Swirl unit, orifice plate, and spray nozzle including same

Abstract

In a spray nozzle ( 10 ), a carrier ( 12 ) defines a spray aperture ( 20 ), a groove ( 30 ) surrounding the spray aperture for receiving an o-ring ( 32 ), a first locating bore ( 26 ) for slidably receiving an orifice plate ( 14 ) seated against the o-ring ( 32 ) and for aligning the orifice plate with the spray aperture, and a second locating bore ( 28 ) for slidably receiving a swirl unit and aligning the swirl unit ( 16 ) with the orifice plate and spray aperture. The swirl unit ( 16 ) defines on its peripheral surface a recessed flat ( 58 ) forming a fluid passageway between the swirl unit and carrier. The swirl unit ( 16 ) includes a swirl chamber ( 60 ) defined by a curvilinear surface ( 62 ) formed within the swirl unit, and an inlet port ( 64 ) formed in fluid communication between the swirl chamber and fluid passageway. The nozzle body ( 18 ) is threadedly received within the carrier ( 12 ) behind the swirl unit ( 16 ) to axially press the swirl unit, and in turn press the orifice plate ( 14 ) against the adjacent surface of the carrier.

1. A swirl unit for a spray nozzle, wherein the spray nozzle includes a carrier defining a spray aperture on one end for emitting a spray, a first pair of locating surfaces formed on approximately opposite sides of the carrier relative to each other and axially spaced adjacent to the spray aperture for receiving an orifice plate, and a second pair of locating surfaces formed on approximately opposite sides of the carrier relative to each other and formed on an opposite side of the first pair of locating surfaces relative to the spray aperture for receiving the swirl unit, wherein the swirl unit comprises:
 a first end surface engageable with an orifice plate received within the carrier adjacent to the first locating surfaces; a second end surface axially spaced relative to the first end surface; a peripheral surface formed between the first and second end surfaces, wherein the peripheral surface defines at least two locating surfaces formed on approximately opposite sides of the swirl unit relative to each other and dimensioned for slidably contacting the second locating surfaces of the carrier upon inserting the swirl unit therein; at least one recessed surface spaced radially inwardly from the at least two locating surfaces of the swirl unit to thereby define a fluid passageway between the swirl unit and carrier; and a swirl chamber defined by an approximately curvilinear surface, and an inlet port formed in fluid communication between the swirl chamber and fluid passageway and defined at least in part by an inlet surface formed between the curvilinear surface and the recessed surface.    
     
     
       2. A swirl unit as defined in  claim 1 , wherein the carrier further defines at least one retaining surface located on an opposite side of the second pair of locating surfaces relative to the first pair of locating surfaces and extending inwardly a predetermined distance for retaining the swirl unit within the carrier, and the at least one recessed surface of the swirl unit is spaced radially inwardly from the at least two locating surfaces of the swirl unit a distance greater than the predetermined distance defined by the at least one retaining surface of the carrier for clearing the retaining surface upon inserting the swirl unit into the carrier adjacent to the second locating surfaces. 
     
     
       3. A swirl unit as defined in  claim 1 , wherein the second pair of locating surfaces of the carrier are formed by a bore approximately defined by a first radius, and the peripheral surface is defined at least in part by a second radius selected for slidably contacting the second locating surfaces of the bore upon inserting the swirl unit therein. 
     
     
       4. A swirl unit as defined in  claim 2 , wherein the recessed surface is defined by an approximately planar surface formed on the peripheral surface. 
     
     
       5. A swirl unit as defined in  claim 1 , further defining a tapered surface formed between the peripheral and first end surfaces and tapering inwardly toward the first end surface for facilitating slidable movement of the swirl unit through the carrier. 
     
     
       6. A swirl unit as defined in  claim 1 , further comprising a tool-engaging surface formed on the second end surface and engageable with a tool for pressing the swirl unit toward the orifice plate and rotating the swirl unit and second end surface thereof into a position for engagement with the at least one retaining surface to thereby secure within the carrier the swirl unit and orifice plate. 
     
