Patent Description:
The present invention relates to automotive washer nozzles for cleaning relatively small external surfaces such as external camera lens surfaces, and cleaning them very well with no requirement for a mechanical wiper or the like.

Fluidic type washer nozzles are well known for high efficiency (big coverage, high speed with low flow rate) spray performance. However, the major limitation of fluidic nozzle is that the nozzle assembly's package size needs to be large enough (for example, the linear distance from the fluid inlet or feed to the exit orifice or front to back thickness needs to be at least <NUM> for most of fluidic circuits).

For some applications, package size is a big concern due to very limited available space. Jet spray nozzles were commonly used in such limited space applications. Because of their excessively narrow spray pattern, jet spray nozzles typically must be supplied with very high cleaning fluid flow rates or must be operated for longer spray durations to effectively clean a glass or external lens surface. Jet spray nozzles have smaller package size than fluidic nozzles, but do not have effective spray patterns for many automotive cleaning applications such as cleaning a camera lens, where the surface must be cleaned very well, and without requiring a mechanical wiper or the like.

Some shear nozzles can be made to generate useful sprays for washing and can be made adjustable with ball-shaped inserts which are configured to move within a socket in a nozzle housing, but size constraints have remained a problem. Automotive designers want very compact nozzle assemblies for automotive washer nozzles, but also want an even spray distribution. Automotive OEMs also want a nozzle which is very economical and versatile. For example, exterior trim assemblies often combine many functions, such as the Center High Mounted Stop Light ("CHIMSL") light assemblies now required by US DOT regulations. Center High Mounted Stop Light ("CHIMSL") assemblies can include other features such as external cameras, but cleaning the lenses on those cameras becomes problematic, if the automotive stylist's design for exterior trim is to be preserved.

There are many examples of automotive exterior trim assemblies with awkwardly incorporated spray nozzles which may preserve the aesthetic appearance of the automotive trim but do not generate a spray which will adequately cleans a window or other surface. An early example is provided in <CIT> which has a vehicle <NUM> with an exterior panel or surface <NUM> including Center High Mounted Stop Light ("CHIMSL") trim assembly <NUM> having a lens <NUM> with a spray tip <NUM> configured to spray jets of washing fluid through apertures <NUM> from beneath nozzle hood <NUM> (as reproduced in Prior Art <FIG>). This nozzle configuration will reliably pour jets of washing fluid downwardly, generally onto the rear window or backlight glass of the vehicle, but little more can be said for the spray's ability to clean any particular surface. Nozzle configurations like that shown in <FIG> work well enough to clean a rear window if the wiper blade is also used, but the spray from this nozzle, alone, does little to clean the window.

Cleaning something as small and specialized as a vehicle's external view camera lens surface is much more demanding, from a technical perspective (as set forth in applicant's commonly owned patent application publications including <CIT>), but automotive OEM designers seek ever smaller and more visually inconspicuous solutions for external lens cleaning sprays. Nozzles for generating these sprays would be most desirable if they were readily configured for incorporation into an aesthetically pleasing and easily installed exterior trim assembly incorporating a plurality of diverse components such as a Center High Mounted Stop Light ("CHIMSL"), one or more external view cameras, and one or more nozzle assemblies as would be required to clean the external surfaces of those cameras (or adjacent windows). <CIT> is directed to yield oscillating spray distributions from the top and bottom of an insert. The spraying nozzle of <CIT> includes a fluid flow insert that is inserted into a cavity. The insert includes top and bottom outer surfaces having fluidic circuits fabricated therein to yield oscillating sprays. In <CIT>, fluid flows through the fluidic circuits and power nozzles and interaction chambers of the upper and lower fluidic circuits. The flow is then distributed from the outlet in an oscillating spray pattern. The spray plane includes an oscillating spray of fluid.

There is a need, therefore, for a practical, economical very compact yet effective automotive washer nozzle configuration and cleaning method which can be implemented in smaller and more visually inconspicuous package for incorporation into an aesthetically pleasing and easily installed exterior trim assembly incorporating a plurality of possibly diverse components such as a Center High Mounted Stop Light ("CHIMSL"), one or more external view cameras, and the nozzle assemblies required to clean the external surfaces of the cameras or adjacent windows.

Accordingly, it is an object of the present invention to overcome the above mentioned difficulties by providing a new way to integrate a nozzle assembly which can reliably generate the desired sprays with spray aiming and orientation features by aiming one or more open orifices from a very compact (e.g., <NUM> dia. ) spray head.

