Spray orifice disk and valve

Abstract

A spray orifice disk for a valve for a flowing fluid and, in particular, for a metering or injection valve for an internal combustion engine, including a disk body and a spray orifice set-up, which is formed in the disk body and is configured with at least one spray orifice for dispensing supplied fluid, and including at least one channel for supplying the fluid to the spray orifice. The spray orifice, the channel and/or the transition between the channel and the spray orifice being configured to form a swirl geometry of the spray orifice disk in such a manner, that during operation, due to interaction of one or more jets of the fluid emerging from the spray orifice in turbulence atomization, an oval cross-sectional pattern of the spray is formed, in particular, in the form of a flat spray.

Claims

1. A spray orifice disk for a valve for a metering valve or an injection valve, for at least one of an internal combustion engine and an exhaust gas aftertreatment, comprising: a disk body; a spray orifice set-up which is formed in the disk body, the spray orifice set-up being configured with a plurality of spray orifices for dispensing supplied fluid as a spray, and respective channels for supplying the fluid to a respective ones of the spray orifices; and a swirl chamber formed at a transition between each specific ones of the channels and the respective one of the spray orifices; wherein a center of the swirl chamber is arranged with an offset from a longitudinal axis of the channel, wherein the plurality of the spray orifices are arranged respectively on a first circle, and a second circle whose diameter is smaller than the first circle, whose center is a lateral center of the spray orifice disk, and adjacent holes of the spray orifices are arranged on different respective ones of the first and second circles, wherein a direction of the offset of the swirl chambers are inside of an acute angle formed by the channel connected to the spray orifice arranged on the first circle and the channel connected to the spray orifice arranged on the second circle.

2. The spray orifice disk as recited in claim 1, wherein an oval cross-sectional pattern of the spray is produced: (i) at low pressures in the range of approximately 3.Math.105 Pa (3 bar) to approximately 10.Math.105 Pa (10 bar), (ii) to have a uniform distribution of the fluid in the spray, and/or (iii) to have a reduced droplet size of the spray, having an SMD value of less than 80 μm.

3. The spray orifice disk as recited in claim 1, wherein each of the channels connected to each of the plurality of spray orifices respectively extends from each said swirl chamber to a valve opening.

4. The spray orifice disk as recited in claim 1, wherein two of the spray orifices are formed on the first circle and the second circle respectively.

5. The spray orifice disk as recited in claim 1, wherein the fluid injected from the spray orifices connected to the channels which forms the acute angle have swirl directions opposite to each other.

6. A metering or injection valve for at least one of an internal combustion engine and an exhaust gas aftertreatment, comprising: a valve seat body, which terminates a valve chamber and has a valve opening; and a spray orifice disk situated downstream from the valve seat body, wherein the spray orifice disk includes: a disk body; a spray orifice set-up which is formed in the disk body, the spray orifice set-up being configured with a plurality of spray orifices for dispensing supplied fluid as a spray, and respective channels for supplying the fluid to a respective ones of the spray orifices; and a swirl chamber formed at a transition between each specific ones of the channels and the respective one of the spray orifices; wherein a center of the swirl chamber is arranged with an offset from a longitudinal axis of the channel, wherein the plurality of the spray orifices are arranged respectively on a first circle, and a second circle whose diameter is smaller than the first circle, whose center is a lateral center of the spray orifice disk, and adjacent holes of the spray orifices are arranged on different respective ones of the first and second circles, wherein a direction of the offset of the swirl chambers are inside of the acute angle formed by the channel connected to the spray orifice arranged on the first circle and the channel connected to the spray orifice arranged on the second circle.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a schematic and sectional side view of a part of a valve according to the present invention.

(2) FIGS. 2, 3-1 and 3-2 are a schematic and sectional side view and top views of specific embodiments of a spray orifice disk according to the present invention.

(3) FIGS. 4 through 6 show specific embodiments of the spray orifice disk of the present invention, having a 4-hole, 4-channel geometry.

(4) FIGS. 7 and 8 show schematic and sectional top views of specific embodiments of the spray orifice disk according to the present invention, having a 2-hole, 2-channel geometry and a combination including two colliding jets.

(5) FIGS. 9 and 10 show schematic and sectional top views of specific embodiments of the spray orifice disk according to the present invention, having a 1-hole, 2-channel geometry.

