Patent Publication Number: US-9427751-B2

Title: Irrigation sprinkler nozzle having deflector with micro-ramps

Description:
FIELD 
     This disclosure relates generally to an irrigation sprinkler nozzle and, in particular, to an irrigation sprinkler nozzle having a deflector. 
     BACKGROUND 
     Efficient irrigation is a design objective of many different types of irrigation devices, such as gear-drive rotors, rotary spray nozzles, and fixed spray nozzles. That objective has been heightening due to concerns at the federal, state and local levels of government regarding the efficient usage of water. Over time, irrigation devices have become more efficient at using water in response to these concerns. However, those concerns are ongoing as demand for water increases. 
     As typical irrigation sprinkler devices project streams or sprays of water from a central location, there is inherently a variance in the amount of water that is projected to areas around the location of the device. For example, there may be a greater amount of water deposited further from the device than closer to the device. This can be disadvantageous because it means that some of the area to be watered will be over watered and some of the area to be watered will receive the desired about of water or, conversely, some of the area to be watered will receive the desired amount of water and some will receive less than the desired about of water. In other words, the distribution of water from a single device is often not uniform. 
     One measure of how uniformly water is applied to an area being watered is called Distribution Uniformity “DU”, which is expressed as a percentage. One common measure of Distribution Uniformity is the Lower Quarter Distribution Uniformity (“DU lq ”), which is a measure of the average of the lowest quarter of samples, divided by the average of all samples: 
               DU   lq     =       Average   ⁢           ⁢   Catch   ⁢           ⁢   of   ⁢           ⁢   Lower   ⁢           ⁢   Quarter   ×   100       Average   ⁢           ⁢   Catch   ⁢           ⁢   Overall             
For example, if all samples are equal, the DU is 100%. If a proportion of the area greater than 25% receives zero application the DU will be 0%. DU can be used to determine the total watering requirement during irrigation scheduling. For example, one may want to apply not less than one inch of water to the area being watered. If the DU were 75%, then the total amount to be applied would be the desired about of water (one inch) divided by the DU (75%), or 1.33 inches of water would be required so that only a very small area receives less than one inch of water. The lower the DU, the less efficient the distribution and the more water that must be applied to meet the minimum desired. This can result in undesirable over watering in one area in order to ensure that another area receives the minimum water desired.
 
     Another measurement is called the Scheduling Coefficient (“SC”). Unlike the DU, the scheduling coefficient does not measure average uniformity. Instead, it is a direct indication of the dryness of the driest turf areas (critical areas). The measurement is called the Scheduling Coefficient because it can play a role in establishing irrigation times. It is based on the critical area to be watered. To calculate the SC, one first identifies the critical area in the water application pattern which is receiving the least amount of water. The amount of water applied to this critical area is divided into the average amount of water applied throughout the irrigated area to obtain the Schedule Coefficient. The scheduling coefficient indicates the amount of extra watering needed to adequately irrigate the critical area. If perfect uniformity were obtained, the scheduling coefficient would be 1.0 (no extra watering needed to adequately irrigate the critical area). By way of example, assume that an irrigation pattern has a scheduling coefficient of 1.8. After 15 minutes of irrigation, a critical area would still be under-watered due to non-uniformity. It will take an additional 12 minutes (15 minutes×0.8) to apply an adequate amount of water to the critical area (or 27 minutes total). While that is the amount of time needed to water the critical area, the result is that other areas will be over-watered. 
     There are many applications where conventional spray nozzle irrigation devices are desirable for use. Unfortunately, conventional spray nozzle irrigation devices can undesirably have lower DU lq  values. For example, some conventional fixed spray devices can have DU lq  values of about 65% and be considered to have a very good rating, DU lq  values of about 70% for rotors are considered to have a very good rating. 
     SUMMARY 
     Spray nozzles having either an arcuately fixed or adjustable spray patterns are described herein, wherein the nozzles have deflectors that are configured with depending ribs having micro-structures that cooperate with other geometry of the rib and deflector to define a plurality of different micro-ramps for dividing the discharged water into different sprays having different characteristics. The different sprays with the different characteristics combine to provide for an improved spray pattern. The result is that advantageously higher DU lq  and lower SC values can be achieved, including in a variable arc nozzle. 