In accordance with the present invention, a compact spray head according to claim <NUM> comprises a molded compact shear spray nozzle member. The new and surprisingly small (e.g., <NUM> dia. ) compact shear spray nozzle member with a selectable spray orientation is configured very economically in a unitary or one-piece molded part. This compact nozzle member or spray head is configured with first and second shear nozzle orifices which are oriented and aimed to generate sprays having selected fan angles. The spray fan angle may be selected from within the range of <NUM>° to <NUM>°. The nozzle assembly of the present invention makes available configurations with greatly reduced package size and cost, without sacrificing spray coverage.

A split-lip shear nozzle embodiment of the present invention encompasses a very compact spray head design for an automotive washer nozzle. The spray fan is dual shear shaped, producing an even distribution, which may be selectively varied from <NUM>° to <NUM>°. The visually inconspicuous split lip shear spray head is a distally projecting almost hemispherical bump which may be as small as <NUM> in diameter and yet provides a range of available spray aim, yaw and roll angles. The split-lip shear nozzle embodiment is preferably a one-piece plastic molded component with laterally spaced spray orifices separated by a splitter and the spray head is configured in a manner which provides improved mold-ability and versatility of application.

The above and still further objects, features and advantages of the present invention will become apparent upon consideration of the following detailed description of a specific embodiment thereof, particularly when taken in conjunction with the accompanying drawings, wherein like reference numerals in the various figures are utilized to designate like components.

Turning now to a detailed description of the automotive trim mounted spray nozzle assembly and compact shear spray nozzle member of the present invention, <FIG> illustrate specific, illustrative embodiments for the shear spray nozzle configurations and the methods for selecting and aiming the nozzles to provide desired sprays. All of the illustrated embodiments provide a very compact spray head design which reliably generates a spray fan or pattern which is made up of two or three shear-shaped planar sprays that evenly distribute cleaning fluid (e.g., water) over a combined spray fan angle of selected angular spread (e.g., <NUM>° to <NUM>°). All of the automotive trim mounted spray nozzle assemblies and compact shear spray nozzle members of the present invention (e.g. <NUM>) are well suited for integration into an automotive exterior trim piece such as Center High Mounted Stop Light ("CHIMSL") assembly <NUM> for use on a vehicle <NUM>, as illustrated in <FIG>. The nozzle assemblies and nozzle members described below (e.g. <NUM>, <NUM>, <NUM>) could also easily be incorporated very inconspicuously into a vehicles exterior panel <NUM> or external component (e.g., a side mirror assembly) along with an external view camera (not shown) to provide a very compact camera wash nozzle.

Beginning with the spray head embodiment illustrated in <FIG>, compact shear spray nozzle member or spray head <NUM> could be as small as <NUM> in diameter (<NUM>, D-D as shown in <FIG>), and the design of spray head <NUM> can be configured to provide various spray aim, yaw and roll angles (see <FIG> and <FIG>). The illustrated embodiment of spray head <NUM> is readily molded from suitable plastic materials and is configured for better mold-ability and versatility of application.

Spray head <NUM> is molded, preferably in a one-piece unitary structure from fluid impermeable durable plastic material, into a substantially cylindrical hollow member having a substantially open proximal end <NUM> defining a substantially circular open lumen <NUM> enclosed within and coaxially aligned with the central axis of a distally a projecting nearly cylindrical (slightly tapered, frustoconical) sidewall <NUM>. The central flow axis <NUM> of spray head <NUM> extends distally and the diameter <NUM> of spray head <NUM> (e.g., <NUM>) is measured from side to opposing side across central spray axis <NUM>, as best seen in <FIG>.

Spray head lumen <NUM> is configured to accelerate fluid passing distally through lumen <NUM> and has a first proximal cylindrical segment 104A which terminates distally into a proximal narrowing tapered sidewall segment 104B which narrows or tapers distally to a smaller inside diameter at central cylindrical segment 104C. Central cylindrical segment 104C terminates distally into a distal narrowing tapered sidewall segment 104D, which terminates distally in a somewhat dome-shaped fluid impingement shear generating chamber 114SC, as shown in <FIG>, <FIG> and <FIG>. The configuration of the interior surfaces of dome-shaped shear generating chamber 114SC is shown in detail in the cross sectional view of <FIG>, where the distal end of the lumen or channel <NUM> is seen to provide concave fluid impingement surfaces. Pressurized fluid flowing from a reservoir is pumped into lumen <NUM> where it is accelerated as it flows distally toward shear generating chamber 114SC where a high velocity spray is forced into a selected spray pattern by first and second laterally spaced spray outlets <NUM>, <NUM> which are defined, in part by a substantially planar wall segment or splitter <NUM>.