(6) FIGS. 11 through 20 show different specific embodiments of the spray orifice disk according to the present invention, having a 4-hole, 4-channel geometry and corresponding embodiments of the spray orifices, the atomization cones, and their cross sections.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

(7) In the following, exemplary embodiments of the present invention are described in detail, with reference to FIGS. 1 through 20. Identical elements and components, as well as elements and components that function equally or equivalently, are denoted by the same reference numerals. The detailed description of designated elements and components is not repeated in every instance of their appearance.

(8) The depicted features and further characteristics may be isolated from one another as desired, and combined arbitrarily with one another, without departing from the essence of the present invention.

(9) FIG. 1 shows a schematic and sectional side view of a detail of a specific embodiment of a valve 1 according to the present invention, which utilizes a spray orifice disk 10 of the present invention.

(10) Valve 1 includes a valve seat support 2, in the lower region of which valve seat 7 is formed and attached to valve seat support 2 via first fastening element 9-1. At its lower end, a valve member 8 includes a closing head 5, which, in this case, is spherically shaped and may be seated on valve seat 7 in a controlled manner, in order to occlude or uncover a valve opening 6 in a controlled manner. Valve seat 7 is formed by a conical surface of a valve seat body 4 and includes valve opening 6 at its lower end. At the endface of valve seat body 4 and opposite to valve opening 6, a spray orifice disk 10 of the present invention, which includes a disk body 20 and a spray orifice set-up 30, is attached to the outside of valve seat body 4 by second fastening elements 9-2.

(11) Spray orifice disk 10 includes several openings, via which one or more spray orifices 31 of the spray orifice set-up are formed on the one side. On the other side, flowing fluid 11 is directed from valve chamber 3 through valve opening 6 to spray orifices 31, with the aid of channels 33 leading to spray orifice 31, and optionally via swirl chambers 32 formed in the transition between channels 33 and respective spray orifices 31.

(12) Flowing fluid 11 leaves valve 1 through a specific spray orifice 31, in the form of one or more atomization cones 12, which are synonymously referred to as spray or spray cones, as well.

(13) FIGS. 2 and 3-1 show a schematic and sectional side view and a schematic and sectional top view of a specific embodiment of the spray orifice disk 10 of the present invention, having two spray orifices 31. Spray orifices 31 are formed in disk body 20 as vertical spray orifices 31. In use, as shown in FIG. 1, they are fluid-mechanically in contact with the side of spray orifice disk 10 facing way from spray orifice 31, and there, with corresponding valve opening 6, via a respective channel 33, and, in the transition between channel 33 and spray orifice 31, with a swirl chamber 32.

(14) Two spray orifices 31 are formed in the specific embodiment of FIG. 3-1. The number and the geometry of spray orifices 31 may be varied, in order to adapt the advantages produced by the present invention, regarding the geometry of spray cone 12, its uniformity, as well as the droplet size distribution.

(15) In the specific embodiment of FIG. 3-1, channels 33, which convey flowing fluid 11, are linear and are placed eccentrically with regard to the spray orifice geometry. The shape of channels 33 and the degree of eccentricity may be varied, as well.

(16) The same applies to swirl chambers 32 and their size, orientation and shape.

(17) In FIGS. 2 and 3-1, the spray orifice disk has essentially the shape of a circular disk having lateral center 15 and center axis 16.

(18) FIG. 3-2 shows a schematic and partly sectional top view of a specific embodiment of the spray orifice disk 10 of the present invention, comparable to the view of FIG. 3-1, but having a 4-hole, 4-channel configuration. Thus, this spray orifice disk 10 is formed with (i) a spray orifice set-up 30 having four spray orifices 31, which are situated on a circular line 38, concentrically about lateral center 15 of spray orifice disk 10, (ii) four supplying channels 33, pairs of which subtend an angle 36 about lateral center 15, and (iii) in each instance, a swirl chamber 32 between channel 33 and spray orifice 31. In operation, using the design, geometry and relative layout of channels 33, swirl chambers 32 and spray orifices 31, a corresponding momentum 40 is generated for flowing fluid 11 and the atomization cones 12 forming at the outlet of the spray orifices.

