Gapped scanner nozzle assembly and method

Abstract

A fluidic scanner nozzle comprising an interaction chamber defined between an upstream end and a downstream end with a longitudinal chamber axis. The upstream end having an inlet opening for receiving and delivering pressurized fluid into said interaction chamber along said chamber axis. The downstream end having an outlet orifice for issuing a generally conical outlet spray of liquid droplets from said chamber into ambient environment and an axial gap positioned between said upstream end and said downstream end. The upstream and downstream ends may define inner cavities having a hemisphere shape. The axial gap may define a cylindrical sidewall segment aligned between an upper hemisphere shaped inner cavity and a lower hemisphere shaped inner cavity. The axial gap includes a selected axial length and an inside diameter that may be either a continuous axial gap or a stepped axial gap.

Claims

1. A fluidic scanner nozzle comprising: an interaction chamber defined axially between an upstream end and a downstream end and having a longitudinal chamber axis; said upstream end having an inlet opening for receiving pressurized fluid and delivering the pressurized fluid into said interaction chamber along said chamber axis, wherein said upstream end is an inlet member that defines an inner cavity having a hemisphere shape; said downstream end having an outlet orifice for issuing a generally conical outlet spray of liquid droplets from said chamber into an ambient environment wherein said downstream end is an outlet member that defines an inner cavity having a hemisphere shape, wherein the inner cavity of the inlet member is an upper hemisphere shape and the inner cavity of the outlet member is a lower hemisphere shape; and an axial gap positioned between said upstream end and said downstream end of the interaction chamber, wherein said axial gap defines a cylindrical sidewall segment aligned between said inlet member and said outlet member wherein said axial gap within said interaction chamber defines a vortex inducing chamber between the inlet member and the outlet member.

2. The fluidic scanner nozzle of claim 1 wherein the outlet member is configured to receive and be axially aligned with the inlet member in a congruent relationship to form said interaction chamber.

3. The fluidic scanner nozzle of claim 1, wherein said axial gap is positioned between a portion of the inlet member and the outlet member.

4. The fluidic scanner nozzle of claim 1, wherein said axial gap includes a selected axial length and an inside diameter that is wider than an inside diameter of either (a) the inlet member or (b) the outlet member.

5. The fluidic scanner nozzle of claim 1, wherein said axial gap is positioned between a portion of the inlet member and the outlet member and is a stepped axial gap.

6. The fluidic scanner nozzle of claim 1, wherein said axial gap is positioned between a portion of the inlet member and the outlet member and is a continuous axial gap.

7. A fluidic scanner nozzle comprising: an interaction chamber defined axially between an inlet member and an outlet member and having a longitudinal chamber axis; said inlet member including an upstream end having an inlet opening for receiving pressurized fluid and delivering the pressurized fluid into said interaction chamber along said chamber axis, wherein said inlet member defines an inner cavity having a hemisphere shape; said outlet member defines an inner cavity having a hemisphere shape wherein the inner cavity of the inlet member is an upper hemisphere shape and the inner cavity of the outlet member is a lower hemisphere shape and includes a downstream end having an outlet orifice for issuing a generally conical outlet spray of liquid droplets from said chamber into an ambient environment; and an axial gap positioned between said upstream end and said downstream end of said interaction chamber wherein said axial gap defines a sidewall segment aligned between said inlet member and said outlet member wherein said axial gap within said interaction chamber defines a vortex inducing chamber between the inlet member and the outlet member.

8. The fluidic scanner nozzle of claim 7, wherein said inlet member and outlet member are secured and sealed together to define said interaction chamber therebetween, said inlet member including a first open end longitudinally opposite said inlet opening and said outlet member including a second open end longitudinally opposite said outlet orifice, and wherein said first open end is inserted within said second open end.

9. The fluidic scanner nozzle of claim 7 wherein the outlet member is configured to receive and be axially aligned with the inlet member in a congruent relationship to form said interaction chamber.

10. The fluidic scanner nozzle of claim 7, wherein said axial gap defines a cylindrical sidewall segment aligned between an upper hemisphere shaped inner cavity and a lower hemisphere shaped inner cavity.

11. The fluidic scanner nozzle of claim 7, wherein said axial gap includes a selected axial length and an inside diameter that is wider than an inside diameter of either (a) the inlet member or (b) the outlet member.

