Patent Document

BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   This invention relates to liquid spray nozzles and more particularly to a spray nozzle having openings angled towards each other to form a triangular spray pattern and a mixing chamber shaped to reduce turbulence and clogging. 
   2. Description of the Related Art 
   Spray nozzles for generating streams of liquid are well known as seen from U.S. Pat. No 6,322,008 to Mark Aker, et al, which is hereby incorporated by reference. This patent describes a nozzle having at least two openings on its face, spaced apart from one another and angled towards each other such that two individual streams cross each other at a point distant from the face of the nozzle. A non-atomized, pressurized stream passes through each opening and meets at an intersection point, forming a flat, triangular pattern. The nozzle is useful in spraying polyester gelcoat applications and reduces emissions of volatile organic compounds. 
   Often, the materials sprayed using this nozzle or similar nozzles are very viscous or harden quickly. For example, boat hulls are often formed by spraying resins over a mold. In some applications, fillers are added to the resin such as calcium sulfate, calcium carbonate and aluminum trihydrate to improve fire retardency. These fillers further thicken the resins. The viscosity of these liquids and their fast hardening times often cause problems with the nozzle such as clogging. Other than the general problem of clogging of the nozzle openings, the flow of the material within the nozzle causes problems. Turbulence within the nozzle creates dead-spots where the material being sprayed may sit without passing through the nozzle. After time, that material may harden, reducing the area within the nozzle, leading to different dead spots. Eventually, more material may harden within the nozzle, leading to reduced flow. Finally, part of the hardened material may break away and clog the openings in the nozzle or may exit the nozzle and attach itself to the target object. As this build-up occurs, the spraying operation must be stopped, the nozzle removed and cleaned or replaced, and the spraying operation restarted. This stop/restart operation reduces the efficiency of the application and may affect the overall quality of the spray by creating runs or uneven applications. 
   What is needed is a nozzle that will provide all the advantages of the prior nozzles while reducing accumulation within the nozzle, hence reducing clogging and the need for replacing or cleaning the nozzle during the spray operation. 
   SUMMARY OF THE INVENTION 
   In one embodiment, a nozzle for spraying a liquid is disclosed including two openings in the face of the nozzle adapted for generating a non-atomized liquid stream of the same liquid from each of the two openings, the two openings having a first opening and a second opening, the first opening spaced apart from the second opening and the first opening and the second opening angled along a common axis towards each other at an angle of from 1° and 89°. The nozzle is adapted to receive the non-atomized liquid stream of the same liquid directed through the two openings by a pressurized source. The inside cavity of the nozzle is substantially conical in shape. The two openings are configured so the non-atomized liquid stream of the same liquid from the first opening meets the non-atomized liquid stream of the same liquid from the second opening at an apex some distance from the common axis without interference from any solid object interposed between the common axis and the apex, the meeting of the non-atomized liquid streams of the same liquid creates a triangular liquid spray pattern. 
   In another embodiment, a nozzle for spraying a liquid is disclosed including two openings passing through a face of the nozzle, the two openings include a first opening and a second opening. The first opening is spaced apart from the second opening by from 0.010 to 2.0 inches and the first opening and the second opening are angled along a common axis towards each other at an angle of from 10 and 89°. The nozzle is adapted for generating a non-atomized liquid stream of the same liquid, the non-atomized liquid stream of the same liquid is directed through the two openings by a pressurized source. The nozzle has an inside cavity that is substantially conical in shape. The two openings are configured so the non-atomized liquid stream of the same liquid from the first opening meets the non-atomized liquid stream of the same liquid from the second opening at an apex distal from the common axis without interference from any solid object interposed between the common axis and the apex, the meeting of the non-atomized liquid streams of the same liquid creates a triangular liquid spray pattern. 