     
       7. A swirl unit as defined in  claim 2 , wherein the carrier defines at least two retaining surfaces spaced on approximately opposite sides of the carrier relative to each other, and each extending inwardly a predetermined distance for retaining the swirl unit within the carrier, and wherein the peripheral surface of the swirl unit defines at least two recessed surfaces on approximately opposite sides of the swirl unit relative to each other, and each recessed surface is spaced radially inwardly from the at least two locating surfaces of the swirl unit a distance greater than the predetermined distance defined by at least one respective retaining surface for clearing the retaining surfaces upon inserting the swirl unit into the carrier adjacent to the second locating surfaces. 
     
     
       8. A swirl unit as defined in  claim 1 , in further combination with an orifice plate defining a first end surface engageable with the carrier, a second end surface axially spaced relative to the first end surface and engageable with the first end surface of the swirl unit, a spray orifice formed through the orifice plate, and a peripheral surface formed between the first and second end surfaces and dimensioned for slidably contacting the first locating surfaces upon inserting the orifice plate into the carrier. 
     
     
       9. A swirl unit and orifice plate as defined in  claim 8 , wherein the orifice plate further defines a tapered surface at the juncture of the peripheral and first end surfaces for facilitating insertion of the orifice plate into the carrier adjacent to the first locating surfaces. 
     
     
       10. A swirl unit for a spray nozzle, wherein the spray nozzle includes a carrier defining a spray aperture on one end for emitting a spray, a first locating bore axially spaced adjacent to the spray aperture for receiving an orifice plate, and a second locating bore formed on an opposite side of the first locating bore relative to the spray aperture for receiving the swirl unit, wherein the swirl unit comprises:
 a first end surface engageable with an orifice plate received within the first locating bore; a second end surface axially spaced relative to the first end surface; a peripheral surface formed between the first and second end surfaces; first means for slidably contacting a surface forming the second locating bore upon inserting the swirl unit therein and aligning the swirl unit with the spray aperture; second means for receiving fluid through the swirl unit, and discharging fluid in a swirling pattern therefrom; and third means spaced radially inwardly relative to the first means for defining a fluid passageway between the swirl unit and carrier coupled in fluid communication with the second means to direct fluid into the second means and, in turn, discharge the fluid in a swirling pattern therefrom.    
     
     
       11. A swirl unit as defined in  claim 10 , wherein the carrier further defines at least one retaining surface located on an opposite side of the second locating bore relative to the first locating bore and extending inwardly a predetermined distance for retaining the swirl unit within the carrier, and the third means is defined by at least one recessed surface spaced radially inwardly a distance greater than the predetermined distance defined by the at least one retaining surface of the carrier for clearing the retaining surface upon insertion of the swirl unit into the carrier. 
     
     
       12. A swirl unit as defined in  claim 10 , wherein the first means is defined by at least two locating surfaces formed on approximately opposite sides of the peripheral surface relative to each other, and approximately defined by a radius for slidably contacting the surface forming the second locating bore upon inserting the swirl unit therein. 
     
     
       13. A swirl unit as defined in  claim 11 , further comprising means for engaging a tool for pressing the swirl unit toward the orifice plate and rotating with the tool the swirl unit and second end surface thereof into a position for engagement with the at least one retaining surface to thereby secure within the carrier the swirl unit and orifice plate. 
     
