U.S. patent application number 17/402868 was filed with the patent office on 2021-12-02 for clog resistant in-line vortex element irrigation emitter.
The applicant listed for this patent is DLHBOWLES, INC.. Invention is credited to Shridhar Gopalan, Benjamin D. Hasday, Gregory A. Russell, Christopher F. South.
Application Number | 20210368700 17/402868 |
Document ID | / |
Family ID | 1000005779507 |
Filed Date | 2021-12-02 |
United States Patent
Application |
20210368700 |
Kind Code |
A1 |
Hasday; Benjamin D. ; et
al. |
December 2, 2021 |
CLOG RESISTANT IN-LINE VORTEX ELEMENT IRRIGATION EMITTER
Abstract
A clog resistant in-line vortex emitter and drip irrigation
assembly and method uses a double-sided circuit and a series of
vortex chambers of optimized dimensions to create a pressure drop
with large dimensions and good clog resistance. The vortex chamber
100 also allows for a lower exponent than traditional circuits.
This gives a pressure regulating property to the no-moving-parts
circuit. The vortex emitter allows for some pressure regulation
without sacrificing recyclability or requiring moving parts. The
vortex circuit of the present disclosure is optimized for an
emitter efficiency Ef value wherein Ef=(k/Ackt)*Amin such that k is
a unitless head loss coefficient, Ackt is the area of the circuit,
and Amin is the minimum cross sectional area of the circuit. A
higher k per a given area with larger dimensions allows for a
smaller part with a lower chance of clogging.
Inventors: |
Hasday; Benjamin D.;
(Baltimore, MD) ; Russell; Gregory A.;
(Catonsville, MD) ; Gopalan; Shridhar;
(Westminster, MD) ; South; Christopher F.;
(Washington D.C., DC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
DLHBOWLES, INC. |
Canton |
OH |
US |
|
|
Family ID: |
1000005779507 |
Appl. No.: |
17/402868 |
Filed: |
August 16, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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16001432 |
Jun 6, 2018 |
11116151 |
|
|
17402868 |
|
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|
62515973 |
Jun 6, 2017 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A01G 25/023
20130101 |
International
Class: |
A01G 25/02 20060101
A01G025/02 |
Claims
1. A vortex emitter assembly for an irrigation tube comprising: a
backing plate including an inlet portion to receive fluid from a
tube; a vortex circuit having a unitary body with a plurality of
vortex chambers defined along a first surface and a plurality of
vortex chambers defined along a second surface opposite the first
surface wherein each vortex chamber of the plurality of vortex
chambers includes an inlet region, a power nozzle, an interaction
region and a throat having dimensions to create a pressure drop of
fluid flow therein; a pressure compensating component defined
within the unitary body and in fluid communication with the vortex
circuit, the pressure compensating component including an exit
hole; and a support plate having an outlet wherein the backing
plate is attached to the first surface of the vortex circuit and
the support plate is attached to the second surface of said vortex
circuit such that the outlet of the support plate is in alignment
with the exit hole of the pressure compensating component; wherein
said vortex emitter assembly is configured to be attached to an
irrigation tube.
2. The vortex emitter assembly of claim 1, wherein at least one of
the vortex chambers includes a convergence angle that is defined by
a perimeter wall of said the vortex chamber that extends from an
apex of the power nozzle along the inlet region and an opposite
wall along the inlet region, wherein said convergence angle is
between about 45.degree. to about 80.degree. such that the inlet
region has a different shape than the interaction region.
3. The vortex emitter assembly of claim 1 wherein said power nozzle
includes a width Pw and a depth (Pd) wherein said power nozzle
width (Pw) includes a ratio with said power nozzle depth (Pd) that
is in the range of about 0.75:1 to about 1.25:1.
4. The vortex emitter assembly of claim 1 wherein said interaction
region includes a diameter (IRD) and the power nozzle includes a
width (Pw) wherein said interaction region diameter (IRD) includes
a ratio with said width (Pw) that is in the range of about 2:1 to
about 3:1.
5. The vortex emitter assembly of claim 4 wherein said ratio
between said interaction region diameter (IRD) and said width (Pw)
is about 2.15:1.