The fluid flows into the nozzle inlet <NUM> and into lumen <NUM>, where it is forced to flow distally along the narrowing fluid flow channel defined by lumen <NUM> and be emitted as a spray of fluid droplets from the split or first and second throat outlets <NUM>, <NUM>. As fluid flows along the fluid flow channel from the channel's inlet <NUM> which receives fluid from and is in fluid communication with a fluid supply or reservoir, the fluid is accelerated in the tapered transition regions <NUM>, <NUM> which reduce the cross sectional area of fluid flow lumen <NUM>. The shear spray generating chamber 1148C is in fluid communication with and receives fluid from the lumen or fluid flow lumen <NUM> and that fluid flows around the fluid-impermeable substantially planar wall segment or splitter <NUM> and around the opposing channel sidewalls to create a first substantially planar spray <NUM> from first shear outlet <NUM> and a second substantially co-planar spray <NUM> from second spray outlet <NUM>, and the combined sprays from throat outlets <NUM> and <NUM> have at least a small overlap (see <FIG>) and so together generate a relatively evenly distributed spray with a selected fan angle in the range of <NUM> degrees to <NUM> degrees. The co-planar sprays <NUM> and <NUM> are projected distally in fans which are inclined at an aim angle, as best seen in Fig. <NUM>, and the spray shape and aim angle are determined, in part by the configuration of the nozzle outlet orifice defining notch wall segments <NUM>, <NUM>, <NUM>, as best seen in <FIG>, <FIG>, <NUM> and <NUM>. Notch wall segment <NUM> is substantially planar, is aligned vertically or with central axis <NUM> (as best seen in <FIG>) and terminates proximally in angled notch wall segment <NUM>, which defines the outer edges of outlets <NUM> and <NUM>. The lower notch wall segment <NUM> also terminates proximally in angled notch wall segment <NUM>, as best seen in <FIG>.

For the embodiment illustrated in <FIG>, the central spray axis for outlets <NUM> and <NUM> is centered between the planes of notch walls <NUM> and <NUM> and defines an "exit angle" which corresponds to the spray's aim "AIM" angle illustrated in Figs <NUM> and <NUM>. In the exemplary embodiment shown in Fig. <NUM>, the exit angle EA is <NUM> degrees from a vertical plane 11OP which is parallel to central axis <NUM>, but exit angle EA could be larger (for a more horizontal AIM angle) or smaller (so the AIM angle is closer to parallel with plane 110P). Inside shear chamber 114SC, the distal end wall or top wall 114TW defines a Top approach "TA" angle which is <NUM> degrees from vertical, and the chamber's sidewall 114SW defines a Bottom approach "BA" angle which is <NUM> degrees from vertical, meaning that the included angle between these shear chamber wall segments is about <NUM> degrees from each other and this defines the Impingement angle ("IA") proximate the spray throat outlets <NUM>, <NUM>. In the embodiment illustrated in <FIG>, the Throat outlet opening span is <NUM> to <NUM> (preferably <NUM>) from the edge of notch wall <NUM> to the edge of vertical notch wall <NUM> (See <FIG>) and the Throat outlet span from each exit's side (at the corresponding edge of notch wall <NUM> to the splitter <NUM>) is <NUM> to <NUM> (preferably <NUM>) (See <FIG>). The Throat outlet offset "TO" from the back flat (defined by notch wall <NUM> and the edges of the throat outlets <NUM>, <NUM>) is preferably <NUM> to <NUM> (preferably <NUM>), and the Throat outlet angles "TEA" (for angled wall segments within the chamber 114SC proximate the throat outlet edges) are <NUM> degrees to <NUM> degrees (preferably <NUM> degrees) from either side (<NUM> degrees from vertical at notch wall <NUM> and <NUM> degrees from vertical at notch wall <NUM>).