   In another embodiment, a nozzle for spraying a liquid is disclosed including a device for mounting two circular openings on a fixed support along a common axis, the two circular openings include a first circular opening and a second circular opening. The first circular opening spaced apart from the second circular opening and the first circular opening and the second circular opening angled along the common axis towards each other at an angle of from 10 and 89°. The nozzle is adapted to receive a non-atomized liquid stream of the same liquid directed through each of the two circular openings by a pressurized source. The nozzle has an inside cavity that is substantially conical in shape. The two circular openings are configured so the non-atomized liquid stream of the same liquid from the first circular opening meets the non-atomized liquid stream of the same liquid from the second circular opening at an apex at a distance from the common axis without interference from any solid object interposed between the common axis and the apex, the meeting of the non-atomized liquid streams of the same liquid creates a triangular liquid spray pattern. 
   In another embodiment, an improved nozzle for spraying a liquid is disclosed including at least one pair of openings in a face of the nozzle adapted for generating an uninterrupted non-atomized solid liquid stream of the same liquid from the at least one pair of openings directed towards each other, each opening from each pair of openings being spaced apart from each other and angled along a common axis towards each other at an angle of from 1° and 89°. The nozzle is adapted to receive the uninterrupted non-atomized solid liquid stream of the same liquid directed through each opening by a pressurized source and the openings are configured so the uninterrupted non-atomized solid liquid stream of the same liquid from each opening meets at a distance from the common axis without interference from any solid object interposed between the common axis and the meeting of the uninterrupted non-atomized solid liquid stream of the same liquid. The meeting of the uninterrupted non-atomized solid liquid stream of the same liquid creates a triangular liquid spray pattern. The improvement comprises a conical shaped cavity within the nozzle behind the face. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention can be best understood by those having ordinary skill in the art by reference to the following detailed description when considered in conjunction with the accompanying drawings in which: 
       FIG. 1  illustrates a front perspective view of a nozzle of the prior art. 
       FIG. 2  illustrates a rear perspective view of a nozzle of the prior art. 
       FIG. 3  illustrates a front perspective view of the nozzle and spray pattern of the present invention. 
       FIG. 4  illustrates a rear perspective view of the nozzle of the present invention. 
       FIG. 5  illustrates a sectional view along lines  5 - 5  of  FIG. 4 . 
       FIG. 6  illustrates a sectional view along lines  6 - 6  of  FIG. 4 . 
       FIG. 7  illustrates a front perspective view of the nozzle and spray pattern of a second embodiment of the present invention. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Throughout the following detailed description, the same reference numerals refer to the same elements in all figures. 
   Referring to  FIG. 1 , a front perspective view of a nozzle of the prior art is shown. The nozzle  10  of the prior art shown in  FIG. 1  and  FIG. 2  is affixed to a spray gun (not shown) which has a pressurized source (also not shown) such as a pump that directs liquid through the nozzle  10  openings  18  and  20 . The openings  18  and  20  are spaced apart at a distance and angled towards each other such that liquid flowing from the first opening  18  meets the liquid flowing from the second opening  20  at an apex some distance from the face of the nozzle. In some embodiments, the liquids flowing from the first opening  18  and from the second opening  20  are the same while in other embodiments, a different liquid flows from the second opening. In some embodiments, more than one pair of openings is deployed (not shown). In some embodiments, the face  28  is flat (not shown) while in some embodiments, the face  28  is shaped or etched. In the prior art, the side surface  30  is generally rounded. 
   Referring to  FIG. 2 , a rear perspective view of a nozzle of the prior art is shown. The surface behind the face  19  of the prior art is generally flat and the inside walls  17  of the nozzle  10  are generally cylindrical relating to the outside wall  30  shape. Pressurize liquid enters the cavity formed by the inside walls  17  and the surface behind the face  19  and exits through the openings  18 ,  20  (opening  20  is not visible in  FIG. 2 ). Because of the shape of the cavity, the flow of liquid creates turbulence within the cavity. The turbulence causes small amounts of the liquid to loop and remain within the cavity for an extended period of time. For many applications, such as liquid polyester resins, polyurethane resins and polyurethane foams, the liquids will harden in as little as 15 seconds. Therefore, these small amounts of liquids caught in the turbulence and tend to harden. The hardened particles attach to the inside surfaces  17 ,  19  and create additional turbulence or dead spots. Eventually, some of the hardened particles reach the openings  18 ,  20  and, if small enough, pass through and create an uneven spray or, if large enough, clog one or both openings  18 ,  20 . The shape of the cavity of the prior art is not ideal for a nozzle that delivers a spray of high viscosity liquids. In addition to the hardening and clogging issue, the turbulence also affects the flow in the stream, creating a laminar flow that is less laminar than desired. 