12. The fluidic scanner nozzle of claim 7, wherein said axial gap is positioned between a portion of the inlet member and the outlet member and is a stepped axial gap.

13. The fluidic scanner nozzle of claim 7, wherein said axial gap is positioned between a portion of the inlet member and the outlet member and is a continuous axial gap.

14. The fluidic scanner nozzle of claim 7, wherein said outlet member further comprises a continuous face having a plurality of outlet members configured to be aligned with a plurality of inlet members within a housing.

15. The fluidic scanner nozzle of claim 14, wherein said housing is a shower head assembly.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The operation of the present disclosure may be better understood by reference to the following detailed description taken in connection with the following illustrations, wherein:

(2) FIG. 1A is a schematic illustration of an embodiment of a prior art configuration that includes a cylinder with a dome-top or end plate for producing an oscillating toroid;

(3) FIG. 1B is a schematic illustration of another embodiment of a prior art configuration that includes a flat-topped member or end plate for producing an oscillating toroid;

(4) FIG. 1C is a schematic illustration of another embodiment of a prior art configuration that includes an outlet aperture in a dimpled-top member for producing an oscillating toroid;

(5) FIG. 1D is a diagrammatic illustration of the prior art configuration illustrating a functional aspect of FIG. 1A;

(6) FIG. 2A illustrates a perspective view of a prior art embodiment of a front face and a rear face of a housing that accommodates fluidic oscillators;

(7) FIG. 2B illustrates a perspective view of a prior art embodiment of a front face and a rear face of a housing that accommodates fluidic oscillators;

(8) FIG. 3A illustrates a perspective cross-sectional view of a prior art embodiment of a scanner showerhead incorporating eight fluidic oscillators having outlet apertures and throats providing selected scanning spray patterns;

(9) FIG. 3B illustrates an exploded top perspective view of the device of FIG. 3A, illustrating, from left to right, top (or rear) and bottom (or front) housing and internal components according to the prior art;

(10) FIG. 3C is an exploded bottom perspective view of the device of FIG. 3A, illustrating, from left to right, top and bottom housing and internal components, according to the prior art;

(11) FIG. 3D is a cross sectional side view of a spherical fluidic oscillator circuit according to the device of FIG. 3A

(12) FIG. 4A is a cross-sectional side view of a gapped fluidic oscillator assembly with a stepped gap according to an embodiment of the present disclosure;

(13) FIG. 4B is a cross-sectional side view of a gapped fluidic oscillator assembly with a stepped gap according to an embodiment of the present disclosure;

(14) FIG. 4C is a cross-sectional side view of a gapped fluidic oscillator assembly having a shortened stepped gap according to an embodiment of the present disclosure;

(15) FIG. 4D is a cross-sectional side view of a gapped fluidic oscillator assembly having an elongated stepped gap according to an embodiment of the present disclosure;

(16) FIG. 5A is a cross-sectional side view of a gapped fluidic oscillator assembly with a continuous gap according to another embodiment of the present disclosure;

(17) FIG. 5B is a cross-sectional side view of a gapped fluidic oscillator assembly with a continuous gap according to another embodiment of the present disclosure;

(18) FIG. 5C is a cross-sectional side view of a gapped fluidic oscillator assembly having an elongated continuous gap according to an embodiment of the present disclosure;

(19) FIG. 5D is a cross-sectional side view of a gapped fluidic oscillator assembly having an elongated continuous gap according to an embodiment of the present disclosure;

(20) FIG. 6A is a table illustrating various measurements related to various gap sizes for fluidic oscillators having a continuous gap according to the present disclosure; and

(21) FIG. 6B is a table illustrating various measurements related to various gap sizes for fluidic oscillators having a stepped gap according to the present disclosure.

DETAILED DESCRIPTION

(22) Reference will now be made in detail to exemplary embodiments, examples of which are illustrated in the accompanying drawings. It is to be understood that other embodiments may be utilized and structural and functional changes may be made. Moreover, features of the various embodiments may be combined or altered. As such, the following description is presented by way of illustration only and should not limit in any way the various alternatives and modifications that may be made to the illustrated embodiments.