     Water is discharged through one or more flow openings upstream of the deflector in a direction that is generally parallel a central axis of the nozzle (or at an angle from perpendicular thereto). When the discharged water hits an inclined portion of the deflector, the deflector redirects the water outwardly, with the ribs generally confining the water to being radially outwardly. However, the momentum of the water reacts to the impact with the deflector by wanting to move outwardly against the bottom of channels formed between adjacent pairs of the ribs as well against the sidewalls of the ribs. Essentially, the behavior of the water upon impact with the deflector is such that a significant fraction wants to remain close to the structure as opposed to completely filling the channels. In other words, a large fraction of the water tends to “ride along” the sides of the ribs and the bottom of the channels. In order to take advantage of this behavior of the discharged water, very minute structural variances in the portions of the deflector that the water comes into contact with can have a significant impact on the water passing thereagainst. That is, making non-uniform ribs, such as with steps or other protuberances or variations, can provide micro-ramps for altering the flow pattern of the water thereagainst as compared to adjacent water flows. In this manner, the discharging flow of water can be segregated by the deflector into different sprays having different characteristics which can be tailored to achieve certain objectives, such as sprays that are intended to irrigate different areas which, when combined, can result in a more efficient irrigation spray pattern. 
     In one aspect, a spray nozzle is provided having a deflector body downstream of a flow opening to deflect water discharge from the flow opening. The deflector body has a plurality of depending ribs forming channels for water flow therebetween, and a plurality of the ribs each have an outwardly-extending step at least partially along the length of the ribs such that a micro-ramp extends into the channels for directing a portion of the water flow. 
     In another aspect, a spray nozzle is provided having a base having a longitudinal axis and at least one water passage extending through base. A deflector body has an upper deflector portion and a lower neck and is fixed relative to the base. The deflector body has a plurality of radially-outward extending, depending ribs forming channels for water flow therebetween, where the ribs each having a pair of sidewalls and a bottom wall with the sidewalls each having a primary micro-ramp projecting laterally a first distance from the sidewall and spaced from a bottom of the channel to define a primary path for water flow outwardly from the nozzle. 
     In either of the foregoing aspects, the spray nozzle may be of a fixed-arc type or a variable arc-type. In the case of a variable arc-type spray nozzle, a first nozzle body may be provided having a first helical surface. A second nozzle body can be rotatably associated with the first nozzle body and can include a second helical surface. The first and second helical surfaces are configured to cooperate to define an arcuate flow opening adjustable in size to determine an arc of water distribution upon rotation of the first nozzle body relative to the second nozzle body. In one example, the second nozzle body can be in the form of a collar and the first nozzle body can include a deflector that are mounted for relative rotation. The collar has a collar helical surface configured to cooperate with a deflector helical surface of the deflector to define an arcuate flow opening, upstream of an upper deflector portion, that is adjustable in size to determine an arc of water distribution upon rotation of the collar relative to the deflector. 
     A method is also provided for distributing water from the spray nozzle which includes the step of deflecting at least some of the water radially outward along a plurality of flow paths disposed between adjacent pairs of the ribs and the bottom of the channels, a first of the flow paths on a side of the steps closer to the bottom wall having a first fraction of the total discharged water volume and a second of the flow paths on a side of the step opposite the bottom wall having a second fraction of the total discharged water volume, the second fraction being different than the first fraction. 