It will be appreciated by persons having skill in the art that molded compact shear spray nozzle member <NUM> provides a molded compact one-piece spray head having an open proximal end <NUM> in fluid communication with an interior lumen <NUM> with tapering transition regions having progressively smaller internal lumen cross sectional areas to accelerate washing fluid toward shear-spray generating chamber 114SC with its elongated spray orifice having a first orifice edge at notch wall <NUM> opposing a second orifice edge at notch wall <NUM>. Distal shear-spray generating chamber 114SC also having a first (distal end) concave wall segment defining a first fluid impingement angle, where that first concave wall segment terminates in the first spray orifice edge at notch wall <NUM>. The distal shear-spray generating chamber 114SC also has a second concave wall segment defining a second fluid impingement angle (as seen in <FIG>), where the second concave wall segment terminates in the second spray orifice edge at notch wall <NUM>. The exterior of compact shear spray nozzle member <NUM> terminates in a distal substantially hemispherical or bump-shaped exterior surface (possibly including a flatted end wall) and the spray orifice generates the outwardly projecting fluid spray fan from the orifice which is split to define throat exits <NUM> and <NUM>.

When in use for cleaning camera lenses, automotive glass surfaces or the like, washing fluid is fed into and distributed across the full feed via the conical area upstream or prior to the shear chamber 114SC, as the feed is not directly centered in the cap or dome shaped chamber's distal end. The throat geometry is set up after the multi-lip shear nozzle in that there are varying throat exit angles. The nozzle utilizes a branched center portion of the throat, as can be seen in <FIG> and <FIG>, in order to eliminate the heavy center of the spray. This effectively creates two smaller more uniform spray fans <NUM>, <NUM> at some equal angle from center. The angle of these fans is determined by the angle created by the splitter <NUM> and the sidewall. The angle of each individual fan may be controlled by the angle of impingement and offset distance from the throat.

As illustrated with an alternative embodiment compact shear spray nozzle member 100B illustrated in <FIG>, the spray's Yaw may be selected to be asymmetrical by opening one side (e.g., 118B) more than the other. A relatively wide spray angle for spray 158SB may be achieved with this design, which produces a like uniform spray, which does not foam, with a slightly heavier band where the two fans <NUM>, 158SB meet.

In accordance with the present invention, a new way to make a <NUM> diameter shear shape spray nozzle <NUM> with variable spray orientation in one-piece molded part is provided. The spray fan angle may be varied from <NUM>° to <NUM>° and the generated spray exhibits a uniform, non-foaming fan. The nozzle is configurable so that spray orientation angles (aim, roll and yaw) may be varied from <NUM>° to <NUM>°. The package size and cost are therefore greatly reduced without sacrificing spray coverage. Furthermore, the design of this nozzle allows for rotation of the cap about central axis <NUM> based on a clocking feature, allowing the nozzle configuration of the present invention to be easily adapted for use in other automotive lens or window surface washing applications.

As shown in <FIG>, fluid is fed to a substantially elongated orifice defined behind splitter wall segment <NUM>, and that orifice is at least partially blocked by splitter <NUM>. The shear chamber defines substantially hemispherical shaped surface which guides and distributes the distal fluid flow to expand at the elongated or elliptical orifice which is divided by splitter wall segment <NUM> to define throat exits or spray orifices <NUM>, <NUM> and that expanding flow forms a split sheet-shaped spray fan, where the placement of the splitter defines two throat exits or orifices. The spray orientation (aim, roll and yaw angles) is determined by the spray exit guide surfaces which are substantially normal to the inrushing fluid's angle of impingement (as indicated in <FIG>). The first and second spray fans are formed as shown in <FIG> and <FIG>). The spray fan angle is determined and controlled by adjusting height and width of elliptical orifice is divided by splitter wall segment <NUM> to define throat exits or spray orifices <NUM>, <NUM>. The spay distribution may be uniform and light ended.

As noted above, the compact shear spray nozzle member <NUM> of <FIG> may be incorporated into and aimed from a surface of a CHMSL trim assembly (e.g., <NUM>) to provide an unobtrusive but very effective way to clean an external lens surface.

