Patent Publication Number: US-7584908-B2

Title: Spray nozzle apparatus and method

Description:
BACKGROUND OF THE INVENTION 
     Spray nozzles, or tips, can be used to apply liquid solutions of agro-chemicals and fertilizers. For example, several spray nozzles can be used to apply pesticides or other chemicals to a farm field. The nozzle configuration can have a significant impact on the type of spray pattern that is produced, which affects the amount of coverage that is achieved by each nozzle. Fan spray nozzles can widen a stream of liquid into a fan by passing the liquid through a slotted end. Deflector style nozzles can produce a spray pattern by forcing a stream of liquid against a deflector plate. Each configuration can exhibit different characteristics. For example, the way that a nozzle is configured can impact the reliability and reproducibility of the spray stream. 
     SUMMARY OF THE INVENTION 
     In one embodiment, a spray nozzle for spraying liquid can include a body, a spray orifice, a filter, and an insert. The body can have a spray outlet portion, and the spray outlet portion can terminate in a substantially spherical dome. The spray orifice can be included in the spray outlet portion and can be positioned before the substantially spherical dome in a flow path. The spray orifice can also be substantially V-shaped. The filter can be at least partially positioned within the body. The insert can be positioned at least partially in the spray outlet portion and can include an entry shaft having a substantially rectangular cross section. The insert can also include one or more projections. 
     In some embodiments, a method of spraying liquid from a spray nozzle can include receiving the liquid in a body of the spray nozzle, filtering the liquid with a filter, creating turbulence in the liquid using one or more projections in an entry shaft of a flow control insert, introducing air into the liquid using an air gap within the flow control insert, and dispersing the liquid using a spray orifice. The filter can be received by the body of the spray nozzle. The entry shaft of the flow control insert can have a substantially rectangular cross section. The spray orifice can be positioned before a spherical dome in a flow path, and the spray orifice can be substantially V-shaped. 
    
    
     
       Other embodiments will become apparent by consideration of the detailed description and accompanying drawings. 
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a side view of a spray nozzle according to one embodiment of the invention. 
         FIG. 2  is a front view of the spray nozzle of  FIG. 1 . 
         FIG. 3  is a bottom view of the spray nozzle of  FIG. 1 . 
         FIG. 4A  is an exploded side view of the spray nozzle of  FIG. 1 . 
         FIG. 4B  is an exploded front view of the spray nozzle of  FIG. 1 . 
         FIG. 5A  is a cross-sectional side view of the spray nozzle of  FIG. 1 . 
         FIG. 5B  is a top view of a spray nozzle insert according to one embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION 
     Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings. 
       FIGS. 1-5A  illustrate a spray nozzle  10  according to one embodiment of the invention. The spray nozzle  10  can be used for dispersing liquid agricultural solutions (e.g., herbicide, pesticide, fertilizer, fungicide, insecticide, etc.) over a farm field or for other liquid spraying applications. The spray nozzle  10  can include wings  14  and  18 , a nozzle body  22 , a filter  24 , and a spray outlet portion or tube  26 . In some embodiments, the wings  14  and  18 , the nozzle body  22 , and the spray outlet tube  26  can be molded, or similarly constructed, into a single component. However, the spray nozzle  10  can be constructed of separate components that are assembled together. In some embodiments, the spray nozzle  10  can include only a single wing. 
     The spray nozzle  10  can be coupled to a host holder (not shown), that can provide liquid from a liquid supply (e.g., a holding tank). The spray nozzle  10  can be coupled to the host holder by inserting the host holder into the spray nozzle  10  and turning the spray nozzle  10  counter-clockwise by gripping the wings  14  and  18 . Alternatively, the spray nozzle  10  can be coupled to the host holder using a clockwise turn. In some embodiments, the spray nozzle  10  can be secured to the host holder with a snap-fit after being rotated. Rotating the spray nozzle  10  until it is secured to the host holder can aid in correctly orienting a spray stream. For example, rotating the spray nozzle  10  until a snap-fit is achieved can automatically align the spray stream in the proper direction. 
     The wings  14  and  18  can be offset with respect to each other (i.e., not aligned axially), as shown in  FIG. 2 . This offset orientation can allow components of the spray nozzle  10  to be assembled without interference from the wings  14  and  18 . For example, in some embodiments, a flow control pin (as shown and described with respect to  FIGS. 4A-5B ) can be inserted into the spray outlet tube  26  before using the spray nozzle  10 . Offsetting the wings  14  and  18  can allow the bottom of the wings  14  and  18  to approximately coincide with the bottom of the spray outlet tube  26 , while providing room for the flow control pin to be inserted. Such an arrangement can reduce the overall height of the spray nozzle  10 . 
     The filter  24  can be used to prevent foreign material (e.g., debris, solid particles, etc.) from passing through the spray nozzle  10 . Such materials may block the flow or disrupt the spray pattern of the spray nozzle  10 , requiring removal the spray nozzle  10  for cleaning or replacement of the spray nozzle  10 . In some embodiments, the filter  24  can include a separate filter body and filtering material, as shown and described with respect to  FIG. 4 . 
