Nozzle and method of making same

Abstract

Nozzle and a method of making the same are disclosed. The method includes forming a material into a nozzle forming microstructured pattern comprising a plurality of nozzle hole forming features and planar control cavity forming features; forming at least one different material into a nozzle pre-form using the nozzle forming microstructured pattern, with the nozzle pre-form comprising a plurality of nozzle pre-form holes and sacrificial planar control cavities; and forming a nozzle from the nozzle pre-form, said forming the nozzle comprising removing enough of the at least one different material to remove the sacrificial planar control cavities so as to form a top surface of the nozzle pre-form into a top surface of the nozzle, and to form each of the nozzle pre-form holes into a nozzle through hole.

What is claimed is: 
     
         1 . A method of making a nozzle, said method comprising:
 forming a material into a nozzle forming microstructured pattern comprising a plurality of nozzle hole forming features and planar control cavity forming features;   forming at least one different material into a nozzle pre-form using the nozzle forming microstructured pattern, with the nozzle pre-form comprising a plurality of nozzle pre-form holes formed from the nozzle hole forming features and sacrificial planar control cavities formed from the planar control cavity forming features; and   forming a nozzle from the nozzle pre-form, said forming the nozzle comprising removing enough of the at least one different material to remove the sacrificial planar control cavities so as to form a top surface of the nozzle pre-form into a top surface of the nozzle, and to form each of the nozzle pre-form holes into a nozzle through hole,   wherein the removal of the sacrificial planar control cavities allows the nozzle through holes to be opened in a desired manner.   
     
     
         2 . The method according to  claim 1 , wherein said step of forming at least one different material comprises forming a plurality of different materials into the nozzle pre-form by depositing each different material as a different portion onto the nozzle forming microstructured pattern so that the resulting nozzle pre-form comprises multiple portions, with each portion being a different material. 
     
     
         3 . The method according to  claim 2 , wherein either (a) none of the multiple portions is in the form of a thin electrically conductive seed layer, (b) the multiple portions are at least three portions, or (c) both (a) and (b). 
     
     
         4 . The method according to  claim 2 , wherein one of the multiple portions forms an inlet side surface of the nozzle that is dissolvable into a fuel so as to be delivered with the fuel through the nozzle and into a combustion chamber of an internal combustion engine, with the portion forming the inlet side surface being a material selected from the group of materials consisting of a combustion catalyst, a corrosion inhibitor, a combustion byproduct deposit inhibitor, a ceramic, a metal alloy, a material that lowers frictional forces at the interface between the fuel and the inner surface of the nozzle, a material that facilitates air to fuel mixing, a material that facilitates a desired heat transfer between a fuel injector that comprises the nozzle and the outside of the nozzle exposed to the combustion chamber of an internal combustion engine, or any combination of these materials. 
     
     
         5 . The method according to  claim 3 , wherein one of the multiple portions forms an inlet side surface of the nozzle that is dissolvable into a fuel so as to be delivered with the fuel through the nozzle and into a combustion chamber of an internal combustion engine, with the portion forming the inlet side surface being a material selected from the group of materials consisting of a combustion catalyst, a corrosion inhibitor, a combustion byproduct deposit inhibitor, a ceramic, a metal alloy, a material that lowers frictional forces at the interface between the fuel and the inner surface of the nozzle, a material that facilitates air to fuel mixing, a material that facilitates a desired heat transfer between a fuel injector that comprises the nozzle and the outside of the nozzle exposed to the combustion chamber of an internal combustion engine, or any combination of these materials. 
     
     
         6 . The method according to  claim 2 , wherein one of the multiple portions forms an inlet side surface of the nozzle, one of the multiple portions forms an outlet side surface of the nozzle, and one of the multiple portions forms an intermediate portion of the nozzle between the inlet side surface and the outlet side surface, with the material of the inlet side surface being compatible with the fuel passing through the nozzle, the material of the outlet side surface being suitable for the environment inside of a combustion chamber of an internal combustion engine, and the material of the intermediate portion not being suitable for use as the inlet side surface or outlet side surface, but the material of the intermediate portion has another desirable property selected from being relatively inexpensive, having desirable thermal characteristics, having vibrational characteristics, having acoustic characteristics, or any combination of these properties. 
     
     
         7 . The method according to  claim 4 , wherein with the portion forming the inlet side surface is a combustion catalyst material that is relatively porous, compared to the other portions, so as to significantly increase the interface surface area between the combustion catalyst material and the fuel passing through the nozzle. 
     
