Плоская вентилятор | Производитель форсунок с точным литьем

Введение

In modern industrial processes, Точное распределение жидкости имеет решающее значение для эффективности, Качество продукта, и сохранение ресурсов.

Среди различных технологий спрея, а flat fan nozzle stands out as one of the most widely used due to its ability to generate uniform, linear spray patterns.

With applications spanning сталь -депляция, cleaning-in-place (Прозрачный), сельское хозяйство, охлаждение, и покрытие, flat fan nozzles represent the precision core of many spray systems.

This article provides a comprehensive, data-driven perspective on their design, производительность, материалы, приложения, and comparative advantages.

1. What Is a Flat Fan Nozzle?

А flat fan nozzle is a precision-engineered spray device that transforms pressurized fluid—whether liquid, gas-liquid mixture, or slurry—into a two-dimensional, fan-shaped spray pattern.

Unlike conical сопла that distribute fluid volumetrically, flat fan nozzles concentrate discharge into a thin sheet, обеспечение controlled surface contact, uniform line coverage, and reduced overspray.

Four primary parameters characterize them:

• Угол распыления: 15° –170 °
• Скорость потока: 0.1–100 л/мин
• Эксплуатационное давление: 0.5–200 бар
• Размер капель (SMD): 20–1,000 μm

This versatility makes them suitable for low-pressure agricultural spraying а также high-pressure industrial descaling and cleaning.

Рабочий принцип

The spray formation process relies on three sequential fluid mechanics phenomena, governed by Bernoulli’s principle and surface tension dynamics:

• Fluid Conditioning: Pressurized fluid enters the nozzle’s inlet cavity, where turbulence is reduced via tapered or cylindrical channels.
  This ensures a steady, ламинарный поток (Reynolds Number Re = 2,000–10,000) before reaching the spray-forming element—critical for uniform sheet formation.
• Формирование листа: Fluid passes through a V-groove, sectorial deflector, or slot-like orifice, which reshapes it into a thin, flat sheet (толщина: 5–50 мкм).
  Например, a V-groove with a 60° angle forces fluid to spread laterally, while a sectorial deflector (positioned at 45° to the orifice) splits circular flow into a fan.
• Sheet Breakup: As the flat sheet exits the nozzle, it interacts with ambient air.
  Air shear forces and surface tension cause the sheet to fragment into droplets—with size distribution controlled by pressure (higher pressure → finer droplets) and orifice geometry (Narrower orifices → smaller droplets).
  For low-pressure applications (1–5 bar), droplet size is typically 200–500 μm; for high-pressure cleaning (50+ бар), it shrinks to 50–100 μm.

2. Structural Design

The performance of a flat fan nozzle is determined by its structural components, each optimized to regulate fluid flow, распылитель однородность, Сопротивление сногся, and mechanical durability.

Core Structural Components

Inlet Cavity

The inlet cavity conditions incoming fluid to minimize turbulence, a primary cause of uneven spray. Two common designs dominate:

• Tapered Cavity: A conical channel with a 15°–30° angle, used for high-pressure applications (≥50 бар).
  It reduces pressure loss by 15–20% compared to cylindrical cavities, ensuring consistent flow to the spray-forming element.
  Например, high-pressure industrial cleaning nozzles (100 бар) use tapered cavities to maintain spray integrity.
• Cylindrical Cavity: A straight channel, cost-effective for low-to-medium pressure (0.5–50 бар) tasks like agricultural spraying.
  It is easier to manufacture but may introduce minor turbulence at pressures >30 бар.

Spray-Forming Element

This is the “heart” of the nozzle, responsible for shaping fluid into a fan. Two dominant designs:

• V-Groove Geometry: A precision-machined V-shaped channel (depth: 0.1–2 мм, угол: 30°–90°) in the nozzle core.
  Fluid spreads along the groove’s walls, forming a uniform sheet. Ideal for low-to-medium pressure (1–50 бар) and clean fluids (no particulates), as grooves can clog with debris.
  Used in agricultural pesticide nozzles (НАПРИМЕР., TeeJet XR series, 80° V-groove).
• Sectorial Deflector: A flat metal/ceramic plate (толщина: 0.5–2 мм) positioned 1–3 mm from the outlet orifice.
  Fluid exits through a circular orifice and impacts the deflector at 45°–60°, spreading into a fan.
  Resistant to clogging (suitable for particulate-laden fluids like descaling water), it is used in high-pressure industrial applications (50–200 бар).