   Referring to  FIG. 3 , a front perspective view of the nozzle and spray pattern of the present invention is shown. The nozzle  110  of the present invention shown in  FIG. 3  and  FIG. 4  is affixed to a spray gun (not shown) which has a pressurized source (also not shown) such as a pump that directs liquid through the nozzle  110  openings  118  and  120 . The openings  118  and  120  are spaced apart at a distance and angled towards each other such that liquid  114  flowing from the first opening  118  meets the liquid  116  flowing from the second opening  120  at an apex  122  distal from the face  128  of the nozzle. In some embodiments, the liquids flowing from the first opening  118  and from the second opening  120  are the same while in other embodiments, a different liquid flows from the second opening  120 . In some embodiments, more than one pair of openings is deployed (not shown). In some embodiments, the face  128  is flat (not shown) while in some embodiments, the face  128  is shaped or etched. 
   The liquid streams  114 ,  116  flow from the openings  118 ,  120  at an angle towards one another such that they meet at an apex  122  and form a triangular spray pattern  124  beyond the apex  122 . The angle of the between openings  118 ,  120  can range anywhere between 1° and 89°. The smaller the degree of angle with respect to the face  128 , the closer the two streams meet at the apex  122 . It is preferred for use in the spray of resin to have the angle of the openings  118 ,  120  range between 2° and 55°. In some embodiments, the openings  118 ,  120  are circular as shown. In other embodiments, the openings  118 ,  120  are oval or any other shape (not shown). Generally, in non-circular configurations, the opening size can be from 0.00002 to 3.5 square inches. In the preferred embodiment, the openings  118 ,  120  are circular with a diameter in the range of 0.005 to 0.175 inches. In one embodiment, the distance between the openings can be from 0.01 to 2.0 inches. In agricultural and water nozzles, the angle of the openings  118 ,  120  is preferred to be between 5° and 75° with a circular opening diameter between 0.01 to 0.2 inches with a distance between openings  118 ,  120  of between 0.1 and 16 inches. In the preferred embodiment, the side surface  130  is generally rounded. 
   Referring to  FIG. 4 , a rear perspective view of the nozzle of the present invention is shown. The inside cavity (surface behind the face of the nozzle  110 ) is generally conical (cone-shaped)  119 . Pressurized liquid enters the inside cavity formed by the cone  119  that is formed between the back edge  121  of the nozzle and the surface  144  behind the face  128 . The liquid exits through the openings  118 ,  120  (openings are not visible in  FIG. 4 ) along axis  132  of the face  128 . A conical shaped cavity is defined by the cone-shaped wall  119  and a generally flat surface  144  behind the face  128 . Cuts  142  are made into the cone shaped wall  119  allowing the liquid to flow to the openings  118 ,  120 . The cuts  142  are preferably rounded to reduce turbulence and clogging. Because of the cone-shape of the cavity, the liquid flows smoothly through the cavity, reducing turbulence that would otherwise cause small amounts of the liquid to loop and remain within the cavity for an extended period of time, creating the problems highlighted in the discussion of the prior art ( FIG. 2 ). For many applications, such as liquid polyester resins, polyurethane resins and polyurethane foams, the liquids will harden in as little as 15 seconds. Therefore, the shape of the cavity reduces turbulence so that these small amounts of liquids don&#39;t harden and clog the openings  118 ,  120 . In the preferred embodiment, the side walls  130  are tubular as shown. The overall shape of the cavity will be shown in  FIG. 5  and  FIG. 6 . 