     In any of the foregoing aspects, the deflector body may optionally have an upper portion with an underside with the depending ribs thereon and a lower portion with a neck depending from the underside with a plurality of flow notches disposed about its outer periphery. The flow notches may be aligned with channels formed between the ribs such that a water flow path extends through the flow notches into the channels. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an exploded perspective view of an exemplary embodiment of a variable arc irrigation nozzle, depicting a deflector, a collar, a base and an adjustment screw, where the deflector includes a plurality of radially-extending ribs forming channels for water flow therebetween, the ribs having micro-ramps configured for providing different aspects of the spray pattern; 
         FIG. 2  is a perspective view of the variable arc irrigation nozzle of  FIG. 1  in an assembled configuration; 
         FIG. 3  is a top plan view of the assembled variable arc irrigation nozzle of  FIG. 1 ; 
         FIG. 4  is a cross-section view of the assembled variable arc irrigation nozzle taken along line IV-IV of  FIG. 3 ; 
         FIG. 5  is a cross-section view of the assembled variable arc irrigation nozzle similar to  FIG. 4 , but showing diagrammatic flow paths discharging from the nozzle; 
         FIG. 6  is a top plan view of the base of the variable arc irrigation nozzle of  FIG. 1 ; 
         FIG. 7  is a perspective view of the collar of the variable arc irrigation nozzle of  FIG. 1 ; 
         FIG. 8  is a perspective view of the underside of the deflector of the variable arc irrigation nozzle of  FIG. 1 ; 
         FIG. 9  is a detailed perspective view of some of the ribs on the underside of the deflector of the variable arc irrigation nozzle of  FIG. 1 ; 
         FIG. 10  is a detailed bottom plan view of a portion of the underside of the deflector of the variable arc irrigation nozzle of  FIG. 1 ; 
         FIG. 11  is a perspective view of a section of the deflector of the variable arc irrigation nozzle of  FIG. 1  showing details of the ribs; 
         FIG. 12  is a side elevation view of the deflector of the variable arc irrigation nozzle of  FIG. 1 ; 
         FIG. 13  is an image based upon Computational Fluid Dynamics (“CFD”) analysis of water flow along the ribs of the variable arc irrigation nozzle of  FIG. 1 ; and 
         FIG. 14  is a schematic diagram depicting an idealized flow discharging from the variable arc irrigation nozzle of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION 
     As shown in the exemplary drawings, a new and improved sprinkler spray nozzle for use in irrigation is provided. The spray nozzle has a deflector that provides for the separation of discharging water into different sprays in order to improve the overall spray pattern and, in particular, the DU lq  and SC values associated with the spray nozzle. Unlike conventional spray nozzles, which often have deflectors with simple, radially-extending vanes, the deflector of the exemplary embodiment has a deflector with depending ribs, where the ribs in turn each have one or more micro-ramps or other structures protruding into the flow paths of the water which guide the deflected water flow in different sprays which can have different characteristics. The different sprays with the different characteristics combine to provide for an improved spray pattern. Moreover, the spray pattern can be tailored by adjusting the geometries of the micro-ramps and the ribs depending upon the desired application or irrigation spray pattern. In one aspect, the deflector can receive discharging water from an arcuately-adjustable opening such that the arc of the spray pattern can be adjusted. However, the deflector described herein and, in particular, the division of the deflected fluid, can also be incorporated into a fixed spray-type sprinkler nozzle or a rotary-type sprinkler nozzle. 
     In an exemplary embodiment, a spray nozzle  10  for an irrigation device includes a base  12 , a collar  14 , a deflector  16  and a screw  18 , as illustrated in  FIG. 1 . The base  12  includes a lower skirt  20  and an upper skirt  22 , both surrounding a central opening. The lower skirt  20  includes internal threads  40  (illustrated in  FIG. 4 ) to allow the base  12  (and hence the assembled nozzle  10 ) to be threadingly connected to a riser, stand or the like of a sprinkler for receiving pressurized water. The upper skirt includes external threading  24  configured to mate with internal threading  42  of the collar  14 , as shown in  FIG. 4 . The collar  14  can be rotated relative to the base  12  along the mating threads  24  and  42  such that the collar  14  can rotate about the base  12 . The deflector  16  includes an upper deflector surface  58  with a depending neck  50 , as illustrated in  FIG. 12 . The deflector surface  58  is disposed on an opposite side of the collar  14  from the base  12 , and the neck  50  of the deflector  16  extends through the collar  14  and partially into the central opening of the base  12 , as depicted in  FIG. 4 . The depending neck  50  of the deflector  16  is adapted to be attached to the base  12 , as will be described in greater detail herein, such that the deflector  16  is not rotatable relative to the base  12 . The screw  18  may be an adjustable flow rate adjustment screw to regulate water flow through the nozzle  10 . 