Outlet Orifice

The orifice defines the spray’s final shape and flow rate, with two key designs:

• Rectangular Orifice: Aspect ratio (ширина:высота) = 5:1 к 20:1, machined to ±0.01 mm tolerance.
  Ensures the spray fan retains its flat profile over distance (up to 5m), critical for conveyor-based applications (НАПРИМЕР., food cooling).
  A 2mm-wide, 0.2mm-tall rectangular orifice delivers a 90° spray angle at 10 бар.
• Slot Orifice: A narrow, linear opening (ширина: 0.1–1 мм), used for narrow-angle sprays (15°–30°) in precision tasks like electronics coating.
  It minimizes overspray but requires clean fluids to avoid clogging.

Connection and Mounting Variants

Different connection methods are adopted based on system design, replacement frequency, and maximum allowable pressure.

3. Spray Performance Metrics

• Угол распыления (тур): Определяет ширину покрытия. Пример: В 300 mm standoff, а 65° nozzle covers ~380 mm width.
• Impact Force Distribution: Narrow angles (15°–30°) yield higher impact per unit width; wide angles (90° –120 °) provide broader, lighter coverage.
• Размер капель (Средний диаметр сочетания, SMD): Hydraulic flat fans produce 100–600 мкм droplets; air-assisted variants can reach 50–200 мкм.
• Единообразие: Tapered-edge designs require 30–50% overlap between adjacent nozzles for consistent coverage.

4. Common Material Selection of Flat Fan Nozzle

The material of a flat fan spray nozzle determines its сопротивление коррозии, эрозия, давление, и температура, ultimately defining its service life and total cost of ownership.

Comparative Material Selection Table

5. Типы & Variants of Flat Fan Nozzle

Flat fan nozzles are highly versatile, с геометрия, internal design, and material construction tailored to control Угол распыления, размер капель, влияние, coverage uniformity, and resistance to wear or corrosion.

Standard Types

Full-Width Flat Fan Nozzles

• Generate a uniform spray across the entire orifice width, maintaining consistent coverage along a target surface.
• Fluid dynamics: Laminar flow is conditioned in the inlet cavity and reshaped by the V-groove or deflector to produce a coherent liquid sheet.

  

• Приложения: Conveyor-based food processing, industrial surface cleaning, and coating operations.
• Spray angles typically range 60° –120 °, with flow rates 0.1–100 л/мин.

Even-Flat (Extended-Flat) Сопла

• Engineered to provide uniform distribution across the fan width, minimizing edge effects or overspray.
• Often incorporate precision-machined V-grooves or sectorial deflectors to stabilize sheet thickness across the span.

  

• Приложения: Precision agricultural spraying, chemical coating, and automated CIP (Clean-In-Place) система.

Narrow-Angle Flat Fan Nozzles

• Spray angles 15°–45°, обеспечение focused impact for high-energy surface cleaning or precision liquid deposition.

  

• High local momentum allows effective removal of residues, оксидная шкала, or debris.
• Pressure range: 10–200 бар; скорость потока: 0.1–50 L/min.

Wide-Angle Flat Fan Nozzles

• Spray angles 130° –170 °, optimized for низкий давление, broad coverage.
• Useful for подавление пыли, ирригация, or washdown applications where minimizing nozzle count reduces system complexity.
• Pressure range: 0.5–20 бар; typical droplet size: 200–500 мкм.

  

Specialty Variants

Anti-Drip / Shut-Off Nozzles

• Включить internal check valves or precision seat designs to prevent post-spray fluid leakage.
• Critical in applications requiring exact dosing, такой как сельское хозяйство, Фармацевтические препараты, и химическое распыление.

Air-Assisted / Air-Atomizing Flat Fan Nozzles

• Compressed air mixes with liquid at the nozzle tip, Усиление primary and secondary atomization.
• Производит fine droplets (Sauter Mean Diameter 20–100 μm) at moderate pressures, extending coverage and improving uniformity.
• Приложения: high-precision coating, painting lines, and pesticide spraying.