     The spray outlet tube  26  can include separate portions of varying diameter. As shown in  FIGS. 1 and 3 , in some embodiments, the spray outlet tube  26  can include three portions having three different diameters. For example, a main portion  34  of the spray outlet tube  26  can have the relatively largest diameter. An outlet portion  38  can be positioned at one end of the main portion  34  and can have a relatively smaller diameter than the main portion  34 . Additionally, a stepped-down portion  42  can be positioned within an intermediate section and can have a relatively smaller diameter than the outlet portion  38 . A spray orifice  46  can be “notched” out of the stepped-down portion  42  and can include a vertical edge  50  and an angled edge  54 . The angled edge  54  of the spray orifice  46  can be altered according to the desired spray pattern of the spray nozzle  10 . For example, increasing the angle of the angled edge  54  can increase the width of a spray pattern. The spray that is produced by the spray orifice  46  can be angled forward or rearward and can depend on the attachment of the spray nozzle  10  to the host device. For example, in some embodiments, the spray nozzle  10  can be attached to the host device using a half (i.e., 180 degree) turn or rotation. As a result, the user can choose between a forward angled spray orientation and rearward angled spray orientation, each orientation being positioned 180 degrees from each other, in order to provide the best coverage. 
       FIG. 3  also illustrates an air intake opening  30 . As described in greater detail with respect to  FIG. 5 , the air intake opening  30  can be used to introduce air into the liquid before dispersing the liquid. Introducing air into the liquid stream can result in the production of relatively larger spray droplets that contain air bubbles. Increasing the size of the droplets by adding air can reduce the number of relatively small droplets (e.g., less than 200 microns) that are dispersed by the spray nozzle  10 . Fewer larger air-charged (or aerated) droplets can provide similar coverage to more smaller droplets due to the contact characteristics of the larger air-charged droplets. For example, the air-charged or aerated droplets can explode when they contact a surface (e.g., a plant) and spread numerous smaller droplets over the entire surface. 
       FIGS. 4A and 4B  illustrate the internal and external components of the spray nozzle  10 , which can include the filter  24 , a sealing ring  60 , a filter coupling insert  64 , the nozzle body  22 , the spray outlet tube  26 , and a flow control insert or “venturi” insert  68 . In other embodiments, the spray nozzle  10  can include more or fewer components than those shown. For example, in one embodiment, the filter coupling insert  64  and the flow control insert  68  can be combined into a single component. 
     The filter  24  can include a filter body  72  and a filter material  76 . In some embodiments, the filter material  76  can be positioned to substantially surround the filter body  72  when the filter  24  is assembled. The filter material  76  can be retained by the filter body  72  using retaining protrusions  80 , which can extend out and over the end of the filter material  76 , as shown in  FIGS. 1 and 2 . In some embodiments, the filter material  76  can be a wire mesh having holes sized to allow liquid to pass through. However, the holes of the wire mesh can also be small enough that they do not allow foreign material to pass through. In other embodiments, the filter material  76  can be a gauze material, a molded plastic gauze material, or a slotted plastic cylinder. Other suitable types of materials can also be used for the filter material  76 . The filter body  72  can include one or more filter body rings  84  connected to a base  88 . The space between each of the filter body rings  84  can create one or more openings, which can allow fluid to pass through the filter body  72 . The base  88  of the filter body  72  can be sized so that it can be coupled to the filter coupling insert  64 . 
     The sealing ring  60  can be rubber, or a similar material, that has the ability to create a fluid-tight seal. As shown in  FIGS. 4A and 4B , the sealing ring  60  can be positioned adjacent to the filter coupling insert  64  and around the base  88  of the filter body  72  when the spray nozzle  10  is assembled. During use, the sealing ring  60  can be compressed between the host holder and the filter coupling insert  64  and can be used to prevent liquid from escaping between the host holder and the nozzle body  22 . 
     As shown in  FIGS. 4A and 4B , the filter coupling insert  64  can include an outer ring  92 , a main opening  96 , and an outlet  100 . In some embodiments, the filter coupling insert  64  can be a standard-sized component that can be used with a variety of nozzles. The outer ring  92  can have a width that is substantially the same as the width of the sealing ring  60 . As a result, the outer ring  92  can provide a support surface for the sealing ring  60 . The main opening  96  can be generally circular and can be sized to receive the base  88  of the filter body  72 . In some embodiments, the base  88  of the filter body  72  can be received by the main opening  96  (of the filter coupling insert  64 ) with a snap-fit, so that the outer edge of the base  88  can engage with an edge of the main opening  96 , and a bottom of the base  88  can contact a surface of the main opening  96 . In some embodiments, the base  88  of the filter body  72  can include nodules  90  that aid in connecting the filter  24  to the filter coupling insert  64 . The outlet  100  can include a passage that allows the liquid to pass from the filter coupling insert  64  to the flow control insert  68 . As a result, the liquid can be substantially isolated from air chambers that may be otherwise created by the nozzle body  22 . As shown in  FIG. 4B , the filter coupling insert  64  can also include a flow control insert opening  104 , which can allow the flow control insert  68  to be inserted into the filter coupling insert  64  when the spray nozzle  10  is assembled. 
