baffle 64 may redirect air flow toward air vanes 50 (not illustrated in
In some implementations of the present invention, a fan system of a fluid dispersion system may be assembled, generally, according to the following steps which, in some implementations, may not be performed in the order presented and, in some implementations, one or more of the following steps may not be performed. First, a rear plate of a first fan housing may be removed. Next, a plurality of first guide vanes may be removed from the first fan housing. Following, a fan shaft may be removed from a fan system. Then, a second axial fan with a plurality of second guide vanes may be set in place within a second housing, with the second guide vanes disposed on an outflow side of the second axial fan. Next, a first axial fan and the first guide vanes may be set in place within the first fan housing, with the first guide vanes disposed on an outflow side of the first axial fan. Following, the shaft may be slid through the center of each of the axial fans and the guide vanes and then secured. Then, the first axial fan and the second axial fan, along with the first guide vanes and the second guide vanes, may be secured within the first housing and the second housing, respectively. Next, the rear plate may be secured to the first fan housing. Following, one or more air vanes may be installed within a dispersion chamber of the fluid dispensing system. Then, one or more air baffles may be installed within the dispersion chamber.
In some implementations of the present invention, a fan system of a fluid dispersion system may be disassembled according to the following steps which, in some implementations, may not be performed in the order presented and, in some implementations, one or more of the following steps may not be performed. First, one or more air baffles may be removed within the dispersion chamber (or the air baffles may be removed with the rear plate of the first fan housing). Next, one or more air vanes may be removed from within a dispersion chamber of the fluid dispensing system. Following, a rear plate or wall may be unsecured from a first fan housing and removed. Then, a first axial fan and a second axial fan, along with a plurality of first guide vanes and second guide vanes, may be unsecured from within the first fan housing and a second housing, respectively. Next, a fan shaft may be unsecured and removed. Following, the first axial fan and first guide vanes may be removed from the first fan housing. Then, the second axial fan and second guide vanes may be removed from the second housing.
It is to be understood that variations, modifications, and permutations of embodiments of the present invention may be made without departing from the scope thereof. It is also to be understood that the present invention is not limited by the specific embodiments, descriptions, or illustrations or combinations of either components or steps disclosed herein. Thus, although reference has been made to the accompanying figures, it is to be appreciated that these figures are exemplary and are not meant to limit the scope of the invention.
The present application claims priority to, and the benefit of, U.S. Provisional Patent Application No. 63/606,947, filed Dec. 6, 2023, which is hereby incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63606947 | Dec 2023 | US |
