Плоска насадка вентилятора | Виробник насадки з точним литтям

Вступ

In modern industrial processes, precision liquid distribution is critical for efficiency, Якість продукції, and resource conservation.

Among various spray technologies, з 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 сталевий скид, cleaning-in-place (CIP), сільське господарство, охолодження, і покриття, flat fan nozzles represent the precision core of many spray systems.

This article provides a comprehensive, data-driven perspective on their design, виконання, матеріали, заявки, and comparative advantages.

1. What Is a Flat Fan Nozzle?

A 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 форсунки that distribute fluid volumetrically, flat fan nozzles concentrate discharge into a thin sheet, забезпечення controlled surface contact, uniform line coverage, and reduced overspray.

Four primary parameters characterize them:

• Кут розпилення: 15° –170 °
• Витрата: 0.1–100 л/хв
• Робочий тиск: 0.5–200 бар
• Розмір крапельки (SMD): 20–1,000 μm

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

Принцип роботи

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, ламінарний потік (Reynolds Number Re = 2,000–10,000) before reaching the spray-forming element—critical for uniform sheet formation.
• Формування аркушів: Fluid passes through a V-groove, sectorial deflector, or slot-like orifice, which reshapes it into a thin, flat sheet (товщина: 5–50 мкм).
  Наприклад, 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, розпилення рівномірності, Опір засмічення, 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.
  Наприклад, 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, кут: 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 (Напр., TeeJet XR series, 80° V-groove).
• Sectorial Deflector: A flat metal/ceramic plate (товщина: 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:висота) = 5:1 до 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 (Напр., 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

• Кут розпилення (то): Визначає ширину покриття. Приклад: В 300 mm standoff, a 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.
• Розмір крапельки (Середній діаметр Sauter, SMD): Hydraulic flat fans produce 100–600 мкм droplets; air-assisted variants can reach 50–200 мкм.
• Рівномірність: 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 резистентність до корозії, ерозія, тиск, і температура, ultimately defining its service life and total cost of ownership.

Comparative Material Selection Table

5. Типи & Variants of Flat Fan Nozzle

Flat fan nozzles are highly versatile, з геометрія, internal design, and material construction tailored to control кут розпилення, Розмір крапельки, вплив, 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.

  

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

Even-Flat (Extended-Flat) Форсунки

• 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.

  

• Заявки: Precision agricultural spraying, chemical coating, and automated CIP (Чисто) системи.

Narrow-Angle Flat Fan Nozzles

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

  

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

Wide-Angle Flat Fan Nozzles

• Spray angles 130° –170 °, optimized for низький тиск, broad coverage.
• Useful for Придушення пилу, зрошення, 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

• Включати internal check valves or precision seat designs to prevent post-spray fluid leakage.
• Critical in applications requiring exact dosing, наприклад сільське господарство, фармацевтичні препарати, і хімічне обприскування.

Повітряний / Air-Atomizing Flat Fan Nozzles

• Compressed air mixes with liquid at the nozzle tip, посилення primary and secondary atomization.
• Виробляти fine droplets (Sauter Mean Diameter 20–100 μm) at moderate pressures, extending coverage and improving uniformity.
• Заявки: 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 використовується в electronics cleaning, PCB coating, or micro-fabrication processes.
• Require filtered fluids to prevent clogging; precise CNC machining ensures consistent sheet quality.

Високий тиск / Abrasion-Resistant Nozzles

• Constructed with hardened stainless steel, дуплексні сплави, or ceramic inserts.
• Designed to handle абразивні суспензії, сталевий скид, and high-pressure cleaning (>100 бар).
• Internal geometries may incorporate tapered inlet cavities and reinforced deflectors to extend lifespan.

Регульований / Interchangeable Nozzles

• Дозволяти field adjustment of spray angle, витрата, 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 МІТЕМЕНТАЦІЯ, Розширене виробництво, and rigorous quality control.

Each stage—from raw material selection to final testing—directly impacts розпилення рівномірності, droplet size control, довговічність, and chemical/abrasive resistance, making it critical for applications ranging from сталевий скид до precision coating and food processing.

Material Selection and Preparation

Material choice governs Корозійна стійкість, wear tolerance, механічна міцність, і термічна стабільність:

• Інвестиційне кастинг

• • Виробляти near-net shape components with complex internal geometries, such as inlet cavities, deflector mounts, and orifice supports.
  • Minimizes залишкові напруги, reducing post-machining operations and improving structural stability under high pressure.
  • Зазвичай використовується для нержавіюча сталь (316Л, 17-4 РН), дуплексні сплави, Монель, and Hastelloy, which are widely applied in chemical, нафтохімічний, and high-pressure cleaning industries.

• Точність кування

• • Посилює механічні властивості including tensile strength, втома, і ударна в'язкість, 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 термічна обробка (solution annealing or precipitation hardening) Для оптимізації corrosion resistance and hardness.

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

• • Ceramic Powder Processing:

• • • High-purity powders are pressed under controlled pressure і 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.
    • Заявки: abrasive slurry descaling, видобуток, and high-pressure cleaning.

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

Core Machining & Precision Fabrication

• ЧПУ фрезерування & Обертання: Створює V-grooves, sectorial deflectors, and slot orifices with tolerances ±0.01 mm to ensure consistent spray angle and droplet size.
• Електрична обробка розряду (EDM): Дозволяє precision orifices in hardened alloys or ceramics where conventional cutting fails.
• Laser Micromachining: Використовується для micro-scale applications, such as electronics or laboratory nozzles, producing slot widths <0.2 мм.
• Полірування & Дешевий: Internal channels are polished to reduce turbulence, prevent debris accumulation, and stabilize sheet breakup.