(23) As used herein, the words “example” and “exemplary” mean an instance, or illustration. The words “example” or “exemplary” do not indicate a key or preferred aspect or embodiment. The word “or” is intended to be inclusive rather an exclusive, unless context suggests otherwise. As an example, the phrase “A employs B or C,” includes any inclusive permutation (e.g., A employs B; A employs C; or A employs both B and C). As another matter, the articles “a” and “an” are generally intended to mean “one or more” unless context suggest otherwise.

(24) Similar reference numerals are used throughout the figures. Therefore, in certain views, only selected elements are indicated even though the features of the system or assembly may be identical in all of the figures. In the same manner, while a particular aspect of the disclosure is illustrated in these figures, other aspects and arrangements are possible, as will be explained below.

(25) In the described embodiment of FIGS. 3A-3D, the spherical shape of the interaction chamber 180 was assumed to be critical for performance of the fluid oscillation produced. The fluid spray pattern generated sweeps or scans in a preselected conical pattern size and direction. Fluid from the oscillation chamber is ejected in a variable-direction spray that scans randomly across a selected area that is defined by the conical outer shape of the spray pattern. A study was conducted to determine if improvements were available to improve tolerances due to manufacturability and whether changes in tolerances or arrangement would have a demonstrable effect on the behavior of the fluid spray pattern.

(26) This study determined that the shape of the interaction chamber may be adjusted to improve tolerances related to manufacturability and assembly while maintaining performance of fluidic circuit as measured by flow rate and cone angle. The variability of a step geometry was identified to adjust both the flow rate and cone angle at identifiable relationships that will be discussed below.

(27) Provided is an embodiment of a gapped scanner nozzle assembly 200 and its components parts. In one embodiment, referring now to FIG. 4A, the gapped scanner nozzle assembly 200 of the present disclosure is configured in an economical method to generate a fluidic spray output which delivers a spray with a surprisingly uniform cone angle 220. In one embodiment, the gapped scanner nozzle assembly 200 comprises a two-part fluidic oscillator may be utilized with a plurality of similar assemblies, that may or may not include the gapped feature, in a housing similar as identified in FIGS. 3A-3C above. Additionally, the gapped scanner nozzle assembly 200 may be used independently of a shower head housing.

(28) The gapped scanner nozzle assembly may include an inlet member 210 that defines an upper inner cavity and an outlet member 230 that defines a lower inner cavity. The inner cavity of the inlet member 210 may define an upper hemisphere shape and the inner cavity of the outlet member 230 may define a lower hemisphere shape. The outlet member 230 may be configured to receive and be axially aligned with the inlet member 210 in a congruent relationship. The gapped scanner assembly 200 may include an axial or longitudinal gap 250 between a portion of the inlet member 210 and the outlet member 230 wherein the axial gap may define a cylindrical sidewall segment aligned between an upper hemisphere shaped inner cavity and a lower hemisphere shaped inner cavity. The axial gap may have a selected axial length and a wider inside diameter than the inside diameters of either (a) the inlet lumen hemisphere defining member or (b) outlet orifice hemisphere defining member. The gapped scanner nozzle assembly 200 defines a lumen or vortex inducing chamber between the backing (power nozzle) defining member and the front member.

(29) The fluidic scanner nozzle assembly may be considered a gapped fluidic nozzle assembly 200. This nozzle includes an interaction chamber 260 defined axially between an upstream end 212 and a downstream end 232 and having a longitudinal chamber axis 270. The upstream end having an inlet opening 214 for receiving pressurized fluid and delivering the pressurized fluid into said interaction chamber 260 along said chamber axis 270. The downstream end 232 having an outlet orifice 234 for issuing a generally conical outlet spray 220 of liquid droplets from the interaction chamber 260 into ambient environment.

(30) The axial gap 250 may be positioned between said upstream end 212 and said downstream end 232. More particularly, the outlet member 230 is configured to receive and be axially aligned with the inlet member 210 in a congruent relationship to form said interaction chamber 260. Wherein the axial gap 250 is positioned between a portion of the inlet member 210 and the outlet member 230. In one embodiment, the axial gap 250 defines a cylindrical sidewall segment aligned between an upper hemisphere shaped inner cavity and a lower hemisphere shaped inner cavity. The axial gap 250 within said interaction chamber 260 defines a vortex or toroidal flow inducing chamber between the inlet member and the outlet member.