6. The vortex emitter assembly of claim 1, wherein said interaction
region includes a diameter (IRD) and the throat includes a diameter
(Td) wherein said interaction region diameter (IRD) includes a
ratio with said throat diameter (Td) that is in the range of about
1.49:1 to about 3.89:1.
7. The vortex emitter assembly of claim 6, wherein said ratio
between said interaction region diameter IRD and said throat
diameter Td is about 2.69:1.
8. The vortex emitter assembly of claim 1, further comprising a
filter component in fluid communication with the vortex
circuit.
9. The vortex emitter assembly of claim 1 wherein said vortex
emitter assembly is configured to be positioned along an inner
surface of a tube to distribute a desired amount of pressurized
fluid from the tube to the environment.
10. The vortex emitter assembly of claim 9 wherein a plurality of
vortex emitter assemblies are positioned along said inner surface
of said tube.
11. The vortex emitter assembly of claim 2, wherein said
convergence angle is about 55.degree..
12. The vortex emitter assembly of claim 1 wherein said power
nozzle includes a width (Pw) and a depth (Pd) wherein said width
(Pw) includes a ratio with said depth (Pd) that is about 1:1.
13. A vortex emitter assembly for an irrigation tube comprising: a
backing plate including an inlet portion to receive fluid from a
tube; a unitary body that includes a pressure compensating
component defined in the unitary body and a vortex circuit defined
in the unitary body, the vortex circuit having a with a plurality
of vortex chambers defined along a first surface and a plurality of
vortex chambers defined along a second surface opposite the first
surface wherein each vortex chamber of the plurality of vortex
chambers includes an inlet region, a power nozzle, an interaction
region and a throat having dimensions to create a pressure drop of
fluid flow therein; a pressure compensating component in fluid
communication with the vortex circuit, the pressure compensating
component including a diaphragm; and a support plate wherein the
backing plate is attached to the first surface of the unitary body
such that the inlet portion is aligned with the diaphragm and the
support plate is attached to the second surface of said unitary
body wherein said vortex emitter assembly is configured to be
attached to an irrigation tube.
14. The vortex emitter assembly of claim 13, wherein at least one
of the vortex chambers includes a convergence angle defined by a
perimeter wall of said vortex chamber that extends from an apex of
the power nozzle along the inlet region and an opposite wall along
the inlet region, wherein said convergence angle is between about
45.degree. to about 80.degree. such that the inlet region has a
different shape than the interaction region.
15. The vortex emitter assembly of claim 13 wherein the support
plate includes an outlet and the pressure compensating component
includes and exit hole such that the outlet of the support plate is
in alignment with the exit hole of the pressure compensating
component.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. Utility
application Ser. No. 16/001,432 entitled "CLOG RESISTANT IN-LINE
VORTEX ELEMENT IRRIGATION EMITTER," which claims priority to and
benefit of U.S. Provisional Application No. 62/515,973 entitled
"CLOG RESISTANT IN-LINE VORTEX ELEMENT IRRIGATION EMITTER," filed
on Jun. 6, 2017, each of which are hereby incorporated by reference
in their entireties.
FIELD OF THE DISCLOSURE
[0002] The present disclosure pertains generally to devices for use
as drip irrigation emitters. More particularly, the present
disclosure pertains to drip irrigation emitters that provide a
substantially constant drip flow-rate over a wide range of line
pressures. The present disclosure is particularly, but not
exclusively, useful as a self-cleaning, pressure compensating,
irrigation drip emitter optimized for assemblies having multiple
irrigation drip emitters mounted to a supply tube to form an
irrigation assembly or system.
BACKGROUND
[0003] Drip emitters are commonly used in irrigation systems to
convert water flowing through a supply tube at a relatively high
flow rate to a relatively low flow rate at the outlet of each
emitter. Each drip emitter generally includes a housing defining a
flow path that reduces high pressure water entering the drip
emitter into relatively low pressure water exiting the drip
emitter. Multiple drip emitters are commonly mounted on the inside
or outside of a water supply tube. In one type of system, a large
number of drip emitters are mounted at regular and predetermined
intervals along the length of the supply tube to distribute water
at precise points to surrounding land and vegetation. These
emitters may either be mounted internally (i.e., in-line emitters)
or externally (i.e., on-line or branch emitters). Some advantages
to in-line emitters are that the emitter units are less susceptible
to being knocked loose from the fluid carrying conduit and the
conduit can be buried underground if desired (i.e., subsurface
emitters) which further makes it difficult for the emitter to be
inadvertently damaged (e.g., by way of being hit or kicked by a
person, hit by a lawnmower or trimmer, etc.).