     
         8 . The method according to  claim 1 , further comprising:
 providing a microstructured mold pattern defining at least a portion of a mold and comprising a plurality of replica nozzle holes and replica planar control cavities,   wherein said forming comprises molding the first material into a nozzle forming microstructured pattern using the microstructured mold pattern, with the plurality of nozzle hole forming features being molded from the replica nozzle holes, and the planar control cavity forming features being molded from the replica planar control cavities.   
     
     
         9 . The method according to  claim 8 , wherein the microstructured mold pattern comprises at least one fluid channel feature connecting at least one replica nozzle hole to (a) at least one other replica nozzle hole, (b) a portion of the mold beyond the outer periphery of the microstructured mold pattern, or (c) both (a) and (b). 
     
     
         10 . The method according to  claim 8 , wherein each replica nozzle hole and its connected replica planar control cavity are configured such that upon removal of the corresponding sacrificial planar control cavity, to form the planar top surface of the nozzle, the nozzle through holes are configured to form at least one fuel plume shape-control feature. 
     
     
         11 . The method according to  claim 1 , wherein at least one nozzle hole forming feature has an exterior surface that comprises at least one fluid flow affecting feature and forms a featured nozzle through-hole, the fluid flow affecting feature is transferred to the interior surface of the featured nozzle through-hole, and the fluid flow affecting feature induces cavitations or turbulence in the flow of a fluid passing through the featured nozzle through-hole so as to reduce the size of droplets formed by the fluid exiting the outlet opening of the featured nozzle through-hole. 
     
     
         12 . The method according to  claim 11 , wherein the nozzle is a fuel injector nozzle, the fluid is a fluid fuel, and the cavitations or turbulence induced by the fluid flow affecting feature also improves the mixing of the fuel with air, when the fuel exit the outlet opening of the featured nozzle through-hole and enters a combustion chamber of an internal combustion engine. 
     
     
         13 . The method according to  claim 11 , wherein the fluid flow affecting feature comprises at least one or any combination of a bump, continuous annular ridge, spaced apart discontinuous ridge, and riblet. 
     
     
         14 . The method according to  claim 1 , wherein at least one nozzle hole forming feature comprises a curved side configured to include a converging and diverging fluid flow feature that forms a featured nozzle through-hole, and the fluid flow feature causes fluid flowing through the featured nozzle through-hole to converge and then diverge at least one time before exiting through its outlet opening. 
     
     
         15 . The method according to  claim 1 , wherein at least one nozzle hole forming feature comprises a curved side configured to include multiple converging and diverging fluid flow features that forms a featured nozzle through-hole, and the fluid flow features cause fluid flowing through the featured nozzle through-hole to converge and then diverge multiple times before exiting through its outlet opening. 
     
     
         16 . The method according to  claim 1 , wherein each nozzle hole forming feature has a different configuration such that fluid flowing through the nozzle through-holes exit the outlet openings so as to form a non-symmetrical fluid plume. 
     
     
         17 . A method of making a nozzle, said method comprising:
 forming a first material into a nozzle forming microstructured pattern comprising a plurality of nozzle hole forming features;   forming a different material into a nozzle pre-form using the nozzle forming microstructured pattern, with the nozzle pre-form comprising a plurality of nozzle pre-form holes formed from the nozzle hole forming features; and   forming a nozzle from the nozzle pre-form, with said forming the nozzle comprising removing enough of the different material to open an outlet opening in each of the nozzle pre-form holes so as to form each of the nozzle pre-form holes into a nozzle through hole,   wherein either (a) the different material comprises a plurality of different materials, the nozzle pre-form is formed by depositing each of the different materials as a separate portion onto the nozzle forming microstructured pattern so that the resulting nozzle pre-form comprises multiple portions, with each portion being a different material, and forming the nozzle comprises removing enough of at least one of the different materials to open an outlet opening in each of the nozzle pre-form holes so as to form each of the nozzle pre-form holes into a nozzle through hole, (b) at least one nozzle hole forming feature has an exterior surface that comprises at least one fluid flow affecting feature and forms a featured nozzle through-hole, the fluid flow affecting feature is transferred to the interior surface of the featured nozzle through-hole, and the fluid flow affecting feature induces cavitations or turbulence in the flow of a fluid passing through the featured nozzle through-hole so as to reduce the size of droplets formed by the fluid exiting the outlet opening of the featured nozzle through-hole, (c) at least one nozzle hole forming feature comprises a curved side configured to include a converging and diverging fluid flow feature that forms a featured nozzle through-hole, and the fluid flow feature causes fluid flowing through the featured nozzle through-hole to converge and then diverge at least one time before exiting through its outlet opening, (d) at least one nozzle hole forming feature comprises a curved side configured to include multiple converging and diverging fluid flow features that forms a featured nozzle through-hole, and the fluid flow features cause fluid flowing through the featured nozzle through-hole to converge and then diverge multiple times before exiting through its outlet opening, (e) each nozzle hole forming feature has a different configuration such that fluid flowing through the nozzle through-holes exit the outlet openings so as to form a non-symmetrical fluid plume, or (f) any combination of (a) to (e).   
     