(31) As illustrated by FIGS. 4A through 4D, the axial gap may be a stepped axial gap. Here, the inlet member 210 may include a shoulder 216 that protrudes outwardly therefrom. The shoulder 216 may be an annular member that radially protrudes about a side of the inlet member 210 and is configured to abut against an opening of the outlet member 230. The inlet member 210 including a first open end 218 longitudinally opposite said inlet opening 214 and said outlet member 230 including a second open end 237 longitudinally opposite said outlet orifice 234. The first open end 218 may be is inserted within said second open end 238.

(32) The outlet member 230 may include a step portion 236. The step portion 236 may be an annular shoulder located within the cavity of the outlet member 230. Once the inlet member 210 is inserted within the outlet member 230, the shoulder 216 may abut against the second open end 238 such that the stepped axial gap 250 is formed between the first open end 218 and the step portion 236 of the outlet member 230.

(33) The axial gap 250 may be of a generally cylindrical shape within the interaction chamber 260 and may includes a selected axial length between the first open end 218 and the step portion 236. Further, the axial gap may include an inside diameter that is wider than an inside diameter of either (a) the cavity of the inlet member or (b) the cavity of the outlet member.

(34) FIG. 4A illustrates an embodiment of the nozzle assembly that may be part of a housing having a plurality of nozzle assemblies. This housing may a shower head such as described in FIGS. 3A-3C above. FIG. 4B illustrates an embodiment of the fluidic nozzle assembly 200 that includes a lumen member 270 that extends from the inlet member 210. The lumen member 270 may be fastened to a source of pressurize fluid and may include a plurality of threads for selective attachment thereto. FIG. 4C illustrates an embodiment of the gapped fluidic nozzle assembly 200 having a small axial gap 250 wherein FIG. 4D illustrates an embodiment gapped fluidic nozzle assembly 200 having an elongated axial gap 250.

(35) As illustrated by FIGS. 5A through 5D, the axial gap may be a continuous axial gap 250′. The continuous axial gap is positioned between a portion of the inlet member and the outlet member such that it has a common continuous diameter with the inlet member 210 and the outlet member 230. Here, the first open end 218′ extends longitudinally to abut against the stepped portion 238 of the outlet member 238 thereby defining said continuous axial gap 250′. Here two hemispherical shaped cavities are oppositely positioned relative one another with said continuous axial gap 250′ positioned therebetween to define the interaction chamber 260′. FIGS. 5A and 5B illustrate smaller sized continuous axial gaps 250′. FIGS. 5C and 5D illustrate elongated continuous axial gaps 250′ while FIGS. 5B and 5D include lumen members 270.

(36) In one embodiment, either nozzle assembly 200, 200′ includes the inlet member 210 and outlet member 230 that may be positioned in a front plate so that the bottom of the inlet member 210 engages the ledge or top of the outlet member 230. Their may be a plurality of inlet members 210 inserted within a plurality of outlet members 230 incorporated within a shower head assembly. The inlet members 210 may be secured in place by the tight fit of the outer side wall, thereby forming a fluidic oscillator interaction chambers and corresponding scanning spray outlets and outlet throats. In operation, the shower head is secured to a suitable source of fluid under pressure. The fluid circulates in the chamber and flows at equal flow rates into the several inlet power nozzles 214 and enters the fluidic interaction chambers 260, 260′ under pressure, circulates in the chamber to produce a fluidic oscillation, and is ejected through the corresponding outlet aperture 234 to generate from each outlet a scanning fluidic spray output which is delivered in a uniform cone angle, illustrated in FIG. 4A by 220. This scanning spray output may randomly scan across and around the defined cone angle 220 to produce a highly desirable flow pattern for use, for example in a shower.

(37) This scanner nozzle member configuration is well suited for use in a multi-spray nozzle (e.g., showerhead) assembly and the method of the present invention which provides some significant advantages. The simplicity of the scanner nozzle member's geometry, which includes an essentially non-spherical interaction region with coaxial, opposed inlet lumen (power nozzle) and outlet orifice (throat)—and tolerance of a range of gap sidewall lengths allows for simplified construction of scanner fluidic arrays.