(19) In a form analogous to FIG. 3-2, FIGS. 4 to 6 show schematic and partly sectional top views of other refinements of the spray orifice disk 10 of the present invention, having a 4-hole, 4-channel configuration.

(20) In the specific embodiment of FIG. 4, there is a 4-hole, 4-channel geometry including four equal-length channels 33 parallel to each other, via which flowing fluid 11 is supplied to four spray orifices 31 having their swirl chambers 32 in between. Channel spacings 34 and channel lengths 35 may be varied to refine atomization cone 12 or atomization cones 12, in a manner analogous to the geometries and layouts of channels 33, of swirl chambers 32 and also of the spray orifices 31 themselves.

(21) FIG. 5 shows likewise a 4-hole, 4-channel geometry, in which pairs of the four channels 33 subtend a particular, first channel angle 36. This may be varied in the same manner as central distance 37 from lateral center 35 of spray orifice disk 10, in order to adjust the characteristics of atomization cone 12 or atomization cones 12.

(22) In the specific embodiment according to FIG. 6, a 4-hole, 4-channel geometry is formed, in which first spray orifices 31 of spray orifice pairs are situated on a first circle 38 having a greater circle diameter and second spray orifices 31 of the spray orifice pairs are situated on a second circle 39 of lesser diameter. The pairs of spray orifices 31 and their channels 33 form, in turn, an angle 36 between them. Configuration circles 38 and 39 are concentric with respect to lateral center 15 of spray orifice disk 10.

(23) In this case, besides angle 36, the diameters of circles 38 and 39 may be suitably adjusted, in order to obtain certain characteristics of atomization cone 12 or atomization cones 12.

(24) FIGS. 7 and 8 show two specific embodiments of spray orifice disk 10 of the present invention, having a 2-hole, 2-channel configuration or geometry. FIGS. 9 and 10 show specific embodiments of spray orifice disk 10 of the present invention, having a 1-hole, 2-channel geometry including an oval spray orifice 31.

(25) In the specific embodiment of FIG. 10, a swirl chamber 32 is additionally formed in the transition between channel 33 and actual spray orifice 31.

(26) FIGS. 11 through 20 show spray orifice disks 10 of the present invention, having a 4-hole, 4-channel geometry and swirl chambers 32. In these specific embodiments, in each instance, two channels 33 are oriented in parallel with each other. The rotational direction of swirl chambers 32 are opposed for pairs of spray orifices 31, so that due to this, after emergence of flowing fluid 11 from spray orifice 31, the air of the atmosphere is drawn into the center of the jet, and individual jets 12-1, 12-2 form into a common and oval atomization cone 12. In this context, the direction of momentum is determined by the layout of channels 33.

(27) FIGS. 12 through 14, 17 and 20 show corresponding refinements of the combined spray cone 12.

(28) FIG. 13 shows an angle α.sub.Y 41 of the spray cone 12, and FIG. 14 shows an angle α.sub.X 42 of the spray cone 12.

(29) FIG. 18 shows the left or right part of FIG. 3-2 (the perspective is rotated by 90 degrees), and FIG. 19 shows a close up of one of the arms of FIG. 3-2.

(30) These and further features and characteristics of the present invention are clarified further, in light of the following explanations:

(31) An object of the present invention is to improve conventional atomization designs.

(32) At low pressures of 3 bar to 10 bar, conventional treatment concepts, e.g., including turbulence atomization, produce non-uniform jet distributions and/or relatively large droplet sizes, e.g., having SMD values of ca. 80 μm to 150 μm.

(33) The concept of the present invention is intended to produce a more uniform distribution inside of spray cone 12 and a marked reduction in the droplet size in the spray.

(34) The approach of the present invention is based on attaining uniform spray distributions with the smallest drop sizes. In this context, a basic idea is to design and adapt the swirl geometry in spray orifice disk 10 in such a manner, that through the interaction of the jets after emergence from spray orifice 31, the spray pattern is oval-shaped, in particular, in cross section.

(35) AdBlue metering (DNOX), water injection and fuel injection, in which oval sprays 12 prevent wall wetting, are suited as fields of application. In this manner, e.g., increased conversion rates in DNOX systems in the case of attachment near the engine, or improved dynamics in water and fuel injection, are possible.