     The flow control insert  68  can include a tab  106  that can help to properly align the flow control insert  68  with the spray outlet tube  26 . In some embodiments, the flow control insert  68  can also include a movable protrusion  108  that can couple the flow control insert  68  to an inner surface of the flow control insert opening  104  when the spray nozzle  10  is assembled. As a result, the tab  106  and protrusion  108  of the flow control insert  68  can automatically align and secure the flow control insert  68  to the spray outlet tube  26  and the filter coupling insert  64 , respectively. In some embodiments, the flow control insert  68  can also include sealing grooves  109  that can receive sealing rings. The sealing grooves  109  can be annular grooves that can allow sealing rings (not shown) to be coupled to the flow control insert  68 . The sealing rings can help to create several fluid-tight seals along the length of the flow control insert  68 , so that liquid does not escape between the flow control insert  68  and the filter coupling insert  64  when the nozzle  10  is assembled. 
     Upon assembly, the body  22  of the spray nozzle  10  can receive the filter coupling insert  64 , the filter  24 , and the sealing ring  60 . As a result, the body  22  can at least partially surround the combination of the filter  24 , the sealing ring  60 , and the filter coupling insert  64  (as shown in  FIG. 1 ). In some embodiments, the body  22  of the spray nozzle  10  can include a support lip (as shown and described with respect to  FIG. 5 ) that is sized to contact and support the outer ring  92  of the filter coupling insert  64 . Additionally, the flow control insert opening  104  of the filter coupling insert  64  can be positioned within the spray outlet tube  26 . As a result, the flow control insert  68  can be inserted into the spray outlet tube  26  (and within an interior space defined by the flow control insert opening  104 ). 
       FIG. 5A  illustrates the interior of an assembled spray nozzle  10 . During use, the liquid can flow into the body  22 , and through the filter  24  and the filter material  76  in the entry portion of the body  22 . After passing through the filter material  76 , the liquid can flow through the base  88  of the filter body  72 . The sealing ring  60  can prevent liquid from passing directly to the main opening  96  of the filter coupling insert  64  without first passing through the filter  24 . After passing through the base  88  of the filter body  72 , the liquid can contact a bottom surface of the main opening  96  and pressure can force the liquid down through the outlet  100  of the filter coupling insert  64 . After passing through the outlet  100 , the liquid can enter the flow control insert  68 . 
     As shown in  FIG. 5A , the flow control insert  68  can include an entry shaft  116 , a primary tube  120 , an air gap  124 , and a secondary tube  128 . Upon entering the flow control insert  68 , the liquid can flow down the entry shaft  116 . In some embodiments, the entry shaft  116  can have a generally rectangular cross-section, which can affect the flow characteristics of the liquid before entering the primary tube  120 . Additionally, the entry shaft  116  can include one or more projections or ledges  118  that can be positioned above the primary tube  120 . In other embodiments, more or fewer ledges  118  can be included (e.g., one, three, etc.). The entry shaft  116  and the generally rectangular ledges  118  are also shown in  FIG. 5B . The ledges  118  can induce turbulence in the liquid flow while the liquid travels down the entry shaft  116 . As a result, the entry shaft  116  and ledges  118  can prepare the flow of liquid prior to the liquid entering the primary tube  120 . In some embodiments, such flow preparation can allow air to be more easily introduced to the liquid. 
     After flowing down the entry shaft  116  and over the ledges  118 , the liquid can be forced into the primary tube  120 , which can be arranged substantially perpendicular to the entry shaft  116 . Upon exiting the primary tube  120 , the liquid can pass over the air gap  124 , where air can be introduced. Air can be drawn into the air gap  116  through the air opening  30  at the bottom of the spray outlet tube  26 . After passing over the air gap  124 , the air-charged liquid can be forced into the secondary tube  128 . In some embodiments, the cross-sectional area of an entry portion of the secondary tube  128  is generally smaller than an exit portion of the secondary tube  128 . 
     The liquid can exit the flow control insert  68  and continue into an exit passage  132  of the spray outlet tube  26 . In some embodiments, the exit passage  132  of the spray outlet tube  26  can terminate in a generally dome shaped portion  136 . The spray orifice  46  can be cut into the exit passage  132  before the dome-shaped termination portion  136  in the liquid flow path. As a result, a portion of the liquid can contact the dome-shaped portion  136  before being dispersed, while the remainder of the liquid can be dispersed directly. The spray orifice  46  can be a generally “V-shaped” slot that includes a vertical edge and an angled edge. In some embodiments, positioning the V-shaped spray orifice before the dome-shaped portion  136  in the liquid flow path in the exit passage  132  can produce a fan-type spray pattern. The fan-type spray pattern can be altered according to the spray and configuration of the exit passage  132 , as well as the angle of the V-shaped exit orifice  46 . 
     Various features and advantages of the invention are set forth in the following claims.