Turning now to <FIG>, a nozzle assembly <NUM> is configured for a rear Center High Mount Stop Light (CHMSL) mount bezel mount (e.g., <NUM> but illustrates a configuration that could be incorporated into any body trim assembly bezel or vehicular body panel <NUM>). Compact shear spray bezel mountable nozzle assembly <NUM> provides manufacturing advantages and eliminates manufacturing (process) failure modes that currently exist with the prior art rear shear nozzles. The design illustrated in <FIG> eliminates an often observed adverse spray characteristic known as "shut off" wherein sprue or flash remaining after a molding step corrupts flow at an exit port or spray orifice in prior art nozzles. This small port is subject to flashing issues which can partially or completely shut off spray, severely degrading or stopping the spray. Compact shear spray CHMSL bezel mountable nozzle assembly <NUM> is configured for use with an "insert" <NUM> which is selected from several possible nozzle inserts. Exemplary insert <NUM> creates a spray having a selected fan width, yaw angle and roll angle. Alternative inserts may be used in nozzle assembly <NUM> which can reliably create different sprays. An alternative insert <NUM> is illustrated in <FIG>, as discussed below.

Referring particularly to <FIG> and <FIG>, new nozzle assembly example <NUM> is configured with a new dual orifice shear outlet insert <NUM>. Fluid spray aiming shear outlet insert <NUM> is configured for use in a nozzle assembly housing <NUM> (e.g., as shown in <FIG> and <FIG>) which defines a channel, port or slot <NUM> that receives and provides boundaries for the fluid paths defined in the shear outlet insert <NUM>. Nozzle assembly <NUM> is configured with housing <NUM> which defines a substantially hollow fluid-impermeable structure with an interior lumen <NUM> and one or more ports or slots <NUM>, each defining a substantially rectangular passage or aperture with smooth interior slot wall surfaces <NUM>. The interior sidewall surfaces <NUM> are preferably dimensioned for cost effective fabrication using molding methods and optionally include sidewall grooves positioned and dimensioned to form a "snap fit" with ridges or tabs in a mating shear outlet insert (not shown). Nozzle assembly <NUM> can be configured to include one or more shear outlet inserts or chips which are dimensioned to be tightly received in and held by the port or slot <NUM> defined within the housing <NUM>. When shear outlet insert <NUM> is fitted tightly within port or slot <NUM>, the nozzle assembly provides a channel for fluid communication between the housing's interior lumen <NUM> and the exterior of the housing so that fluid entering the housing's interior lumen may be used to generate an flat fan-shaped spray directed distally and aimed by the orientation and configuration of the housing <NUM> which supports and orients or aims shear outlet insert <NUM>.

Nozzle assembly housing <NUM> is illustrated in a configuration which can be assembled into an automotive trim bezel or other body mount and has a distally projecting spray aiming end <NUM> configured as a visually unobtrusive hemispherical bump defined around the insert receiving slot <NUM>. The housing's distally projecting end aims the spray by defining the orientation of the slot <NUM> and insert <NUM> and so for an insert configured to generate a flat spray with a selected fan angle, the orientation of that flat spray is adjusted by adjusting the orientation of slot <NUM>. Preferably, housing <NUM> is molded from a suitably tough material such as plastic and includes one or more alignment features <NUM> or snap-fit retaining tabs <NUM> on selected exterior surfaces to enable housing <NUM> to be assembled into an automotive trim piece or body panel (e.g., such as bezel10, shown in <FIG>). The housing's fluid inlet lumen <NUM> is preferably configured with a tube-retaining barb fitting <NUM>.

The shear outlet insert <NUM> as illustrated in <FIG> is an elongated solid member having a planar side opposite a fluid channel side <NUM> which has fluid channel214 defined therein. Insert <NUM> has an arcuate end wall 215EW which terminates distally at distal end <NUM> and curves downwardly in a cylindrical section to transversely projecting insert wall segment 215T, and the spray generating outlets <NUM>, <NUM> can be defined in any portion of that arcuately shaped end waii215EW. Insert <NUM> has a proximal end 215P which is inserted into the open distal end of housing slot <NUM> fully, such that the insert's distal end <NUM> is flush with but exposed in the distal end of the housing, whereupon the transversely projecting insert wall segment 215T abuts a cooperating transverse flange wall segment 230FW defined in housing <NUM> (see <FIG>). When pressurized cleaning fluid is pumped into nozzle assembly inlet lumen <NUM>, shear outlet insert <NUM> operates on a fluid shearing mechanism resulting in generation of a spray of distally projecting droplets (not shown). Current prototypes of the shear spray circuit or insert produce a substantially planar spray with a fan angles from <NUM> degrees to <NUM> degrees by generating first and second laterally spaced and aimed spray fans from outlet orifices <NUM> and <NUM>.