Slotted or Precision Flat Fan Nozzles

• Narrow rectangular or slot orifices provide highly controlled fan widths.
• Часто используется в electronics cleaning, PCB coating, or micro-fabrication processes.
• Require filtered fluids to prevent clogging; precise CNC machining ensures consistent sheet quality.

Высокое давление / Abrasion-Resistant Nozzles

• Constructed with hardened stainless steel, Дуплексные сплавы, or ceramic inserts.
• Designed to handle абразивные суппи, сталь -депляция, and high-pressure cleaning (>100 бар).
• Internal geometries may incorporate tapered inlet cavities and reinforced deflectors to extend lifespan.

Регулируемый / Interchangeable Nozzles

• Позволять field adjustment of spray angle, скорость потока, or fan width.
• Provide flexibility for changing operational conditions, such as switching from cleaning to cooling or from narrow to wide coverage.

Differentiating Features and Selection Criteria

6. Production and Manufacturing of Flat Fan Nozzle

The production of flat fan spray nozzles is a high-precision engineering process that combines материаловая наука, Усовершенствованное производство, and rigorous quality control.

Each stage—from raw material selection to final testing—directly impacts распылитель однородность, droplet size control, долговечность, and chemical/abrasive resistance, making it critical for applications ranging from сталь -депляция к precision coating and food processing.

Material Selection and Preparation

Material choice governs коррозионная стойкость, wear tolerance, механическая прочность, и тепловая стабильность:

• Кастинг по выплавляемым моделям

• • Производит near-net shape components with complex internal geometries, such as inlet cavities, deflector mounts, and orifice supports.
  • Minimizes остаточные стрессы, reducing post-machining operations and improving structural stability under high pressure.
  • Обычно используется для нержавеющая сталь (316Л, 17-4 PH), Дуплексные сплавы, Монель, and Hastelloy, which are widely applied in chemical, нефтехимический, and high-pressure cleaning industries.

• Точность ковки

• • Улучшает механические свойства including tensile strength, устойчивость к усталости, и ударная вязкость, making nozzles suitable for abrasive or high-pressure applications.
  • Produces components with refined grain structure, reducing the risk of micro-cracks under repeated hydraulic or thermal stress.
  • Often followed by термическая обработка (solution annealing or precipitation hardening) Чтобы оптимизировать corrosion resistance and hardness.

• Керамика: Alumina or silicon carbide powders are processed into highly wear-resistant inserts.

• • Ceramic Powder Processing:

• • • High-purity powders are pressed under controlled pressure и sintered at high temperature to achieve uniform density and microstructure.
    • Uniform density is critical to prevent micro-cracking during thermal cycling or high-velocity fluid impact, which could compromise spray performance or nozzle lifespan.
    • Приложения: abrasive slurry descaling, добыча, and high-pressure cleaning.

• PTFE Inserts: Applied in aggressive chemical environments for low-pressure spraying.
  Careful molding prevents voids and surface irregularities, maintaining consistent spray distribution.

Core Machining & Precision Fabrication

• Фрезерование с ЧПУ & Поворот: Создает V-grooves, sectorial deflectors, and slot orifices with tolerances ±0.01 mm to ensure consistent spray angle and droplet size.
• Электроэрозионная обработка (электроэрозионная обработка): Включает precision orifices in hardened alloys or ceramics where conventional cutting fails.
• Laser Micromachining: Используется для micro-scale applications, such as electronics or laboratory nozzles, producing slot widths <0.2 мм.
• Полировка & Выслушивание: Internal channels are polished to reduce turbulence, prevent debris accumulation, and stabilize sheet breakup.

Обработка поверхности и покрытия

• Пассивация: Enhances corrosion resistance of stainless steel by forming a protective chromium oxide layer.
• Hard Coatings: Карбид вольфрама, chromium carbide, or ceramic coatings improve устойчивость к истиранию in high-velocity or slurry environments.
• Электрополирование: Improves surface smoothness, reduces fouling, and is critical for sanitary or chemical applications.
• PTFE Coatings: Applied for chemical handling and anti-stick performance in aggressive low-pressure spraying.