(38) All of the scanner throats with the downstream half of the interaction regions (e.g., 230) can be molded in one piece of the showerhead. In this scenario, the power nozzle and upstream half of the interaction region (e.g., 210) are molded individually for each fluidic. The component count for the fluidics is equal to the number of fluidics plus one. This is simpler and more economical to manufacture than other known scanner nozzle assemblies and there are options for greater flexibility and economy making the components are much simpler to design, mold, and assemble, since the axial gap 250 can have a range of tolerable lengths and still provide acceptable performance.

(39) Alternatively, the scanner throats with the downstream half of the interaction regions can be molded in one piece of the showerhead and all of the power nozzles and upstream half of the interaction regions can be molded in one other piece of the showerhead. In this scenario, component count for the fluidics is two, no matter how many fluidics are included. This scenario also allows each showerhead to be designed and built to whatever scanner fluidic geometry is best suited rather than using more or less standard components that are typical in prior fluidic showerheads.

(40) To facilitate the alignment of a large number of fluidics in the assembly, one of the components may be molded out of a flexible material to allow it to conform to the other hard plastic component. To facilitate the alignment of a large number of fluidics in the assembly of the present invention and to allow aiming or bending of the fluidics into various aim angles, both of the components may be molded out of a flexible material to allow them to conform to each other and to a hard face or backing plate that holds prescribed aim angles. The economy inherent in the manufacturing process for making the scanner fluidics and the showerhead nozzle assembly—the non-spherical interaction region's coaxial, opposed inlet (power nozzle) and outlet (throat)—provide the option to economically mold the downstream halves of the interaction regions in the one piece of the showerhead assembly, as discussed above. Since the power nozzle and upstream half of the interaction region are molded individually for each fluidic, the assembly of the showerhead is simplified and the components are much simpler to design and mold.

(41) Notably, the performance of the nozzle assembly 200 having a continuous axial gap relative to the nozzle assemblies having spherical shaped interaction regions disclosed by FIGS. 3A-3C is noted by the table of FIG. 6A. The table of FIG. 6A discloses various measurements related to various gap sizes for fluidic oscillators having a continuous axial gap 250′ according to the present disclosure. The nozzle assembly having a continuous axial gap 250′ with a longitudinal length that is about 50% of the diameter of the first open end 218 performed with a 1% drop in flow rate and produced a variable fluidic spray that defined about a 35% smaller cone circumference. The nozzle assembly having a continuous axial gap 250 with a longitudinal length that is about the same diameter of the first open end 218 performed with a 2% less flow rate and produced a variable fluidic spray that defined about a 60% smaller cone circumference.

(42) Notably, the performance of the nozzle assembly 200 having a stepped axial gap 250 relative to the nozzle assemblies having spherical shaped interaction regions disclosed by FIGS. 3A-3C is noted by the table of FIG. 6B. The table of FIG. 6B discloses various measurements related to various gap sizes for fluidic oscillators having a stepped axial gap 250 according to the present disclosure. The nozzle assembly having a stepped axial gap 250 with a longitudinal length that is about 50% of the diameter of the first open end 218 performed without significant change in flow rate and produced a variable fluidic spray that defined about a 40% smaller cone circumference. The nozzle assembly having a stepped axial gap 250 with a longitudinal length that is about the same diameter of the first open end 218 performed with a 2% less flow rate and produced a variable fluidic spray that defined about a 60% smaller cone circumference.

(43) It was noted, that the nozzle with stepped axial gap diameter provides better fluid outlet flow stability than with the continuous axial gap. It displays higher frequency conical oscillation, a more uniform spray distribution, reduces risk of unwanted aims, and provides constant conical fluid flow diameter results in a lower frequency of the conical oscillation (“scanning”).

(44) Having described preferred embodiments of a new and improved method, it is believed that other modifications, variations and changes will be suggested to those skilled in the art in view of the teachings set forth herein. It is therefore to be understood that all such variations, modifications and changes are believed to fall within the scope of the present invention.

(45) Although the present embodiments have been illustrated in the accompanying drawings and described in the foregoing detailed description, it is to be understood that the gapped fluidic oscillator assemblies are not to be limited to just the embodiments disclosed, but that the systems and assemblies described herein are capable of numerous rearrangements, modifications and substitutions. The exemplary embodiment has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. Accordingly, the present specification is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim.