Spray nozzle

A spray nozzle includes a body and a deflector. The body is aligned and connected to the deflector with a fastener. At least one pin can be used to further align the deflector relative to the body. A single mating surface is provided on each of the body and the deflector.

TECHNICAL FIELD

This disclosure relates to spray nozzles and methods of manufacturing spray nozzles.

BACKGROUND

Spray nozzles are used in a variety of applications to convert a fluid stream into a particular spray pattern. It is often desirable to apply a fluid in a uniform and consistent manner upon a target location. Various spray nozzle designs have been developed in an attempt to generate an appropriate spray pattern.

Some spray nozzle designs include a body that receives the fluid input and passes it through an orifice to a deflector connected to the body. The deflector is positioned opposite the fluid input. The deflector deflects the fluid into a particular spray pattern as the fluid comes out of the body orifice.

SUMMARY

The present disclosure relates to spray nozzles having a body and a deflector. The body is aligned and connected to the deflector with a fastener. At least one pin can be used to further align the deflector relative to the body. The alignment pin can provide improved alignment of the body and deflector. A single mating surface is provided on each of the body and the deflector. The use of a single mating surface can help reduce the cost of manufacturing and improve a seal formed between the body and the deflector that reduces incidence of fluid buildup. There is no requirement that an arrangement include all features characterized herein to obtain some advantage according to this disclosure.

DETAILED DESCRIPTION

A number of shortcomings are common with conventional spray nozzles. One shortcoming involves misalignment of the body and the deflector. Alignment of the body and the deflector is important to the development of a uniform spray pattern. If the body is misaligned with the deflector, the fluid will not be applied to the appropriate location on the deflector, resulting in a non-uniform or misshaped spray pattern. Even a small misalignment can result in a large change in the spray pattern.

One way in which misalignment between the body and deflector occurs is due to the imprecision of a fastener connection. To connect the body to the deflector, a fastener hole is formed in the deflector and a threaded hole is formed in the body. The size of the fastener hole is larger than the size of the fastener passing through the deflector and into threaded engagement with the threaded hole, to enable the fastener to be easily inserted. Therefore, when the fastener is inserted, a small amount of space exists between the fastener and the fastener hole, allowing misalignment to occur between the deflector and the body.

The mating surfaces between the body and deflector can also be important to the design of a spray nozzle. One spray nozzle design includes L-shaped mating surfaces between the deflector and body resulting in four to six mating surfaces. Creating a mating surface can be expensive and difficult due to precise machining requirements needed for proper alignment between parts. The inclusion of more than two mating surfaces (i.e., one on each of the body and deflector) can create problems with tolerance stacks that further enhance the need for precise machining and increase the probability of misalignment. Any misalignment between parts can result in fluid intrusion into spaces between the mating surfaces. Fluid buildup between mating surfaces can result in fluid dripping from the spray nozzle. In addition, misalignment of the body and deflector from improperly machined or positioned mating surfaces can result in undesirable spray patterns. Embodiments according to the present disclosure address these and other shortcomings of existing spray nozzles.

An example spray nozzle10is shown inFIGS. 1-2.FIG. 1is a schematic perspective view of an example spray nozzle10including body12, deflector14, and fastener16. Body12and deflector14are connected together by the fastener16(e.g., a screw or bolt). The fastener16is inserted through fastener holes (not shown) in body12and deflector14. Spray nozzle10is typically connected at one end to an input line of a fluid source, such as a fluid delivery system that provides a flow of fluid to spray nozzle10. Fluid enters spray nozzle10through an axially-extending orifice17through the core of body12. The fluid is expelled from the orifice17into a cavity defined between body12and deflector14and then onto a deflection surface of deflector14. Deflector14is designed to convert the fluid stream into a desired spray pattern for application of the fluid onto a target location.

The construction of spray nozzle10begins, for example, with a length of hexagonal-shaped stock (hereinafter referred to as “hex stock”). The hex stock can be rough cut such that small variations and inconsistencies exist from piece to piece. The use of rough cut hex stock can reduce manufacturing costs. The hex stock is cut into two pieces, one that becomes body12and one that becomes deflector14. Additional steps are then performed, as described herein.

FIG. 2is a schematic side view of spray nozzle10including body12, deflector14, and fastener16, and further including deflection surface18and mating surfaces20and22. Deflection surface18is formed adjacent body12on deflector14. Deflection surface18is shaped to deflect fluid expelled from body12out from spray nozzle10in a desired spray pattern.

Mating surface20is the distal surface of body12(relative to the fluid input) and mating surface22is the proximal surface of deflector14. When body12and deflector14are properly connected, mating surfaces20and22are facing each other in a mating arrangement. Mating surfaces20and22can be highly polished surfaces, such that when mated together form a tight seal against fluid intrusion. For example, the surface can be polished to have a surface variation from about 3 microns to about 10 microns, and preferably from about 5 microns to about 6 microns.

FIGS. 3-5illustrate an example body12of the spray nozzle10shown inFIG. 1.FIG. 3is a schematic perspective view. Body12includes mating surface20, adapter24, hex region26, corner round27, recessed portion28, and orifice30. Adapter24is positioned adjacent to hex region26and opposite recessed portion28and mating surface20. Adapter24is designed to connect with a fluid input line, such as a hose or other fluid delivery system. The adapter24can be formed, for example, by grinding from the hex stock. In some embodiments, adapter24has a cylindrical cross-section or has a tapered shape with a cylindrical cross-section. Adapter24can include fastener threads, if desired, for mating with a connector of the fluid input line.

Hex region26is adjacent to adapter24of body12. Hex region26includes rounded corners, referred to as corner round27. One purpose of corner round27is to provide a precisely cut feature in the original rough cut hex stock from which to measure and position subsequently formed features. Each corner of corner round27has a precise radius measured from central axis31of orifice30, and is separated from adjacent corners by the flat sides of the original hex stock.

Adjacent to hex region26and opposite adapter24is recessed portion28. The diameter of recessed portion28is smaller than the diameter of corner round27, such that the recessed portion28defines a region with cylindrical cross-section radially inward from the outer flat surfaces of the hex stock. Mating surface20is formed on one side of recessed portion28, opposite hex region26.

In some embodiments, recessed portion28and mating surface20perform two functions. First, as described above, mating surface20mates with mating surface22of deflector14. When highly polished, mating surface20forms a fluid tight seal with mating surface22to avoid fluid intrusion between body12and deflector14. Second, after fluid has deflected off of deflection surface18, the fluid can also come into contact with the portion of mating surface20not mated with mating surface22. A rounded edge21defined at the intersection of the surface20and the recessed portion28provides a uniform deflection surface that defines, in part, the shape and uniformity of the resulting spray pattern.

Orifice30extends longitudinally through the core of body12to provide a path for fluid flow through body12. Orifice30can have a consistent diameter throughout or may narrow near mating surface20to reduce the amount of fluid flow and/or increase the fluid pressure.

FIG. 4is a schematic front view of mating surface20of body12illustrating hex region26, recessed portion28, orifice30, and fastener hole32as previously described, and also illustrating pin holes34and pins36. Orifice30extends entirely through the core of body12, as described above. Orifice30is formed, for example, by drilling through body12along a central axis relative to corner round27. If desired, the orifice can be formed (e.g., by drilling) entirely through at a smaller diameter and then formed partially through at a larger diameter. This provides a larger diameter orifice within adapter24and a smaller diameter orifice within recessed portion28to increase the pressure of fluid as it exits body12.

Threaded fastener hole32is a longitudinal hole drilled into mating surface20of body12. Threaded fastener hole32typically extends partially through body12. Threaded fastener hole32provides threaded engagement with the threads of fastener16to connect body12with deflector14. In the illustrated arrangement, fastener hole34is located on a line between orifice30and a flat edge29of hex region26.

Spray nozzle10includes at least one alignment pin36, and preferably two or more alignment pins36. Alignment pins36are placed into pin holes34that are longitudinally formed in mating surface20of body12. Pin holes34typically extend at least partially through body12. The pin holes34are located on an opposite side of fastener hole32. The pin holes34are spaced approximately equal distance from orifice30as the spacing of fastener hole32from orifice30. Pins36fit into pin holes34and also into adjacent pin holes in deflector14(e.g., pin holes44shown inFIG. 6). The use of alignment pins36provides additional stability to spray nozzle10and more precisely align deflector14with body12.

In other embodiments, pin holes can be formed in alternate positions within mating surface20. For example, pin holes need not be uniformly spaced from fastener hole32, but rather can be formed at any desired location and in any desired arrangement. In addition, the sizing of pin holes and the associated pins can be any desirable size.

Pins36provide greater stability and alignment than is possible through the use of fastener16alone. As discussed above, fastener hole46of the deflector (seeFIG. 6) must be made slightly larger than the maximum outer diameter of that portion of fastener16extending through fastener hole46to enable fastener16to pass through the deflector and make threaded engagement with fastener hole32. The spacing between fastener16and fastener hole46leaves room for undesirable movement, allowing deflector14and body12to become misaligned when assembled. Pins36can be closely sized (e.g., with an interference fit) to the size of pin holes34, thereby reducing the room available for movement and misalignment. Furthermore, the use of two alignment pins tightly fit in pin holes36,44can reduce the possibility of movement between the body12and deflector14.

Rough dimensions for an example body12will now be provided with reference toFIGS. 4 and 5. Width W1of the rough hex stock is typically in a range from about 0.8 inches to about 1.0 inch, and preferably from about 0.87 to about 0.89 inches. Corner round27reduces the corners of the hex stock to have diameter D1that is typically in a range from about 0.8 inches to about 1.0 inch, and preferably from about 0.93 inches to about 0.95 inches. Recessed portion28has diameter D2that is typically in a range from about 0.8 inches to about 1.0 inch, and preferably from about 0.85 inches to about 0.87 inches.

Orifice30has diameter D3within recessed portion28that is typically in a range from about 0.11 inches to about 0.14 inches, and preferably from about 0.12 inches to about 0.14 inches. Fastener hole32has diameter D4that is typically in a range from about 0.17 inches to about 0.21 inches, and preferably from about 0.18 inches to about 0.20 inches. Fastener hole32has length L1that is typically in a range from about 0.3 inches to about 0.4 inches, and preferably from about 0.37 inches to about 0.39 inches. L1is long enough to provide adequate engagement with fastener16, but not so long as to extend entirely through hex region26.

One or more pin holes34have diameter D5that is typically in a range from about 0.11 inches to about 0.14 inches, and preferably from about 0.12 inches to about 0.14 inches. Pin holes34have length L2that is typically in a range from about 0.2 inches to about 0.3 inches, and preferably from about 0.24 inches to about 0.26 inches. Pin holes of approximately the same size are also drilled into the adjacent surface of deflector14(e.g., see pin holes44shown inFIG. 4). Pins36have diameter D6that is typically in a range from about 0.0005 inches to about 0.002 inches less than D5, and preferably from about 0.0009 inches to about 0.0011 inches less than D5. Similarly, pins36have length L3that is typically in a range from about 0.001 inches to 0.003 inches less than L2, and preferably from about 0.0019 inches to about 0.0021 inches less than L2. Pins36can have an outer diameter that is about 97 percent to about 100 percent of the inside diameter of pin holes34. Depending on the materials used for pins36, the outer diameter of the pins36can be even smaller than pin holes34such as in the range of about 80 percent to about 100 percent of the inner diameter of pin holes34.

To further aid in understanding the example body12, rough dimensions are provided from this alternate view. Body12has overall length L4that is typically in a range from about 0.9 inches to about 1.1 inches, and preferably from about 0.99 inches to about 1.01 inches. Adapter24has length L5that is typically in a range from about 0.45 inches to about 0.55 inches, and preferably from about 0.49 inches to about 0.51 inches. Hex region26has length L6that is typically in a range from about 0.34 inches to about 0.41 inches, and preferably from about 0.37 to about 0.39 inches. Recessed portion28has length L7that is typically in a range from about 0.11 inches to 0.14 inches, and preferably from about 0.12 inches to about 0.13 inches.

In one embodiment, adapter24includes fastener threads that enable adapter24to be connected to a hose or other fluid delivery system. Standard fastener threads can be used, such as sizes in the range from about 0.0625 inch National Pipe Thread (NPT) to 0.5 inch NPT, and preferably from about 0.125 inch NPT to about 0.375 inch NPT having an outer diameter from about 0.405 inches to about 0.675 inches and having from about 18 to about 27 threads per inch. In this case, orifice30has diameter D7equivalent to the standard size, such as 0.25 inches for 0.25 inch NPT. As described above, D7can taper toward mating surface20, if desired. For example, orifice30has diameter D7for about 0.5 inches to about 0.9 inches, and then tapers to diameter D3for about 0.1 inches to about 0.5 inches.

FIGS. 6-15illustrate an example deflector14of spray nozzle10shown inFIG. 1. The primary purpose of deflector14is to deflect a fluid flow from body12into a desired spray pattern. Any number of different deflection patterns can be designed by adjusting the size and shape of the edge of deflection surface18. In this disclosure, four examples are provided illustrating various designs of deflection edge18of deflector14.FIGS. 6-9illustrate a full deflection pattern deflector that sprays a uniform spray pattern of approximately 180 degrees, about 90 degrees to each side.FIGS. 10-12illustrate a right-hand deflection pattern deflector that sprays a uniform spray pattern of approximately 90 degrees to the right side.FIGS. 13-15illustrate a left-hand deflection pattern deflector that sprays a uniform spray pattern of approximately 90 degrees to the left side.FIGS. 16-18illustrate another embodiment of a left-hand deflection pattern deflector that sprays a uniform spray pattern of approximately 90 degrees to the left-hand side.

Hex region48is adjacent recessed portion40and opposite mating surface22. Hex region48is typically formed during at least some of the same processing steps as hex region26of body12(seeFIG. 3). Rough hex stock is cut to length, and corner round50is then ground into the corners of hex region48to form precisely formed features that can be used for the alignment and measurement of subsequently formed features.

Recessed portion40is then formed by grinding a cylindrical shape into the hex stock until the diameter of recessed portion40is entirely within the hex stock, such that a complete circle cross-section is formed with no flat edges. Sides54and56are then formed in recessed portion40at a desired angle, by removing sections of recessed portion40. Lines passing through the planes of sides54and56converge approximately at a point on an imaginary circle drawn through corner round50. The angle formed by sides54and56is angle A1, shown and described below with reference toFIG. 7.

Curved portion58is then formed to connect sides54and56with an arc. The arc is centered at the center of corner round50and can have a circular shape.

Deflection surface18is formed in recessed portion40between sides54and56and adjacent curved portion58. Deflection surface18includes the area of recessed portion40directly in line with the center of corner round50. In this way, a portion of deflection surface18is directly in line with orifice30of body12when body12and deflector14are connected together. Deflection surface18includes a radius or fillet portion60(also referred to as a concave portion60) and flat portion62(see alsoFIG. 8). Radius portion60includes a right side and a left side that each slope gradually in opposite directions and terminates at one of sides54and56. The sides of radius portion60form angle A2, shown and described below with reference toFIG. 7. Radius portion60curves from mating surface22of recessed portion40to flat portion42. Flat portion42extends from radius portion60, opposite mating surface42, to curved portion58and between sides54and56.

During operation, fluid passing through body12is expelled onto deflection surface18of deflector14. Radius portion60and flat portion62function together to distribute the fluid evenly into a uniform spray out from deflector14. The full deflection spray pattern radiates out from a central region of deflector14in an arc from about 160 degrees to about 200 degrees.

Pin holes44and fastener hole46are drilled into mating surface42of deflector14, and extend laterally into deflector14. Formation of pin holes44and fastener hole46can be done in the same manner as fastener hole32and pin holes34of body12, previously described. Pin holes44and fastener hole46are aligned such that they will match with the respective holes in body12. Precise alignment can be achieved by measuring hole locations from corner round50of deflector14, which matches corner round27of body12.

Rough dimensions will now be provided for an example deflector14. Deflector14is formed from rough hex stock having width W1in the range from about 0.8 inches to about 1.0 inch, and preferably from about 0.87 inches to about 0.89 inches. Corner round50reduces the corners of the hex stock to have diameter D1in the range of about 0.8 inches to 1.0 inch, and preferably from about 0.93 inches to about 0.95 inches. Recessed portion40has diameter D2in the range of about 0.8 inches to about 1.0 inch, and preferably from about 0.85 inches to about 0.87 inches. Fastener hole46has diameter D4in the range of about 0.1 inches to 0.2 inches, and preferably from about 0.18 to about 0.19 inches, and extends entirely through deflector14. One or more pin holes44have diameter D5in the range of about 0.11 inches to about 0.14 inches, and preferably from about 0.12 inches to about 0.13 inches. Pin holes44have length L2in the range of about 0.22 inches to 0.28 inches, and preferably from about 0.24 inches to about 0.26 inches. Curved portion58has diameter D8from about 0.3 inches to 0.4 inches, and preferably from about 0.37 inches to about 0.39 inches.

FIG. 8is a schematic side view of deflector14. To further aid in understanding one embodiment, rough dimensions are provided from this alternate view. Deflector14has overall length L9in the range of about 0.3 inches to 0.4 inches, and preferably from about 0.37 inches to about 0.39 inches. Hex region48has length L10in the range of about 0.19 inches to about 0.24 inches, and preferably from about 0.21 inches to about 0.23 inches. Recessed portion40has length L11in the range of about 0.14 inches to 0.18 inches, and preferably from about 0.15 inches to about 0.17 inches. Flat portion62has length L12in the range of about 0.07 inches to 0.1 inches, and preferably from about 0.084 inches to about 0.086 inches. As a result, when deflector14is connected with body12, gap L13is formed between mating surface20(seeFIG. 2) and flat portion62in the range from about 0.07 inches to about 0.08 inches, and preferably from about 0.074 inches to about 0.075 inches.

FIG. 9is a schematic front view of face52of deflector14. Deflector14includes fastener hole46, and face52. Face52provides a convenient location for printing or engraving a logo, symbol or other identifying mark on spray nozzle10. In one example, a symbol indicating a right, left, or full spray patter is included on face52.

FIGS. 10-12illustrate another embodiment of the deflector having a right-hand spray pattern.FIG. 10is a schematic end view of deflector70. Right-hand spray nozzle deflector70is generally the same as deflector14, except for the design of the deflection surface. Deflector70includes hex region72and recessed portion74. Recessed portion74includes mating surface75, fastener hole76, one or more pin holes78, and deflection surface80. Deflection surface80includes radius portion82and flat portion84.

Rather than directing the fluid to both sides of spray nozzle10, deflector70is designed to direct fluid only to one side of spray nozzle10. In this embodiment, recessed portion74extends roughly three-quarters of the way around the center of hex region72. This design of recessed portion74adds an additional barricade to block the flow of fluid from spraying out of one side of spray nozzle10. The resulting spray pattern has an angle from about 70 degrees to about 110 degrees.

A radius portion82is formed between mating surface75and flat portion84. Radius portion82functions together with flat portion84and recessed portion75to distribute fluid into a uniform spray pattern from about 70 degrees to about 110 degrees.

FIG. 12is a schematic front view of face90of right-hand spray nozzle deflector70including hex region72. Hex region72includes fastener hole76and face90. A logo or other identifying mark can be printed or etched into face90of deflector70.

FIGS. 13-15illustrate another embodiment of the deflector having a left-hand spray pattern.FIG. 13is a schematic end view of deflector100. Right-hand spray nozzle deflector100is generally the same as deflector70, except that the deflector has been flipped 180 degrees to provide a spray pattern out from the opposite side of the deflector. Deflector100includes hex region102and recessed portion104. Recessed portion104includes mating surface105, fastener hole106, one or more pin holes108, and deflection surface110. Deflection surface110includes radius portion112and flat portion114.

FIG. 15is a schematic front view of face120of right-hand spray nozzle deflector100including hex region102. Hex region102includes fastener hole106and face120. A logo or other identifying mark can be printed or etched into face90of deflector70if desired.

FIGS. 16-18illustrate another embodiment of a deflector130having a left-hand deflection pattern. For example, when the deflector130is coupled with a body (e.g., body12shown inFIG. 3) and connected to a fluid source, the spray nozzle provides a uniform spray pattern having a range from about 70 degrees to about 110 degrees from the left side of deflector130.

FIG. 16is a schematic end view of left-hand deflector130.FIG. 17is a left side view of left-hand deflector130.FIG. 18is a front view of face150of deflector130. Left-hand deflector130is similar to left-hand deflector100, shown inFIG. 13, except for the design of the deflection surfaces140. Deflector130includes hex region132and recessed portion134. Hex region132includes a portion of fastener hole136and face150. Recessed portion134includes mating surface135, a portion of fastener hole136, at least one pin hole138, and deflection surface140. Deflection surface140includes groove142and flat portion144. Mating surface135is a surface of deflector130that is opposite and typically parallel to face150.

Deflector130is designed to direct fluid only to one side of spray nozzle10. In this embodiment, recessed portion134extends roughly three-quarters of the way around a central region of hex region132. When connected with a body (e.g., body12, shown inFIG. 3) recessed portion134functions to block the flow of fluid from spraying out from all but a region of the spray nozzle having an angle from about 70 degrees to about 110 degrees.

Groove142is formed within recessed portion134and is positioned between mating surface135and flat portion144. In some embodiments, groove142includes a flat surface with sidewalls aligned from about 85 degree to about 95 degree angles to the flat portion144. Groove142is formed, for example, using a flat tipped drill or router bit. In some embodiments, the flat surface of groove142is angled relative to mating surface135, as illustrated. Also in some embodiments, the flat surface of groove142is angled relative to flat portion144. For example,FIG. 17includes angles A5and A6. Angle A6is the angle between surface135and the flat surface of groove142. Angle A5is in a range from about 0 degrees to about 25 degrees, and preferably from about 10 degrees to about 15 degrees. Angle A6is the angle between surface135and flat portion144. Angle A6is in a range from about 0 degrees to about 20 degrees, and preferably from about 5 degrees to about 10 degrees.

Groove142functions together with flat portion144and recessed portion134to distribute fluid impinging upon the deflection surfaces140from the body (e.g., body12shown inFIG. 3) into a uniform spray pattern of approximately from about 70 degrees to about 110 degrees. Other embodiments can include other spray patterns, such as spray patterns of more or less than 90 degrees.

A spray nozzle including a body and a deflector can be more precisely aligned by the use of one or more pins. The pins (e.g., pin36shown inFIG. 4) can be sized to closely match the size of pin holes extending laterally into the body and the deflector. In this way the alignment of the body and the deflector is not dependent upon the precision of the fastener or fastener hole.

In some embodiments, the spray nozzle also includes only two mating surfaces between the body and the deflector. This reduces manufacturing costs and increases the quality of the seal between the body and the deflector. By providing a good seal, the spray nozzle is less likely to have fluid intrude between the body and deflector, thereby reducing the chance for dripping or fluid buildup on the spray nozzle.

It is noted that not all of the features characterized herein need to be incorporated within a given arrangement for the arrangement to include improvements according to the present disclosure. In addition, the specific embodiments illustrated and described are only a few examples of the full scope of embodiments contemplated. For example, the disclosure describes embodiments having roughly 90 degree and roughly 180 degree spray patterns. This disclosure also encompasses other spray nozzle embodiments having spray patterns of greater than 180 degrees, between 90 degrees and 180 degrees, and also less than 90 degrees. One skilled in the art will recognize that only minor modifications would be required to the illustrated embodiments to achieve these other desired spray patterns. These alternate spray nozzle designs are therefore also within the scope of this disclosure.

Furthermore, although this disclosure refers to a fastener connection (e.g. fastener16inFIG. 1) to connect the body with the deflector, it is recognized that a wide variety of fasteners could also be used. A fastener is any device or composition capable of connecting the mating surfaces of the body and the deflector. Such fasteners may not require the use of holes in the body and/or the deflector. For example, adhesive could be used to bond the body with the deflector at each of the mating surfaces or at each of the pins and pin holes.

In one aspect, the spray nozzle includes a body, a deflector, and a pin. The body includes a first mating surface, a first pin hole defined in the first mating surface, and a fluid orifice extending through the body and defining a fluid path. The deflector includes a second mating surface abutted with the first mating surface of the body, a second pin hole defined in the second mating surface and aligned with the first pin hole of the body, and a deflection surface from the first mating surface of the body and aligned with the fluid orifice; and a pin positioned in the first and second pin holes to align the fluid orifice and the deflection surface.

In another aspect, a kit is configured to be assembled into a spray nozzle. The kit includes a body, a first deflector, and a pin. The a body includes a first mating surface, a first pin hole extending into the body from the mating surface; and a fluid orifice defined in the first mating surface and defining a fluid path. The first deflector includes a second mating surface arranged to abut with the mating surface of the body when assembled, a second pin hole defined in the second mating surface and arranged for alignment with the first pin hole when assembled, and a deflection surface arranged in alignment with the fluid path and to be spaced from the mating surface of the body when assembled. The pin is sized for insertion within the first and second pin holes to precisely align the fluid orifice and the deflection surface.

Yet another aspect is a method of aligning a spray nozzle body with a spray nozzle deflector. The body includes a fluid orifice, and the deflector defining a deflector surface. The method includes: forming a first hole in a mating surface of the body; forming a second hole in a mating surface of the deflector; inserting a pin into the first and second holes; and applying a pressure to press the body mating surface against the deflector mating surface while maintaining alignment of the deflector surface with the fluid orifice.

Another aspect is a method of forming a spray nozzle. The method includes cutting a first segment and a second segment from length of stock rod; forming the first segment into a body having a first mating surface and a fluid orifice; forming the second segment into a deflector having a second mating surface; forming a first alignment hole in the first surface; forming a second alignment hole in the second surface; inserting a pin into the first and second holes; and applying a pressure to press the first surface against the second surface.