     
         18 . The method according to  claim 17 , wherein said step of forming at least one different material comprises forming a plurality of different materials into the nozzle pre-form by depositing each different material as a different portion onto the nozzle forming microstructured pattern so that the resulting nozzle pre-form comprises multiple portions, with each portion being a different material, and either (i) none of the multiple portions is in the form of a thin electrically conductive seed layer, (ii) the multiple portions are at least three portions, or (iii) both (i) and (ii). 
     
     
         19 . The method according to  claim 17 , wherein said step of forming at least one different material comprises forming a plurality of different materials into the nozzle pre-form by depositing each different material as a different portion onto the nozzle forming microstructured pattern so that the resulting nozzle pre-form comprises multiple portions, with each portion being a different material, and one of the multiple portions forms an inlet side surface of the nozzle that is dissolvable into a fuel so as to be delivered with the fuel through the nozzle and into a combustion chamber of an internal combustion engine, with the portion forming the inlet side surface being a material selected from the group of materials consisting of a combustion catalyst, a corrosion inhibitor, a combustion byproduct deposit inhibitor, a ceramic, a metal alloy, a material that lowers frictional forces at the interface between the fuel and the inner surface of the nozzle, a material that facilitates air to fuel mixing, a material that facilitates a desired heat transfer between a fuel injector that comprises the nozzle and the outside of the nozzle exposed to the combustion chamber of an internal combustion engine, or any combination of these materials. 
     
     
         20 . The method according to  claim 18 , wherein one of the multiple portions forms an inlet side surface of the nozzle that is dissolvable into a fuel so as to be delivered with the fuel through the nozzle and into a combustion chamber of an internal combustion engine, with the portion forming the inlet side surface being a material selected from the group of materials consisting of a combustion catalyst, a corrosion inhibitor, a combustion byproduct deposit inhibitor, a ceramic, a metal alloy, a material that lowers frictional forces at the interface between the fuel and the inner surface of the nozzle, a material that facilitates air to fuel mixing, a material that facilitates a desired heat transfer between a fuel injector that comprises the nozzle and the outside of the nozzle exposed to the combustion chamber of an internal combustion engine, or any combination of these materials. 
     
     
         21 . The method according to  claim 17 , wherein said step of forming at least one different material comprises forming a plurality of different materials into the nozzle pre-form by depositing each different material as a different portion onto the nozzle forming microstructured pattern so that the resulting nozzle pre-form comprises multiple portions, with each portion being a different material, and one of the multiple portions forms an inlet side surface of the nozzle, one of the multiple portions forms an outlet side surface of the nozzle, and one of the multiple portions forms an intermediate portion of the nozzle between the inlet side surface and the outlet side surface, with the material of the inlet side surface being compatible with the fuel passing through the nozzle, the material of the outlet side surface being suitable for the environment inside of a combustion chamber of an internal combustion engine, and the material of the intermediate portion not being suitable for use as the inlet side surface or outlet side surface, but the material of the intermediate portion has another desirable property selected from being relatively inexpensive, having desirable thermal characteristics, having vibrational characteristics, having acoustic characteristics, or any combination of these properties. 
     
     
         22 . The method according to  claim 19 , wherein with the portion forming the inlet side surface is a combustion catalyst material that is relatively porous, compared to the other portions, so as to significantly increase the interface surface area between the combustion catalyst material and the fuel passing through the nozzle. 
     
     
         23 . The method according to  claim 17 , wherein at least one nozzle hole forming feature has an exterior surface that comprises at least one fluid flow affecting feature and forms a featured nozzle through-hole, the fluid flow affecting feature is transferred to the interior surface of the featured nozzle through-hole, and the fluid flow affecting feature induces cavitations or turbulence in the flow of a fluid passing through the featured nozzle through-hole so as to reduce the size of droplets formed by the fluid exiting the outlet opening of the featured nozzle through-hole, and the nozzle is a fuel injector nozzle, the fluid is a fluid fuel, and the cavitations or turbulence induced by the fluid flow affecting feature also improves the mixing of the fuel with air, when the fuel exit the outlet opening of the featured nozzle through-hole and enters a combustion chamber of an internal combustion engine. 
     
