Method of making a nozzle

Abstract

Methods of making nozzles are disclosed. More specifically, methods of making nozzles that may be used as components of a fuel injection system are disclosed.

1 . A method of fabricating a nozzle comprising the steps of:
 forming a first microstructured pattern in a first material, the first microstructured pattern comprising a plurality of discrete microstructures;   deforming at least one of the plurality of discrete microstructures, resulting in at least one deformed discrete microstructure;   replicating the first microstructured pattern in a second material different than the first material to make a replicated structure;   processing the replicated structure into a nozzle having a plurality of through-holes in the second material and corresponding to the plurality of microstructures in the first microstructured pattern, said processing comprising removing the first material from the replicated structure.   
     
     
         2 . The method of  claim 1  wherein said forming comprises casting and curing the first material. 
     
     
         3 . The method of  claim 1  wherein said forming comprises extruding the first material. 
     
     
         4 . The method of  claim 1 , wherein the first material comprises a polymer and the second material comprises a metal. 
     
     
         5 . The method of  claim 1 , wherein said processing further comprises removing enough of the second material of the replicated structure to expose tops of the microstructures in the plurality of microstructures in the first microstructured pattern. 
     
     
         6 . The method of  claim 5 , wherein said removing comprises planarizing the second material. 
     
     
         7 . The method of  claim 1 , wherein the second material comprises an electroplating material, and said replicating comprises electroforming the second material so as to cover over the first microstructured pattern. 
     
     
         8 . The method of  claim 7 , wherein said processing further comprises removing enough of the second material from the replicated structure to expose tops of the microstructures in the plurality of microstructures in the first microstructured pattern. 
     
     
         9 . The method of  claim 1 , wherein the second material comprises a ceramic. 
     
     
         10 . The method of  claim 1 , wherein the plurality of discrete microstructures comprises a discrete microstructure that is at least a portion of a three-dimensional rectilinear body. 
     
     
         11 . The method of  claim 10 , wherein the three-dimensional rectilinear body is an elongated prismatic structure. 
     
     
         12 . The method of  claim 1 , wherein the plurality of discrete microstructures comprises a discrete microstructure that is at least a portion of a three-dimensional curvilinear body. 
     
     
         13 . The method of  claim 1 , wherein said deforming comprises deforming an array of the plurality of discrete microstructures, resulting in an array of deformed discrete microstructures. 
     
     
         14 . The method of  claim 1 , wherein said deforming comprises bending or twisting, resulting in at least one bent or twisted discrete microstructure. 
     
     
         15 . The method of  claim 1 , wherein said deforming occurs by mechanical, thermal or thermomechanical means. 
     
     
         16 . The method of  claim 1 , wherein the plurality of discrete microstructures of the first pattern comprise re-closeable fasteners with posts or mushroom-shaped tops.