     
       14. A spray nozzle, comprising:
 a carrier defining a spray aperture on one end for emitting a spray, at least two first locating surfaces spaced on approximately opposite sides of the carrier relative to each other and axially spaced adjacent to the spray aperture for receiving an orifice plate, and at least two second locating surfaces spaced on approximately opposite sides of the carrier relative to each other and formed on an opposite side of the first locating surfaces relative to the spray aperture for receiving a swirl unit;    an orifice plate defining a first end surface engageable with the carrier, a second end surface axially spaced relative to the first end surface, a spray orifice formed through the orifice plate, and a peripheral surface formed between the first and second end surfaces and dimensioned for slidably contacting the first locating surfaces upon insertion of the orifice plate into the carrier; and    a swirl unit including a first end surface engageable with the orifice plate received within the carrier adjacent to the first locating surfaces, a second end surface axially spaced relative to the first end surface, a peripheral surface formed between the first and second end surfaces and defining at least two locating surfaces formed on approximately opposite sides of the swirl unit relative to each other and dimensioned for slidably contacting the second locating surfaces of the carrier upon insertion of the swirl unit therein, at least one recessed surface spaced radially inwardly from the at least two locating surfaces of the swirl unit to thereby define a fluid passageway between the swirl unit and carrier; a swirl chamber defined by at least one curvilinear surface formed within the swirl unit, and an inlet port formed in fluid communication between the swirl chamber and fluid passageway and defined at least in part by an inlet surface formed between the at least one curvilinear surface and the recessed surface.    
     
     
       15. A spray nozzle as defined in  claim 14 , wherein the carrier further defines at least one retaining surface located on an opposite side of the second locating surfaces relative to the first locating surfaces and extending inwardly a predetermined distance for retaining the swirl unit within the carrier, and wherein the at least one recessed surface is spaced radially inwardly from the at least two locating surfaces of the swirl unit a distance greater than the predetermined distance defined by the at least one retaining surface of the carrier for clearing the retaining surface upon insertion of the swirl unit into the carrier, and the swirl unit further defines a tool-engaging surface formed on the second end surface and engageable with a tool for pressing the swirl unit toward the orifice plate and rotating the swirl unit and second end surface thereof into a position for engagement with the at least one retaining surface to thereby secure within the carrier the swirl unit and orifice plate. 
     
     
       16. A spray nozzle as defined in  claim 14 , wherein the second locating surfaces of the carrier are formed by a locating bore approximately defined by a first radius, and the peripheral surface of the swirl unit is defined at least in part by a second radius selected for slidably contacting the second locating surfaces upon inserting the swirl unit into the bore. 
     
     
       17. A spray nozzle as defined in  claim 16 , wherein the recessed surface is defined by an approximately planar surface formed on the peripheral surface. 
     
     
       18. A spray nozzle as defined in  claim 14 , wherein the swirl unit further defines a tapered surface formed between the peripheral and first end surfaces and tapering inwardly toward the first end surface for facilitating slidable movement of the swirl unit within the carrier. 
     
     
       19. A spay nozzle as defined in  claim 14 , further comprising at least one nozzle body and wherein the nozzle body is received within the carrier on an approximately opposite side of the swirl unit relative to the orifice plate, the nozzle body defines at least one fluid conduit coupled in fluid communication with the fluid passageway and the swirl chamber for introducing fluid through the swirl unit and orifice plate, and the nozzle body is engageable with the swirl unit for securing the swirl unit and orifice plate within the carrier. 
     
     
       20. A spray nozzle as defined in  claim 19 , including first and second carriers, wherein:
 the first carrier defines the at least two first locating surfaces for receiving the orifice plate, and the at least two second locating surfaces for receiving the swirl unit, and is engageable with the second carrier; and    the nozzle body is receivable within the second carrier and engageable with the swirl unit received within the first carrier.    
     
     
       21. A spray nozzle as defined in  claim 20 , wherein the second carrier defines an aperture for receiving the first carrier within the second carrier. 
     
     
       22. A spray nozzle as defined in  claim 20 , further comprising at least one sealing member located between the orifice plate and one of the first and second carriers, and wherein the second carrier defines a threaded aperture for receiving the nozzle body, and the nozzle body is threadedly engageable within the threaded aperture to engage the swirl unit and, in turn, compress the sealing member to effect an approximately fluid-tight seal between the orifice plate and respective carrier. 
     