The exemplary shear outlet insert <NUM> as illustrated in <FIG> has a plurality of sections which cooperate with one another to act upon the flowing fluid passing therethrough to generate a desired spray. The fluid flows from nozzle assembly lumen <NUM> and into port or slot <NUM>, where it is forced to flow along the fluid flow channel214 defined in fluid channel side <NUM> through the sections described below and emitted as a spray of fluid droplets from the split or first and second outlets <NUM>, <NUM>. As fluid flows distally or downstream along fluid flow channel <NUM> from the channel's inlet <NUM> which receives fluid from and is in fluid communication with housing inlet and lumen <NUM>, the fluid is accelerated in tapered transition region 214T which reduces the cross sectional area of fluid flow channel <NUM>. A shear chamber 214SC is in fluid communication with and receives fluid from tapered transition region 214T and that fluid flows around a fluid- impermeable inwardly projecting island protuberance <NUM> and around the generally concave opposing channel sidewalls to create a first substantially planar spray from first shear outlet <NUM> and a second substantially co-planar spray from second spray outlet <NUM>, and the combined sprays from outlets <NUM> and <NUM> have at least a small overlap and so together generate a relatively evenly distributed spray with a selected fan angle in the range of <NUM> degrees to <NUM> degrees.

An alternative example of the shear outlet insert <NUM> as illustrated in <FIG>, and it also has a plurality of sections which cooperate with one another to act upon the flowing fluid passing therethrough to generate a desired spray when inserted into nozzle assembly housing <NUM>. The fluid flows from nozzle assembly inlet <NUM> and into cavity <NUM>, where it is forced to flow along the fluid flow channel <NUM> defined in insert surface <NUM> through the sections described below and emitted as a spray of fluid droplets from the split or first and second outlets <NUM>, <NUM>. As fluid flows distally or downstream along fluid flow channel <NUM> from the channel's inlet <NUM> which receives fluid from and is in fluid communication with housing inlet and lumen <NUM>, the fluid is accelerated in tapered transition region 1214T which reduces the cross sectional area of fluid flow channel <NUM>. A shear chamber 1214SC is in fluid communication with and receives fluid from tapered transition region 1214T and that fluid flows around a fluid-impermeable inwardly projecting island protuberance <NUM> and around the generally concave opposing channel sidewalls 1214TW, 1214SW to create a first substantially planar spray from first shear outlet <NUM> and a second substantially co-planar spray from second spray outlet <NUM>, and the combined sprays from outlets <NUM> and <NUM> have at least a small overlap and so together generate a relatively evenly distributed spray with a selected fan angle in the range of <NUM> degrees to <NUM> degrees.

As with the example described above, Insert <NUM> has an arcuate end wall 1215EW which terminates distally at distal end 1215D and curves downwardly in a cylindrical section to transversely projecting insert wall segment 1215T, and the spray generating outlets <NUM>, <NUM> can be defined in any portion of that arcuately shaped end wall 1215EW. Insert <NUM> has a beveled proximal end 1215P which is inserted into the open distal end of housing slot <NUM> fully, such that the insert's distal end 1215D is flush with but exposed in the distal end of the housing, whereupon the transversely projecting insert wall segment 1215T abuts the cooperating transverse flange wall segment 230FW defined in housing <NUM>.

It will be appreciated by persons having skill in the art that molded compact shear spray nozzle members (e.g., <NUM>, <NUM>), when used in compact shear spray nozzle assembly <NUM> provide a molded compact one-piece spray head having an open proximal end in fluid communication with a fluid channel or lumen <NUM> with tapering transition regions having progressively smaller internal lumen cross sectional areas to accelerate washing fluid toward shear-spray generating chamber 214SC with its elongated spray orifice having a first orifice edge at wall segment <NUM> opposing a second orifice edge at wall segment 215EW. Distal shear-spray generating chamber 214SC also has a first (distal end) concave wall segment 214TW defining a first fluid impingement angle, where that first concave wall segment 214TW terminates in the first spray orifice edge. The distal shear-spray generating chamber 214SC also has a second concave wall segment 214SW defining a second fluid impingement angle, where the second concave wall segment 214SW terminates in the second spray orifice edge. The exterior of compact shear spray nozzle member <NUM> terminates in a distal exterior surface <NUM> and the spray orifice generates the outwardly projecting fluid spray fan from the orifice which is split to define throat exits <NUM> and <NUM>.