     
         24 . The method according to  claim 17 , wherein at least one nozzle hole forming feature has an exterior surface that comprises at least one fluid flow affecting feature and forms a featured nozzle through-hole, the fluid flow affecting feature is transferred to the interior surface of the featured nozzle through-hole, and the fluid flow affecting feature induces cavitations or turbulence in the flow of a fluid passing through the featured nozzle through-hole so as to reduce the size of droplets formed by the fluid exiting the outlet opening of the featured nozzle through-hole, and the fluid flow affecting feature comprises at least one or any combination of a bump, continuous annular ridge, spaced apart discontinuous ridge, and riblet. 
     
     
         25 . A nozzle pre-form for forming a nozzle comprising a plurality of nozzle through-holes, each nozzle through-hole comprising an inlet opening and at least one outlet opening connected to the inlet opening by a hollow cavity defined by an interior surface, said nozzle pre-form comprising a plurality of nozzle pre-form holes corresponding to the nozzle through-holes, with each nozzle pre-form hole having an inlet opening and a hollow cavity, defined by an interior surface, that is filled with a nozzle hole forming feature of a nozzle forming microstructured pattern, the nozzle pre-form being made from a material that is different than the material used to make each nozzle hole forming feature, and the nozzle pre-form being formed into the nozzle by removing the nozzle forming microstructured pattern from the nozzle pre-form, wherein either:
 (a) the nozzle pre-form is made from a plurality of different materials, with each of the different materials being deposited as a separate portion onto the nozzle forming microstructured pattern so that the resulting nozzle pre-form comprises multiple portions and each portion is a different material,   (b) at least one of the nozzle pre-form holes is a featured nozzle pre-form hole, the interior surface of the featured nozzle pre-form hole comprises a fluid flow affecting feature formed from a fluid flow affecting feature on the exterior surface of a corresponding nozzle hole forming feature, and when the nozzle pre-form is formed into the nozzle, the featured nozzle pre-form hole becomes a featured nozzle through-hole having a corresponding fluid flow affecting feature that induces cavitations or turbulence in the flow of a fluid passing through the featured nozzle through-hole so as to reduce the size of droplets formed by the fluid exiting the outlet opening of the featured nozzle through-hole,   (c) at least one of the nozzle pre-form holes is a featured nozzle pre-form hole, the interior surface of the featured nozzle pre-form hole comprises a curved side that includes a converging and diverging fluid flow feature formed from a converging and diverging fluid flow feature on the exterior surface of a corresponding nozzle hole forming feature, and when the nozzle pre-form is formed into the nozzle, the featured nozzle pre-form hole becomes a featured nozzle through-hole having a corresponding curved side configured to include a converging and diverging fluid flow feature that causes fluid flowing through the featured nozzle through-hole to converge and then diverge at least one time before exiting through its outlet opening,   (d) at least one of the nozzle pre-form holes is a featured nozzle pre-form hole, the interior surface of the featured nozzle pre-form hole comprises a curved side that includes a converging and diverging fluid flow feature formed from a converging and diverging fluid flow feature on the exterior surface of a corresponding nozzle hole forming feature, and when the nozzle pre-form is formed into the nozzle, the featured nozzle pre-form hole becomes a featured nozzle through-hole having a corresponding curved side configured to include a converging and diverging fluid flow feature that causes fluid flowing through the featured nozzle through-hole to converge and then diverge multiple times before exiting through its outlet opening,   (e) each of the nozzle pre-form holes, and each of the corresponding nozzle hole forming features, has a different configuration such that, when the nozzle pre-form is formed into the nozzle, fluid flowing through the nozzle through-holes exit the outlet openings so as to form a non-symmetrical fluid plume,   (f) each of the nozzle pre-form holes, and each of the corresponding nozzle hole forming features, has a different configuration such that, when the nozzle pre-form is formed into the nozzle, fluid flowing through the nozzle through-holes flows out of each of the outlet openings differently, or   (g) any combination of (a) to (f).   
     
     
         26 . A nozzle made from the nozzle pre-form according to  claim 25 . 
     
     
         27 . The nozzle according to  claim 26 , wherein said nozzle is a fuel injector nozzle.