     
       23. A spray nozzle as defined in  claim 14 , wherein the carrier defines at least one inner surface extending in an axial direction of the carrier between the first and second locating surfaces, extending about the periphery of the swirl unit, and spaced radially outwardly from the swirl unit relative to the first and second locating surfaces to facilitate removal of the swirl unit from the carrier. 
     
     
       24. A spray nozzle as defined in  claim 14 , further comprising at least one sealing member located between the orifice plate and the carrier, and wherein the carrier defines a smooth approximately planar sealing surface facing the orifice plate and engageable with the sealing member, and the orifice plate defines an annular recess facing the smooth, approximately planar sealing surface of the carrier for receiving therein the sealing member and preventing the collection of particles on the sealing surface of the carrier. 
     
     
       25. A swirl unit as defined in  claim 10 , wherein the third means is defined by at least one recessed surface spaced radially inwardly relative to the first means to thereby define the fluid passageway between the swirl unit and carrier. 
     
     
       26. A swirl unit as defined in  claim 25 , wherein said at least one recessed surface is approximately planar. 
     
     
       27. A swirl unit as defined in  claim 10 , wherein the second means includes a swirl chamber defined by at least one approximately curvilinear surface, and an inlet port formed in fluid communication between the swirl chamber and fluid passageway. 
     
     
       28. A swirl unit for a spray nozzle, wherein the spray nozzle includes a carrier defining a spray aperture on one end for emitting a spray, a first locating surface section for contacting and aligning an orifice plate within the carrier, and a second locating surface section for contacting and aligning the swirl unit within the carrier, wherein the swirl unit comprises:
   a first end surface engageable with an orifice plate received within the carrier adjacent to the first locating surface section; a second end surface axially spaced relative to the first end surface; a peripheral surface formed between the first and second end surfaces, wherein the peripheral surface defines a locating surface section dimensioned for contacting the second locating surface section of the carrier upon inserting the swirl unit therein and locating the swirl unit within the carrier; a recessed surface defined by the peripheral surface and spaced radially inwardly thereon to thereby define a fluid passageway between the recessed surface and carrier; a swirl chamber defined by an approximately curvilinear surface; and an inlet port formed in fluid communication between the swirl chamber and the recessed surface and defined at least in part by an inlet surface formed between the curvilinear surface and the recessed surface for receiving fluid flowing from the fluid passageway and directing the fluid into the swirl chamber.     
     
     
       29. A swirl unit as defined in  claim 28 , wherein the carrier defines a first pair of locating surface sections formed on approximately opposite sides of the carrier relative to each other for receiving an orifice plate, and a second pair of locating surface sections formed on approximately opposite sides of the carrier relative to each other for receiving the swirl unit, and the peripheral surface of the swirl unit defines at least two locating surface sections formed on approximately opposite sides of the swirl unit relative to each other and dimensioned for contacting the second locating surface sections of the carrier upon inserting the swirl unit therein. 
     
     
       30. A swirl unit as defined in  claim 28 , wherein the recessed surface is defined by an approximately planar surface. 
     
     
       31. A swirl unit as defined in  claim 28 , in further combination with an orifice plate defining a first surface located on one side of the orifice plate and engageable with the carrier, a second surface axially spaced relative to the first surface and engageable with the first end surface of the swirl unit, a spray orifice formed through the orifice plate, and a peripheral surface formed between the first and second surfaces and dimensioned for contacting the first locating surface section upon inserting the orifice plate into the carrier and locating the orifice plate within the carrier. 
     
     
       32. A combination as defined in  claim 31 , further comprising a retaining member defining a retaining surface engageable with the swirl unit for retaining the swirl unit and orifice plate within the carrier. 
     
     
       33. A combination as defined in  claim 32 , wherein the retaining member is engageable with the second end surface of the swirl unit for retaining the swirl unit and orifice plate within the carrier. 
     
     
       34. A combination as defined in  claim 32 , further comprising a sealing member seated between the orifice plate and carrier and forming an approximately fluid- tight seal therebetween.   
     