Turning now to <FIG>, another nozzle assembly <NUM> is configured for a rear Center High Mount Stop Light (CHMSL) mount bezel mount (but illustrates a configuration that could be incorporated into any automotive trim piece or body panel). Compact shear spray bezel mountable nozzle assembly <NUM> also provides the manufacturing advantages and eliminates manufacturing (process) failure modes described above. Compact shear spray bezel mountable nozzle assembly <NUM> is configured for use with a distally projecting member or "insert" <NUM> which is selected from several possible nozzle inserts. Exemplary insert <NUM> creates a spray having a selected fan width, yaw angle and roll angle. Alternative inserts may be used in nozzle assembly <NUM> which can reliably create different sprays.

Referring particularly to <FIG> and <NUM>, an automotive trim mounted spray nozzle assembly <NUM> is configured with a new triple orifice shear outlet insert or compact shear projecting member <NUM>. Fluid spray aiming shear outlet insert <NUM> is configured for use in a nozzle assembly housing <NUM> (e.g., as shown in <FIG>) which defines a channel <NUM> that receives and provides boundaries for the fluid paths defined in the shear outlet insert <NUM>. Nozzle assembly <NUM> is configured with housing <NUM> which defines a substantially hollow fluid-impermeable structure with an interior lumen <NUM> in fluid communication with one or more ports or slots <NUM>, each defining a substantially rectangular passage or aperture with smooth interior slot wall surfaces. In a similar manner to slot <NUM> for housing <NUM>, the interior sidewall surfaces are preferably dimensioned for cost effective fabrication using molding methods and optionally include sidewall grooves positioned and dimensioned to form a "snap fit" with ridges or tabs in a mating shear outlet insert (not shown). Nozzle assembly <NUM> can be configured to include one or more shear outlet inserts or chips which are dimensioned to be tightly received in and held by the slot <NUM> defined within the housing <NUM>. When shear outlet insert <NUM> is fitted tightly within port or slot <NUM>, the nozzle assembly provides a channel for fluid communication between the housing's interior lumen and the exterior of the housing so that fluid entering the housing's interior lumen may be used to generate a flat fan-shaped spray directed distally and aimed by the orientation and configuration of housing <NUM> which supports and aims shear outlet insert <NUM>.

Referring again to <FIG> and <NUM>, insert <NUM> has an end wall which terminates distally at distal end <NUM> and abuts an angled wall spray orifice defining wall segment in which are defined outlet orifices <NUM>, <NUM> and <NUM> which can be configured to aim into any angle between (a) an axially aligned distal spray (along the central axis of lumen <NUM>) and (b) a substantially transverse spray (along a line transverse to the central axis of lumen <NUM>).

Nozzle assembly housing <NUM> is illustrated in a configuration which can be assembled into an automotive trim bezel or other body mount and has a distally projecting end cap <NUM> configured as a visually unobtrusive hemispherical bump defined to cover and enclose the insert receiving slot <NUM>. The housing's distally projecting end cap <NUM> provides an aperture which passes the shear spray which is aimed or oriented by defining the orientation of the housing <NUM> and insert <NUM> and so for an insert configured to generate a flat spray with a selected fan angle, the orientation of that flat spray is adjusted by adjusting the orientation of housing <NUM>. Preferably, housing <NUM> is molded from a suitably tough material such as plastic and includes one or more alignment features <NUM> or snap-fit retaining tabs <NUM> on selected exterior surfaces to enable housing <NUM> to be assembled into an automotive trim piece or body panel (e.g., such as bezel10). The housing's fluid inlet lumen <NUM> is preferably configured with a tube-retaining barb fitting <NUM>.

The shear outlet insert or compact shear spray nozzle member <NUM> as illustrated in <FIG> and <NUM> is an elongated solid member having a planar side opposite a fluid channel side <NUM> which has fluid channel defined therein. Insert <NUM> has a proximal end (not shown) which is inserted into housing slot <NUM> such that the insert's distal end <NUM> is exposed. When pressurized cleaning fluid is pumped into nozzle assembly inlet lumen <NUM>, shear outlet insert <NUM> operates on a fluid shearing mechanism resulting in generation of a spray of distally projecting droplets (not shown). Current prototypes of the shear spray circuit or insert <NUM> produce a substantially planar spray with a fan angles from <NUM> degrees to <NUM> degrees by generating first, second and third laterally spaced and aimed spray fans from outlet orifices <NUM>, <NUM> and <NUM>.