Assembly and Multi-Component Integration

• Precise Alignment: Deflector plates, ceramic inserts, and seals must be aligned to maintain fan angle, Толщина листа, and droplet uniformity.
• Mechanical Tolerances: Deviations as small as 0.05 мм может привести к asymmetric sprays or uneven coverage.
• High-Pressure Seals: Industrial nozzles (>100 бар) требовать metallic or high-grade elastomer seals resistant to temperature and chemical attack.

7. Преимущества и ограничения

Flat fan nozzles offer unique benefits but are not universally suitable—understanding tradeoffs is critical for optimal selection.

Преимущества

• Равномерное покрытие: UC = 80–100% (против. full-cone nozzles: 60–75%), reducing fluid waste by 10–15%.
  Например, agricultural low-drift flat fan spray nozzles use 12% less pesticide than full-cone models.
• Controlled Impact: Adjustable pressure allows tailoring impact from gentle (≤0.5 bar) to aggressive (100 бар), making them suitable for delicate (fruit washing) and heavy-duty (сталь -депляция) tasks.
• Low Overspray: Fan-shaped profile minimizes off-target fluid loss—critical for hazardous chemicals (НАПРИМЕР., industrial solvents) and costly coatings (НАПРИМЕР., automotive paint). Overspray is typically <5% (против. Полный конус: 15–20%).
• Гибкость дизайна: Available in sizes (1/8″–4″), материалы (PTFE to ceramic), and pressure ratings (0.5–200 бар), adapting to diverse industries.
• Простота интеграции: Multiple mounting options (резьба, flange, quick-disconnect) enable retrofitting into existing systems.

Ограничения

• Риск засорения: Narrow orifices (≤0.5mm) and V-grooves are prone to clogging with particulates (>10 мкм) or viscous fluids (>1,000 сн).
  Смягчение: Inline filters (5–10 мкм) and regular cleaning.
• Sensitivity to Orifice Damage: Scratches or dents (even 0.02mm deep) distort the spray pattern, reducing UC by 20–30%. Смягчение: Handle nozzles with care; use protective caps during storage.
• Limited High-Viscosity Performance: Жидкость >5,000 сн (НАПРИМЕР., heavy oils) struggle to form a uniform sheet, leading to uneven spray.
  Смягчение: Heat the fluid (reduces viscosity) or use air-assisted variants.
• Distance Dependence: Spray angle and coverage width change with distance—requires precise nozzle positioning (НАПРИМЕР., 2m distance for 90° nozzles to avoid gaps).

8. Industry Applications of Flat Fan Nozzles

Flat fan nozzles are versatile and precise fluid atomization devices used across a wide range of industries.

Металлы & Снижение

• Приложение: Сталь, алюминий, and other metal surfaces require high-pressure water or slurry sprays to remove scale, ржавчина, or debris.
• Technical Advantage: Flat fan nozzles provide равномерное покрытие, allowing consistent descaling without localized over-erosion.
• Operating Parameters: Pressures often range 50–200 бар, with droplet sizes from 50–150 мкм for efficient material removal.
• Пример: Stainless steel pickling or hot-rolled steel descaling lines use ceramic or hardened stainless steel flat fan nozzles to withstand abrasive slurry.

Cleaning and CIP (Clean-In-Place)

• Приложение: Еда, напиток, and pharmaceutical industries rely on precise cleaning of tanks, трубопровод, и конвейеры.
• Technical Advantage: Flat fan nozzles deliver controlled spray angles (60° –120 °) and uniform droplet distribution, ensuring complete surface coverage while minimizing water or chemical consumption.
• Материалы: 316L stainless steel or PTFE inserts are commonly used for chemical resistance and sanitary compliance.
• Пример: CIP systems in dairy processing lines use flat fan spray nozzles to clean stainless steel vats without disassembly.

Покрытие & Поверхностная обработка

• Приложение: Spraying paints, покрытия, клеи, or lubricants on industrial products, Автомобильные компоненты, и электроника.
• Technical Advantage: Flat fan nozzles produce narrow, uniform spray sheets, enabling precise coating thickness control and reduced overspray.
• Operating Parameters: Low to medium pressures (1–20 бар) with fine droplet sizes (20–100 мкм).
• Пример: Automotive painting lines use V-groove stainless steel or sectorial deflector nozzles for consistent primer and topcoat application.