     The illustrated embodiment of the nozzle  10  includes variable arc capability such that the arcuate extent of the spray pattern emanating from the nozzle  10  can be adjusted. The collar  14  includes a radially-inward extending helical ledge  32 , as illustrated in  FIG. 7 . Ends of the ledge  32  are axially spaced and are connected by an axially-extending wall  34 . The ledge  32  has an upwardly-facing surface and a radially-inward edge surface. An upper face  36  of the collar  14  is also helical, having the same pitch as the ledge  32  and with ends thereof joined by an axially extending face wall  38 , also as illustrated in  FIG. 7 . The neck  50  of the deflector  16  includes a downward-facing helical surface  55  and a depending, radially-outward facing helical wall  52 , as illustrated in  FIG. 8 , both of which have the same pitch as the ledge  32  of the collar  14 . The downward-facing helical surface  55  of the deflector  16  lies over the ledge  32  of the collar  14 . 
     As the collar  14  is rotated relative to the deflector  16 , however, the radially-inward edge surface of ledge  32  of the collar  14  is brought into or out of sliding and sealing engagement with the helical wall  52  of the deflector  16  in order to increase or decrease the arcuate extent of a water discharge opening. In a fully closed position, the radially-inward edge surface of the ledge  32  of the collar and the helical wall  52  of the deflector  16  are sealingly engaged to block water flow through the spray nozzle. Rotation of the collar  14  then increase the axially spacing between the edge surface of the ledge  32  of the collar and the helical wall  52  of the deflector  16  such that they have overlying segments that are not sealingly engaged through which the water discharge opening is defined. In this manner, the arcuate extent of the water discharge opening, and thereby the arcuate extent of the spray, can be readily adjusted. By way of example, the collar  14  in  FIG. 4  has been rotated to a position whereby the water discharge opening is about 180-degrees. As can be seen on the left side of  FIG. 4 , the edge surface of the ledge  32  of the collar  14  is sealingly engaged with the helical wall  52  of the deflector  16  but on the right side they are axially spaced. 
     Turning now to details of the upper deflector surface  58  of the deflector  16 , a plurality of radially-extending ribs  60  depend from the underside, as illustrated in  FIGS. 8-11 . Discharge channels for water are formed between adjacent ribs and have bottoms  62  coinciding with the underside of the upper deflector surface  58 . The ribs  60  are each configured to divide the water flow through the channels into different sprays directed to different areas and thereby having different characteristics. The different sprays with the different characteristics are combined to provide for an improved spray pattern having improved DU lq  and SC values as compared to conventional spray nozzles, including conventional spray nozzles configured for variable arc adjustment, as will be discussed in greater detail herein. 
     Each of the ribs  60  has an inner end adjacent the neck  50 , and outer end radially outward from the neck  50 , a pair of sidewalls and a bottom wall  70 . As the ribs  60  are each generally symmetric about a radially-extending line, only one of the sides of a representative rib  60  will be described with it being understood that the opposite side of that same rib  60  has the same structure. With reference to  FIGS. 10 and 11 , the rib  60  has a first step  66  forming in part a first micro-ramp and a second step  68  defining in part a second micro-ramp. The first step  66  is generally linear and positioned at an angle closer to perpendicular relative to a central axis of the deflector as compared to the bottom  62  of the upper deflector surface  58 , as shown in  FIG. 11 . The second step  68  is segmented, having an inner portion  68   a  that extends closer to perpendicular relative to the central axis as compared to an outer portion  68   b , which has a sharp downward angle. 
     The first and second steps  66  and  68  divide the sidewall into three portions having different thicknesses: a first sidewall portion  63  disposed adjacent an outward region of the bottom  62  of the upper deflector surface  58 ; a second, narrower sidewall portion  67  disposed partially on an opposite side of the first step  66  from the first sidewall portion  63 ; and a third, yet narrower sidewall portion  65  having an outer region disposed on an opposite side of the second step  68  from the first step  66 , a middle region disposed on an opposite side of the first step  66  from the bottom  62  of the upper deflector surface  58 , and an inner region disposed adjacent the bottom  62 , as depicted in  FIG. 11 . The outer portion  68   b  of the second step  68  is spaced inwardly from the outer end of the rib  60  by a second sidewall portion  67 . An inclined sidewall segment  69  is disposed radially inward from the second sidewall portion  67 . 