[0004] In addition to the advantages of in-line emitters,
subsurface drip emitters provide numerous advantages over drip
emitters located and installed above ground. First, they limit
water loss due to runoff and evaporation and thereby provide
significant savings in water consumption. Water may also be used
more economically by directing it at precise locations of the root
systems of plants or other desired subsurface locations. Second,
subsurface drip emitters provide convenience. They allow the user
to irrigate the surrounding terrain at any time of day or night
without restriction. For example, such emitters may be used to
water park or school grounds at any desired time. Drip emitters
located above ground, on the other hand, may be undesirable at
parks and school grounds during daytime hours when children or
other individuals are present. Third, subsurface emitters are not
easily vandalized, given their installation in a relatively
inaccessible location (i.e., underground). And fourth, the use of
subsurface drip emitters can prevent the distribution of water to
undesired terrain and the use of subsurface drip emitters prevents
undesirable "overspray." In contrast, above-ground emitters often
generate overspray that disturbs vehicles and/or pedestrians.
[0005] Although some advantages of subsurface emitters are
described above, it would be desirable to provide an improved
in-line drip emitter design that can be used in both subsurface and
above ground applications. For both applications, there is a need
to provide for a relatively constant water output from each of the
emitters in the irrigation system. More specifically, it is
desirable to provide pressure compensation so as to ensure that the
flow rate of the first emitter in the system is substantially the
same as the last emitter in the system. Without such flow rate
compensation, the last emitter in a series of emitters will
experience a greater pressure loss than the first. Such pressure
loss results in the inefficient and wasteful use of water.
[0006] Flow rate compensation has been offered in prior art drip
irrigation assemblies (such as U.S. Pat. No. 4,226,368 (Hunter))
which discloses an assembly with multiple chambers or circuits
providing interconnected vortices, but the flows are poorly
controlled and not optimized to generate the flows preferred for
many drip irrigation applications in that certain critical
dimensions cannot be adapted in a manner which allows for the
circuits to be scaled.
[0007] Traditional prior art drip emitters containing moving parts
and pressure compensating flexible membranes have one side of the
membrane exposed to irrigation line pressure, while the opposite
side of the membrane is exposed to a reduced pressure. For example,
the reduced pressure can be created by forcing a portion of the
water from the irrigation line through a restrictor or labyrinth.
This pressure differential on opposite sides of the membrane causes
the flexible membrane to deform. In particular, the higher line
pressure can be used to force the flexible membrane into a slot
where reduced pressure water is flowing. As the line pressure
increases, the membrane will be pressed further into the slot,
decreasing the effective cross-section of the slot and thus
restricting flow through the slot. As described further below, the
result is a relatively constant flow through the emitter over a
range of line pressures. Unfortunately, the slot is subject to
clogging in the same fashion as the simple orifice emitter.
Further, the membrane is required to form a seal with the edge of
the slot confining flow to the slot. Unfortunately, particulate
buildup may also interfere with the membrane seal causing
non-uniform flow.
[0008] One attempt to solve the problems associated with
particulate buildup in a pressure compensating emitter uses the
reduced-pressure water from the labyrinth to clean the slot and
sealing surfaces during initial pressurization of the irrigation
line. In particular, such an emitter is disclosed by Miller in U.S.
Pat. No. 5,628,462 which issued May 13, 1997, entitled "Drip
Irrigation Emitter," in which a chamber is created between the slot
and the membrane. For the emitter disclosed by Miller, during
initial pressurization of the irrigation line, while the membrane
is only slightly deformed, the chamber is flushed with
reduced-pressure water delivered from the restrictor or labyrinth.