(36) Using a different layout of the channel geometry, e.g., a variation including a variation of the angle 36 subtended by channels 33, one starting point consists in forming jet pairs, which produce an oval cross-sectional shape in the entire spray 12, in particular, by combining individual jets. In combination with different orifice angles of inclination, the momentum of the flow of fluid 11 may be used to direct the jet of spray 12 into the appropriate position.

(37) In order to obtain a desired spray shape, the swirl intensity and the orifice angle of inclination may be varied.

(38) The number of orifices and the channel layout may be varied to obtain a flat spray.

(39) The following advantages of the present invention become apparent: (i) uniform and finely atomized spray, (ii) effective atomization, even at low pressures, e.g., in comparison with turbulence atomization, (iii) use of spray 12 for exhaust pipes having an oval shape, (iv) reduction of wall wetting in the exhaust pipe or intake manifold, (v) inexpensive design of spray orifice disk 10, which may be produced by stamping or laser drilling.

(40) In certain examples of spray orifice disks of the present invention having a 4-hole geometry, every two channels 33 may be positioned parallelly to each other. In this context, the direction of rotation in swirl chambers 32 may be configured to be opposed for the two pairs. Due to that, the air of the atmosphere is drawn into the center of spray 12. An oval spray 12 is formed by combining individual jets. The direction of momentum may be determined by the layout of channels 33.

(41) The shape of spray 12 may be influenced by changing the layout of the pairs of channels 33, by changing the swirl intensity and/or the orifice angle of inclination.

(42) The following geometric and structural aspects of the present invention may be used individually or in arbitrary combination to obtain a flat shape of the atomization cone, in the sense of a flat spray having a uniform spray distribution: (I) If (a) with regard to spray orifices 31, one labels spray orifice diameter d0 and spray orifice area A0, (b) with regard to swirl chamber 32, one labels swirl chamber diameter Ds, and (c) with regard to a channel 33, one labels channel width kn, channel depth kt, channel area Ap, and channel eccentricity kd, as shown in FIG. 16 by reference numeral 50, then the following relations and sizings are applicable to the present invention individually or in arbitrary combination:

(43) $1.2\le \frac{\mathrm{Ds}}{d0}\le 5.00.5\le \frac{\mathrm{Ap}}{A0}\le 10.0$$0.1\le \frac{\mathrm{Ap}}{d0.Math.\mathrm{Ds}}\le 300.1\le \frac{\mathrm{kt}}{\mathrm{kb}}\le 1.3$$0\le \mathrm{kd}\le 0.8.Math.d0$  Channel eccentricity kd, which is denoted by reference numeral 50 in FIG. 16, may assume positive values in the direction of arrow 51 and negative values in the direction of arrow 52. Positive values provide an intensification of the swirl, negative values provide a reduction in the swirl of the jet emerging from a spray orifice 31. (II) In the configurations according to FIGS. 3-2 and 5, angle 36 may be in the range of approximately 70° to approximately 120°, in order to form a swirl geometry where orifice pairs are formed, in which the swirl direction or rotational direction is opposed. (III) In connection with the specific embodiments of FIGS. 7 and 8, the following must be considered:  The specific position of a spray orifice 31 may be on graduated circle diameters of different magnitudes. In this manner, in combination with the inclination of spray orifice 31, the shape of atomization or spray cone 12 may be adjusted.  In order to improve the uniformity, one may work with collision of jets in combination with swirl treatment. In this context, the spray orifices 31 used lie opposite to each other on a graduated circle diameter. The shape of a spray orifice 31 may be both cylindrical and conical, that is, narrowing in the direction of flow. The spray orifices may be inclined inwards. After the collision of the primary jets, atomization or spray cone 12 breaks up orthogonally to the plane of the jets. The shape of atomization or spray cone 12 may be adjusted, using the inclination of the spray orifice. (IV) In the configurations of the present invention shown in FIGS. 12 through 14, 17 and 20, the spray orifices 31 forming the basis of atomization or spray cones 12 and the geometry of spray orifice disk 10 and of spray orifice set-up 30 may be configured in such a manner, that atomization or spray cones 12 have a uniform mass distribution; the shape of the atomization or spray cone being able to be distinctively flat to oval.