     The underside or bottom wall  70  of the rib  60  has a first, generally linear segment  70   a  positioned at an angle closer to perpendicular relative to a central axis of the deflector  16  as compared to an inner, inclined intermediate segment  70   b  and the bottom  62  of the upper deflector surface  58 , as shown in  FIG. 11 . An outer, inclined intermediate segment  70   c  is closer to perpendicular than the inner intermediate segment  70   b  but not as close to perpendicular as the first segment  70   a . An upwardly curved segment  70   d  is disposed at the end of the rib  60 . 
     The geometries of the ribs  60  and the bottom  62  of the of the upper deflector surface  58  cooperate to define a plurality of micro-ramps which divide the discharging water into sprays having differing characteristics. More specifically, and with reference to  FIGS. 5 and 14 , there is a first spray B, a second spray C, a mid-range spray D and a close-in spray E as measured from the location A of the spray nozzle  10 . The first and second sprays B and C may combine or may be coextensive to form a primary spray. The first and second sprays B and C can have the furthest throw, but may be angularly offset from each other to minimize gaps between the sprays. The mid-range spray D and the close-in spray E are progressively closer to the location A of the spray nozzle  10 , as depicted in  FIG. 14 . When the different sprays are combined, the result is a spray pattern which provides for improved DU lq  and SC values as compared to conventional arcuately adjustable, fixed spray nozzles. 
     The micro-ramp associated with the first spray B is defined by the first step  66  and the adjacent portions of the sidewall of the rib  60 , such as portion of sidewall segment  65 ,  69  and  67 , with reference to  FIG. 11 . The micro-ramp associated with the second spray C is defined by the bottom  62  of the upper deflector surface  58  and the adjacent portions of the sidewall of the rib  60 , such as segment  63 , also with reference to  FIG. 11 . As can be seen from the image of  FIG. 13  from the CFD analysis of the water flow, the vast majority of the water tends to flow immediately adjacent the ribs  60  and the bottom  62  of the channels and opposed to evenly filling the space between the ribs  60 . Accordingly, the position of the first step  66  relative to the bottom  62  can be selected to vary the amount or fraction of the water flowing along the first micro-ramp as opposed to the second micro-ramp. For example, moving the first step  66  closer to the bottom  62  will increase the depth of the first micro-ramp and thereby increase its fraction of water as compared to the second micro-ramp. As shown in this example, there is a greater fraction of the water flow in the first micro-ramp as compared to the second micro-ramp. 
     In order to provide for the phase shifting of the spray from the first micro-ramp relative to the spray from the second micro-ramp, the outward ends  67  of the sidewalls of the ribs  60  narrow or taper toward each other, such that a pair of sub-sprays each flowing along the primary micro-ramp on opposite sides of the same rib  60  combine to form a common primary spray. This angularly shifts the first spray from being directly radially outward in the direction of the bottom  62  of the channels. 
     The micro-ramp associated with the mid-range spray D is defined by second step  68  and those portions of the sidewall of the rib  60  on an opposite thereof from the first step  66 , such as a portion of sidewall segments  65 . The sharply inclined end segment  68   b  is configured to direct the water spray more downwardly as compared to the spray from the first micro-ramp. Finally, the micro-ramp associated with the close-in spray E is defined by the underside  70  of the rib  60 , including the downturned end segments  70   b  and  70   c , for directing the water flow a shorter throw as compared to the mid-range spray D, the second spray C and the first spray B. It will be understood that the geometries, angles and extend of the micro-ramps can be altered to tailor the resultant combined spray pattern. Further, while it is presently believed to be preferable to have all or nearly all (at least about 80%, 85%, 90%, or 95%) of the ribs  60  with the micro-ramps, it is foreseeable that in some circumstances it may be preferable to have less than all of the ribs include micro-ramps. For instance, the micro-ramps may be on only one side of each of the ribs, may be in alternating patterns, or the like. 