     
       35. A combination as defined in  claim 33 , wherein the carrier, retaining member, sealing member, orifice plate and swirl unit are locked in a subassembly that can be turned in any direction without the sealing member, orifice plate and swirl unit falling out of the carrier. 
     
     
       36. A combination as defined in  claim 33 , further comprising a nozzle body threadedly engaged with the carrier and defining at least one fluid conduit in fluid communication with the fluid passageway for directing fluid from the at least one fluid conduit into the fluid passageway and, in turn, into the inlet port and swirl chamber. 
     
     
       37. A combination as defined in  claim 31 , wherein the orifice plate defines a first peripheral surface and a second peripheral surface spaced inwardly from the first peripheral surface. 
     
     
       38. A swirl unit as defined in  claim 28 , wherein the second locating surface section of the carrier is spaced on an opposite side of the first locating surface section relative to the spray aperture, and the locating surface section of the peripheral surface of the swirl unit contacts the second locating surface section of the carrier upon inserting the swirl unit therein to locate the swirl unit within the carrier. 
     
     
       39. A swirl unit as defined in  claim 28 , wherein the peripheral surface extends axially from the first end surface to the second end surface. 
     
     
       40. A swirl unit as defined in  claim 39 , wherein the swirl unit is substantially cylindrical. 
     
     
       41. A swirl unit as defined in  claim 40 , wherein the recessed surface is located within the diameter of the peripheral surface. 
     
     
       42. A swirl unit as defined in  claim 40 , wherein the swirl unit defines an axis extending between the first and second end surfaces, the fluid passageway of the recessed surface defines a fluid flow path substantially parallel to the axis, and the inlet port defines a fluid flow path substantially perpendicular to the axis. 
     
     
       43. A spray nozzle, comprising:
   a carrier defining a spray aperture on one end for emitting a spray, a first locating surface section formed on the carrier for contacting and locating the orifice plate within the carrier, and a second locating surface section formed on the carrier for contacting and locating a swirl unit within the carrier;        an orifice plate defining a first surface engageable with the carrier, a second surface axially spaced relative to the first surface, a spray orifice formed through the orifice plate, and a peripheral surface formed between the first and second surfaces and dimensioned for contacting the first locating surface section upon insertion of the orifice plate into the carrier to locate the orifice plate within the carrier; and        a swirl unit including a first end surface engageable with the orifice plate received within the carrier adjacent to the first locating surface section, a second end surface axially spaced relative to the first end surface, a peripheral surface formed between the first and second end surfaces and defining a locating surface section dimensioned for contacting the second locating surface section of the carrier upon insertion of the swirl unit therein and locating the swirl unit within the carrier, a recessed surface defined by the peripheral surface and spaced radially inwardly thereon to thereby define a fluid passageway between the recessed surface and carrier, a swirl chamber defined by at least one curvilinear surface formed within the swirl unit, and an inlet port formed in fluid communication between the swirl chamber and the recessed surface and defined at least in part by an inlet surface formed between the at least one curvilinear surface and the recessed surface for receiving fluid flowing from the fluid passageway and directing the fluid into the swirl chamber.     
     
     
       44. A spray nozzle as defined in  claim 43 , wherein the second locating surface section of the carrier is formed by a locating bore approximately defined by a first radius, and the peripheral surface of the swirl unit is defined at least in part by a second radius that contacts the second locating surface section upon inserting the swirl unit into the bore and locates the swirl unit within the carrier. 
     
     
       45. A spray nozzle as defined in  claim 43 , wherein the recessed surface of the swirl unit is defined by an approximately planar surface. 
     
     
       46. A spray nozzle as defined in  claim 43 , further comprising a retaining member defining a retaining surface engageable with the swirl unit for retaining the swirl unit and orifice plate within the carrier. 
     
     
       47. A spray nozzle as defined in  claim 46 , wherein the retaining member is engageable with the second end surface of the swirl unit for retaining the swirl unit and orifice plate within the carrier. 
     