   Referring to  FIG. 5 , a sectional view along lines  5 - 5  of  FIG. 4  is shown. In this sectional view, the openings  118 ,  120  of the nozzle  110  are bisected, showing the angular relationship between each other. In this embodiment, the face of the nozzle  128  is shown cut in a convex shape. In other embodiments, the face  128  is flat or shaped (not shown). In some embodiments, more than one pair of openings  118 ,  120  is present (not shown). The inside cavity (conical shape)  119  is formed between the back edge  121  of the nozzle and a flat surface  144  behind the face  128  of the nozzle. Cuts  142  made into the cone  119  create a passage through which the liquid can flow to the openings  118 ,  120 . In the preferred embodiment, the cuts  142  are rounded in shape to further reduce turbulence. The cone  119  and the cuts  142  reduce turbulence by providing a smooth transition from the spray gun (not shown) to the openings  118 ,  120 , thereby reducing or eliminating dead spots and turbulence. The improvements of the present invention reduce Volatile Organic Compound (VOC) emissions during the application of resins. 
   Referring to  FIG. 6 , a sectional view along lines  6 - 6  of  FIG. 4  is shown. In this sectional view, only one opening  120  is visible, passing from the cavity to the face  128 . In this embodiment, the face of the nozzle  128  is shown cut in a convex shape. In other embodiments, the face  128  is flat or shaped (not shown). In some embodiments, more than one pair of openings  118 ,  120  is present (not shown). The cone  119  is formed between the back edge  121  of the nozzle  110  and a flat surface  144  of the nozzle  110 . Cuts  142  are formed into the cone  119  creating a passage through which the liquid can flow to the openings  118 ,  120 . In the preferred embodiment, the cuts  142  are rounded in shape to further reduce turbulence. The cone  119  and the cuts  142  reduce turbulence by providing a smooth transition from the spray gun (not shown) to the openings  118 ,  120 , thereby reducing or eliminating dead spots and turbulence. The improvements of the present invention reduce Volatile Organic Compound (VOC) emissions during the application of resins. 
   Referring to  FIG. 7 , a front perspective view of the nozzle and spray pattern of the present invention is shown. The nozzle  210  of the present invention shown in  FIG. 7  is affixed to a spray gun (not shown) which has a pressurized source (also not shown) such as a pump that directs liquid through the nozzle  210  openings  218  and  220 . The openings  218  and  220  are spaced apart at a distance and angled towards each other such that liquid  114  flowing from the first opening  218  meets the liquid  116  flowing from the second opening  220  at an apex  122  distal from the face  128  of the nozzle  210 . In some embodiments, the liquids flowing from the first opening  218  and from the second opening  220  are the same while in other embodiments, a different liquid flows from the second opening  220 . In some embodiments, more than one pair of openings is deployed (not shown). In some embodiments, the face  128  is flat (not shown) while in some embodiments, the face  128  is shaped or etched. 
   The liquid streams  114 / 116  flow from the openings  218 / 220  at an angle towards one another such that they meet at an apex  122  and form a triangular spray pattern  124  beyond the apex  122 . The angle of the between openings  218 / 220  can range anywhere between 1° and 89°. The smaller the degree of angle with respect to the face  128 , the closer the two streams meet at the apex  122 . It is preferred for use in the spray of resin to have the angle of the openings  218 / 220  range between 2° and 55°. In some embodiments, the openings  218 / 220  are circular as shown. In other embodiments, the openings  218 / 220  are oval or any other shape (not shown). Generally, in non-circular configurations, the opening size can be from 0.00002 to 3.5 square inches. In the preferred embodiment, the openings  218 / 220  are circular with a diameter in the range of 0.005 to 0.175 inches. In one embodiment, the distance between the openings can be from 0.01 to 2.0 inches. In agricultural and water nozzles, the angle of the openings  218 / 220  is preferred to be between 5° and 75° with a circular opening diameter between 0.01 to 0.2 inches with a distance between openings  118 / 120  of between 0.1 and 16 inches. In the preferred embodiment, the side surface  130  is generally rounded. 
   Equivalent elements can be substituted for the ones set forth above such that they perform in substantially the same manner in substantially the same way for achieving substantially the same result. 
   It is believed that the system and method of the present invention and many of its attendant advantages will be understood by the foregoing description. It is also believed that it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages. The form hereinbefore described being merely an exemplary and explanatory embodiment thereof. It is the intention of the following claims to encompass and include such changes.

Technology Category: b