     Extending about the outer circumference of a portion of the neck  50  of the deflector  16  are a plurality of radially-projecting and axially-extending ribs  54  which are spaced by axially-extending flow notches  56 . The flow notches  56  have an upstream entrance disposed radially outward from the downwardly-facing helical wall  55 , as illustrated in  FIG. 8 . A downstream exit of the flow notches  56  is aligned with the channels between adjacent ribs  60 , as illustrated in  FIG. 9 . An inclined ramp  64  at the intersection of each of the channels and the flow notches  56  can assist in gradually turning the flow from being generally axially to projecting generally radially outwardly. The flow notches  56  can improve the ability of the spray nozzle  10  to provide for a matched precipitation rate, particularly desirable given the adjustable nature of the arcuate extent of the spray pattern from the spray nozzle  10 . In other words, the flow notches  56  contribute to having proportional volumes of water discharged for given arcuate spray pattern settings. 
     In the exemplary embodiment of a variable arc spray nozzle  10  depicted in the accompanying figures, the nozzle  10  may be configured to have a 12 foot throw. There may be thirty flow notches  56  feeding thirty channels separated by ribs  60 , with thirty ribs  60  total and one rib extending from the ends of the helically-inclined array of ribs  60 , which one rib lacks micro-ramps in the illustrated embodiment. Each of the axially-extending ribs projects outwardly about 0.0255 inches, has a width at its outward end of about 0.024 inches and adjacent ones form a flow notch  56  with an inward taper of about 6.2 degrees with a bottom radius of about 0.0125 inches. The length may be about 0.92 inches. The inclined ramp  64  may be outwardly-inclined at about 20 degrees relative to a central axis. The ribs  60  are spaced at about 10 degrees to about 12 degrees apart. The first step  66  is between about 0.004 and 0.008 inches in width from the sidewall of the adjacent portion of the rib  60 , such as about 0.006 inches. A distal end of each of the ribs  60 , including the first step  66 , may be about 0.040 inches with about a 3 degree taper, with the portion on the opposite side of the step  66  from the bottom wall  62  being about 0.028 inches in width, with a proximate end of each of the ribs  60  being about 0.018 inches. The second step  68  may be between about 0.002 and 0.006 inches in width, such as about 0.004 inches in width. The angle of the linear portion  70   a  of the bottom wall  62  may be about 9 degrees toward a horizontal plane coinciding with the top of the deflector  16 , with the inward segment  70   b  being inclined about 50 degrees away from the plane and the intermediate segment  70   c  being inclined about 20 degrees away from the plane. While these dimensions are representative of the exemplary embodiment, they are not to be limiting, as different objectives can require variations in these dimensions, the addition or subtraction of the steps and/or micro-ramps, and other changes to the geometry to tailor the resultant spray pattern to a given objective. 
     The deflector  16  is attached to the base  12  via engagement between a pair of depending prongs  46  and  48  of the neck  50  and structure surrounding the central opening of the base  12 . More specifically, the base  12  includes an interior center disc  26  supported in spaced relation from the upper skirt  22  via a plurality of connecting webs  30 , as depicted in  FIG. 6 . The central opening  28  extends through the disc  26 . Barbed ends of the prongs  46  and  48  are configured to extend through the central opening  28  to form a cantilever snap fit to secure the deflector  16  relative to the base  12  with the collar  14  therebetween. Further, the central opening  28  is optionally key-shaped or otherwise asymmetric in at least one direction. When one of the prongs  48  is larger than the other of the prongs  46  in its arcuate extent, as depicted in  FIG. 8 , the key-shaped central opening  28  and the differently-sized prongs  46  and  48  can cooperate to ensure that the deflector  16  can only be attached to the base  12  in a single preferred orientation. 
     It will be understood that various changes in the details, materials, and arrangements of parts and components, which have been herein described and illustrated in order to explain the nature of the invention may be made by those skilled in the art within the principle and scope of the invention as expressed in the appended claims.