Поверхневі обробки та покриття

• Пасивація: Enhances corrosion resistance of stainless steel by forming a protective chromium oxide layer.
• Hard Coatings: Карбід вольфраму, chromium carbide, or ceramic coatings improve стійкість до стирання in high-velocity or slurry environments.
• Електропалізація: 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, Товщина листа, and droplet uniformity.
• Mechanical Tolerances: Deviations as small as 0.05 мм може призвести до asymmetric sprays or uneven coverage.
• High-Pressure Seals: Industrial nozzles (>100 бар) вимагати metallic or high-grade elastomer seals resistant to temperature and chemical attack.

7. Переваги та обмеження

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

Переваги

• Рівномірне покриття: UC = 80–100% (проти. full-cone nozzles: 60–75%), reducing fluid waste by 10–15%.
  Наприклад, 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 (сталевий скид) tasks.
• Low Overspray: Fan-shaped profile minimizes off-target fluid loss—critical for hazardous chemicals (Напр., industrial solvents) and costly coatings (Напр., automotive paint). Overspray is typically <5% (проти. повноцінний: 15–20%).
• Гнучкість дизайну: Available in sizes (1/8″–4″), матеріали (PTFE to ceramic), and pressure ratings (0.5–200 бар), adapting to diverse industries.
• Простота інтеграції: Multiple mounting options (різьблений, flange, quick-disconnect) enable retrofitting into existing systems.

Обмеження

• Ризик засмічення: Narrow orifices (≤0.5mm) and V-grooves are prone to clogging with particulates (>10 мкм) or viscous fluids (>1,000 cp).
  Пом'якшення: 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%. Пом'якшення: Handle nozzles with care; use protective caps during storage.
• Limited High-Viscosity Performance: Рідина >5,000 cp (Напр., heavy oils) struggle to form a uniform sheet, leading to uneven spray.
  Пом'якшення: Heat the fluid (reduces viscosity) or use air-assisted variants.
• Distance Dependence: Spray angle and coverage width change with distance—requires precise nozzle positioning (Напр., 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.

метали & Пониження

• Застосування: Сталь, алюміній, and other metal surfaces require high-pressure water or slurry sprays to remove scale, іржавий, or debris.
• Technical Advantage: Flat fan nozzles provide рівномірне покриття, 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.
• Приклад: 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 (Чисто)

• Застосування: Їжа, напій, and pharmaceutical industries rely on precise cleaning of tanks, трубопровід, і конвеєри.
• 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.
• Матеріали: 316L stainless steel or PTFE inserts are commonly used for chemical resistance and sanitary compliance.
• Приклад: CIP systems in dairy processing lines use flat fan spray nozzles to clean stainless steel vats without disassembly.

Покриття & Поверхнева обробка

• Застосування: Spraying paints, покриття, клеї, or lubricants on industrial products, Автомобільні компоненти, та електроніка.
• 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).
• Приклад: Automotive painting lines use V-groove stainless steel or sectorial deflector nozzles for consistent primer and topcoat application.

Охолодження & Гасіння

• Застосування: Rapid cooling of metals, скляний, пластмаси, 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.
• Приклад: Continuous casting lines for steel use flat fan nozzles to cool slabs evenly, preventing cracks and deformation.

Придушення пилу

• Застосування: Видобуток, будівництво, цементувати, and bulk material handling facilities.
• Technical Advantage: Flat fan sprays create uniform mist sheets to capture airborne dust without excessive water usage.
• Operating Parameters: Низький до середнього тиску (1–20 бар) with fine droplets (50–200 мкм) для maximum dust capture efficiency.
• Приклад: Cement plants employ flat fan nozzles over conveyor belts and storage piles to reduce particulate emissions.

Сільське господарство

• Застосування: Пестицид, гербіцид, and fertilizer spraying.
• Technical Advantage: Flat fan nozzles allow uniform coverage across leaves and crops, reduce chemical waste, and limit drift.
• Матеріали: Латунь, нержавіюча сталь, or ceramic inserts depending on хімічна сумісність.
• Operating Parameters: Pressures 1–5 bar; spray angles 60°–110°; droplet size 200–500 μm.
• Приклад: Boom sprayers for row crops use ceramic flat fan spray nozzles підтримувати consistent application rates.

Car Wash & Очищення поверхні

• Застосування: 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.

Електроніка & Precision Applications

• Застосування: Охолодження, прибирання, 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.
• Приклад: Printed circuit board (Друкована 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:

• Плоскі форсунки вентилятора вдарити uniform surface coverage and controllable fan width, що робить їх ідеальними для industrial cleaning, покриття, and agricultural applications.
• Порожні конусні форсунки are suited for targeted sprays or processes requiring minimal fluid usage.
• Повні конусні форсунки пропозиція high-volume coverage but less precision for linear surfaces.
• Air atomizing nozzles надати ultra-fine droplet control but are sensitive to clogging and have lower flow rates.

10. Висновок

З flat fan nozzle is a versatile and indispensable spray technology, bridging the gap between high-impact cleaning and broad, рівномірне покриття.

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, протікати, матеріал, and system design—can reduce water and chemical consumption by 10–30%, improve product quality, and extend equipment life.

Поширені запитання

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 (нержавіючий), 5–10 років (керамічний).

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 (Ш) = 2 × Distance (Р.) × tan(θ/2). Наприклад:

• 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 (Напр., 20% соляна кислота)?

PTFE or PVDF. PTFE resists all acids (включаючи 98% сірчана 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 місяці, so avoid it for strong acids.