The exemplary shear outlet insert <NUM> as illustrated in <FIG> also has a plurality of sections which cooperate with one another to act upon the flowing fluid passing therethrough to generate a desired spray. The fluid flows from nozzle assembly inlet <NUM> and into cavity <NUM>, where it is forced to flow along the fluid flow channel defined in insert surface <NUM> through the sections described below emitted as a spray of fluid droplets from the split or first, second and third outlets <NUM>, <NUM> and <NUM>. As fluid flows along fluid flow channel from the channel's inlet which receives fluid from and is in fluid communication with housing inlet and lumen <NUM>, the fluid is accelerated in tapered transition region 314T which reduces the cross sectional area of fluid flow channel A shear chamber 314SC is in fluid communication with and receives fluid from tapered transition region 314T and that fluid flows around a first fluid-impermeable inwardly projecting island protuberance <NUM> and around the opposing channel sidewalls to create first, second and third substantially co-planar sprays from the outlets, and the combined sprays from the outlets <NUM>, <NUM> and <NUM> have at least a small overlap and so together generate a relatively evenly distributed spray with a selected fan angle in the range of <NUM> degrees to <NUM> degrees.

It will be appreciated by persons having skill in the art that molded compact shear spray nozzle member <NUM>, when used in compact shear spray nozzle assembly <NUM> provide a molded compact spray head having an open proximal end in fluid communication with a fluid channel or lumen <NUM> with tapering transition regions having progressively smaller internal lumen cross sectional areas to accelerate washing fluid toward shear-spray generating chamber 314SC with its elongated spray orifice having a first (upper) orifice edge (at the top of throat exit <NUM> near distal end <NUM>) opposing a second orifice edge (at the bottom of throat exit <NUM>). Distal shear-spray generating chamber 314SC also has a first (distal end) concave wall segment 314TW defining a first fluid impingement angle, where that first concave wall segment is defined in the distal end and terminates in the first (top or distal end) spray orifice edge. The distal shear-spray generating chamber 314SC also has a second convex wall segment 314SW defining a second fluid impingement angle, where the second convex wall segment terminates in the second spray orifice edge. The exterior of compact shear spray nozzle member <NUM> terminates in a distal exterior surface <NUM> and when cap <NUM> is installed, the spray orifice generates the outwardly projecting fluid spray fan from the orifice which is split with islands 316A and <NUM> to define three aligned throat exits <NUM>, <NUM> and <NUM>.

Claim 1:
A compact spray head for use in automotive washer nozzle assembly, comprising:
a molded compact shear spray nozzle member (<NUM>) having an open proximal end (<NUM>) in fluid communication with an interior lumen (<NUM>) with tapering transition regions (104A, 104B, 104C, 104D) having progressively smaller internal lumen cross sectional areas, the interior lumen (<NUM>) being comprised in the molded compact shear spray nozzle member (<NUM>);
said lumen terminating distally in a distal shear-spray generating chamber (114SC) having an elongated spray orifice with a first orifice edge opposite a second orifice edge, the distal shear-spray generating chamber (114SC) being comprised in the molded compact shear spray nozzle member (<NUM>),
said distal shear-spray generating chamber also having a first concave wall segment (114TW) defining a first fluid impingement angle (TA), wherein said first concave wall segment terminates in the first orifice edge;
said distal shear-spray generating chamber also having a second concave wall segment (114SW) defining a second fluid impingement angle (BA), wherein said second concave wall segment terminates in the second spray orifice edge; and
said molded compact shear spray nozzle member including a distal substantially hemispherical or bump-shaped exterior surface and wherein the molded compact shear spray nozzle member (<NUM>) further comprises a substantially planar wall segment, which is a splitter (<NUM>),
wherein two spray orifices (<NUM>, <NUM>) are defined in the elongated spray orifice and in part by the splitter (<NUM>) and wherein said elongated spray orifice is configured to generate an outwardly projecting a uniform fluid spray fan
characterized by,
the tapering transition regions (104A, 104B, 104C, 104D) being a first proximal cylindrical segment (104A) which terminates distally into a proximal narrowing tapered sidewall segment (104B) which narrows or tapers distally to a smaller inside diameter at central cylindrical segment (104C) and the central cylindrical segment (104C) terminates distally into a distal narrowing tapered sidewall segment (104D), which terminates distally in the somewhat dome- shaped fluid impingement shear generating chamber (114SC).