Охлаждение & Гашение

• Приложение: Rapid cooling of metals, стекло, пластмассы, and food products.
• Technical Advantage: Wide-angle flat fan sprays provide uniform surface cooling, reducing thermal gradients and minimizing stress or warping.
• Operating Parameters: Pressures 2–50 bar; droplet size 100–500 μm for effective heat transfer.
• Пример: Continuous casting lines for steel use flat fan nozzles to cool slabs evenly, preventing cracks and deformation.

Подавление пыли

• Приложение: Добыча, строительство, цемент, and bulk material handling facilities.
• Technical Advantage: Flat fan sprays create uniform mist sheets to capture airborne dust without excessive water usage.
• Operating Parameters: От низкого до среднего давления (1–20 бар) with fine droplets (50–200 мкм) для maximum dust capture efficiency.
• Пример: Cement plants employ flat fan nozzles over conveyor belts and storage piles to reduce particulate emissions.

Сельское хозяйство

• Приложение: Пестицид, Гербицид, and fertilizer spraying.
• Technical Advantage: Flat fan nozzles allow uniform coverage across leaves and crops, reduce chemical waste, and limit drift.
• Материалы: Латунь, нержавеющая сталь, or ceramic inserts depending on химическая совместимость.
• Operating Parameters: Pressures 1–5 bar; spray angles 60°–110°; droplet size 200–500 μm.
• Пример: Boom sprayers for row crops use ceramic flat fan spray nozzles поддерживать consistent application rates.

Car Wash & Чистка поверхности

• Приложение: Automated car wash systems and industrial equipment washing.
• Technical Advantage: Flat fan nozzles provide even detergent distribution and water coverage, improving cleaning efficiency while minimizing streaks.
• Operating Parameters: Pressures 2–10 bar; wide-angle sprays for surface coverage.

Электроника & Precision Applications

• Приложение: Охлаждение, уборка, or coating delicate electronic components.
• Technical Advantage: Micro flat fan nozzles spray with narrow slot or V-groove designs allow controlled droplet size (20–50 мкм) and minimal overspray, critical for sensitive assemblies.
• Пример: Printed circuit board (Печатная плата) cleaning lines employ PTFE or stainless steel micro-nozzles to ensure uniform coverage without damaging components.

9. Comparison with Other Types of Nozzles

Highlights / Insights:

• Плоские вентиляционные сопла Excel In uniform surface coverage and controllable fan width, сделать их идеальными для industrial cleaning, покрытие, and agricultural applications.
• Полые конусные сопла are suited for targeted sprays or processes requiring minimal fluid usage.
• Полные конусные сопла предложение high-volume coverage but less precision for linear surfaces.
• Air atomizing nozzles предоставлять ultra-fine droplet control but are sensitive to clogging and have lower flow rates.

10. Заключение

А flat fan nozzle is a versatile and indispensable spray technology, bridging the gap between high-impact cleaning and broad, равномерное покрытие.

Its reliability, adaptability to materials, and range of configurations make it the core component of industrial spray systems worldwide.

Proper nozzle selection—considering spray angle, поток, материал, and system design—can reduce water and chemical consumption by 10–30%, improve product quality, and extend equipment life.

Часто задаваемые вопросы

How often should flat fan nozzles be replaced?

Inspect quarterly; replace when flow deviates by ±10% or spray angle shifts noticeably. Typical service life: 1–3 years (нержавеющая ставка), 5–10 лет (керамика).

Why use ceramic nozzles for steel descaling?

Ceramics resist erosion, maintaining consistent spray angle and flow even at 100–300 бар with abrasive scale.

How do I choose the right spray angle for my application?

Select based on target distance and coverage width, using the formula: Coverage Width (W.) = 2 × Distance (Дюймовый) × tan(θ/2). Например:

• 2m distance + 90° angle = 2m coverage width (ideal for conveyor belts);
• 5m distance + 170° angle = 11.4m coverage width (ideal for dust suppression).
  Narrow angles (15°–30°) are for precision tasks; wide angles (120° –170 °) for large surfaces.

What material should I use for corrosive fluids (НАПРИМЕР., 20% соляная кислота)?

PTFE or PVDF. PTFE resists all acids (включая 98% серная кислота) up to 260°C, while PVDF offers better abrasion resistance for fluids with minor particulates.

316L SS will corrode in >10% HCl within 6 месяцы, so avoid it for strong acids.