     
       48. A spray nozzle as defined in  claim 46 , wherein the carrier, retaining member, orifice plate and swirl unit are locked in a subassembly that can be turned in any direction without the sealing member, orifice plate and swirl unit falling out of the carrier. 
     
     
       49. A spray nozzle as defined in  claim 43 , further comprising a nozzle body threadedly engaged with the carrier and defining at least one fluid conduit in fluid communication with the fluid passageway for directing fluid from the at least one fluid conduit through the fluid passageway, the inlet port, the swirl chamber and, in turn, through the spray orifice of the orifice plate. 
     
     
       50. A spray nozzle as defined in  claim 43 , wherein the peripheral surface of the swirl unit extends axially from the first end surface to the second end surface. 
     
     
       51. A spray nozzle as defined in  claim 50 , wherein the swirl unit is substantially cylindrical. 
     
     
       52. A spray nozzle as defined in  claim 51 , wherein the recessed surface is located within the diameter of the peripheral surface. 
     
     
       53. A spray nozzle as defined in  claim 43 , wherein the swirl unit defines an axis extending between the first and second end surfaces, the fluid passageway of the recessed surface defines a fluid flow path substantially parallel to the axis, and the inlet port defines a fluid flow path substantially perpendicular to the axis. 
     
     
       54. A method comprising the following steps:
   providing a carrier defining a spray aperture on one end for emitting a spray, a first locating surface section formed on the carrier for contacting and locating an orifice plate within the carrier, and a second locating surface section formed on the carrier for contacting and locating a swirl unit within the carrier;        providing an orifice plate defining a first surface engageable with the carrier, a second surface axially spaced relative to the first surface, a spray orifice formed through the orifice plate, and a peripheral surface formed between the first and second surfaces and dimensioned for contacting the first locating surface section upon insertion of the orifice plate into the carrier;        providing a swirl unit including a first end surface engageable with the orifice plate received within the carrier adjacent to the first locating surface section, a second end surface axially spaced relative to the first end surface, a peripheral surface formed between the first and second end surfaces and defining a locating surface section dimensioned for contacting the second locating surface section of the carrier upon insertion of the swirl unit therein, a recessed surface defined by the peripheral surface and spaced radially inwardly thereon to thereby define a fluid passageway between the recessed surface and carrier, a swirl chamber defined by at least one curvilinear surface formed within the swirl unit, and an inlet port formed in fluid communication between the swirl chamber and the recessed surface and defined at least in part by an inlet surface formed between the at least one curvilinear surface and the recessed surface;        providing a nozzle body defining at least one fluid conduit coupled in fluid communication with the fluid passageway;        inserting the orifice plate into the carrier, contacting the peripheral surface of the orifice plate with the first locating surface section of the carrier and thereby locating the orifice plate within the carrier, inserting the swirl unit within the carrier, contacting the peripheral surface of the swirl unit with the second locating surface section of the carrier and thereby locating the swirl unit within the carrier, and assembling the nozzle body to the carrier; and        introducing fluid through the at least one fluid conduit of the nozzle body, through the fluid passageway formed between the recessed surface and carrier in a direction substantially parallel to an axis extending between the first and second end surfaces of the swirl unit, through the inlet port in a direction substantially perpendicular to the axis, through the swirl chamber and, in turn, through the spray orifice of the orifice plate.     
     
     
       55. A method as defined in  claim 54 , further comprising:
   providing a retaining member defining a retaining surface engageable with the swirl unit; and        prior to assembling the nozzle body to the carrier, engaging the carrier with the retaining surface and, in turn, locking the carrier, retaining member, orifice plate and swirl unit in a subassembly that can be turned in any direction without the sealing member, orifice plate and swirl unit falling out of the carrier.     
     
     
       56. A method as defined in  claim 54 , wherein the peripheral surface of the swirl unit is substantially cylindrical, the second locating surface section is defined by a substantially cylindrical surface, and the recess and fluid passageway are located within the diameter of the cylindrical peripheral surface.