As the line pressure increases, the membrane deforms, sealing off
the chamber from reduced pressure water, and restricting flow
through the slot. The above cited prior art references are useful
to set forth the nomenclature of drip emitter assemblies and
components, and so are incorporated by reference in their
entireties for that purpose and for enablement. The prior art drip
emitters are not as effective and economical as is desired and
there is a need for an economical, scalable, effective fluidic
equipped drip irrigation devices suitable for the purposes of
providing a constant drip flow in response to a varying line
pressure that reduces risk of clogging.
SUMMARY
[0009] Accordingly, it is an object of the present disclosure to
overcome the above mentioned difficulties by providing a clog
resistant in-line vortex element irrigation emitter or irrigation
dripper which is easy to use, relatively simple to manufacture, and
comparatively cost effective to install, and over its life cycle.
The vortex emitter structure of the present disclosure may be
designed to be injection molded as a component and then inserted
into an extruded tube as part of a drip irrigation system. The drip
irrigation assembly's tube may be placed in a farm field and fluid
may be pumped in. The emitters take the high pressure and flow
inside the tube and produce a desired flowrate (selectable
depending on the requirements of the environment, terrain or plant
being irrigated). The vortex emitter of the present disclosure has
a higher efficiency than traditional pivot or sprinkler systems.
The emitters not only provide the appropriate pressure attenuation;
they resist clogging from the grit and debris in available ground
water.
[0010] In accordance with the present disclosure, a newly developed
prototype clog resistant in-line vortex element irrigation emitter
gives a greater pressure attenuation for its physical dimensions
than comparable devices in the prior art (as described above). The
large dimensions and the vortex created in each chamber help flush
debris and grit through the system. The circuit of the present
disclosure is also optimized to take up the smallest space
possible. The smaller circuit package along with the natural coring
that occurs with the vortex circuit of the present disclosure saves
on circuit mass. This saves irrigation assembly cost, and allows
for parts to be used in thinner walled tubing as thinner wall
tubing requires a smaller mass to heat for bonding circuits.
[0011] The vortex circuit of the present disclosure includes
inherent pressure regulation and that pressure regulation may be
describe as an optimized exponent. The exponent of an optimized
vortex circuit of the present disclosure may be as low as 0.3
versus a standard (prior art) orifice which has an exponent of 0.5.
What this means for the flow is that as the pressure increases
along the inlet of the drip emitter, the flow only increases a
small amount at the outlet of the drip emitter. As noted above,
prior art drip emitters use gaskets as a pressure compensation
device in alignment with the tortuous drip emitter path. Pressure
compensation gives an exponent of 0 wherein any change in pressure,
the circuit does not increase in flow. The vortex circuit of the
present disclosure, without a pressure compensation device, does
not get to such a low exponent, but it makes up for this as it does
not require a rubber gasket. In the relevant range of irrigation
fluid pressures and flows, the 0.3 exponent may be sufficient to
prevent over-watering plants. The design of the present disclosure
does allow for the optional use of a pressure compensating device.
The instant disclosure does allow for a pressure compensation
device to be added, but for naturally flowing circuits with no
pressure compensation device, the low exponent of the vortex offers
a nice blend of flow control and cost in a non-pressure
compensation device part.
[0012] A filter component may be provided, such as a 3D filter, or
filter positioned along an assembly housing, which may be used with
the disclosed circuit to collect water from the bulk flow within
the irrigation tube or pipe. The clog-resistant inline vortex
emitter of the present disclosure may sits along or above the
bottom of the irrigation fluid tube or pipe which can see
significant settling of debris and grit. The position of the filter
may help remove grit through gravity. The vortex circuit may
include large dimensions for a given pressure drop per area of
circuit when compared with typical emitters. The large dimensions
and the vortex created in each chamber help clear grit and debris
from the system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The operation of the present disclosure may be better
understood by reference to the following detailed description taken
in connection with the following illustrations, wherein:
[0014] FIG. 1 is a top perspective view of an embodiment of a
vortex emitter insert member having a plurality of the vortex
emitter chambers in accordance with the present disclosure;
[0015] FIG. 2 is a top view of an embodiment of the vortex emitter
insert member having a plurality of the vortex emitter chambers in
accordance with FIG. 1;
[0016] FIG. 3 is a bottom view of an embodiment of the vortex
emitter insert member having a plurality of the vortex emitter
chambers in accordance with FIG. 1;
[0017] FIG. 4 is a side view of an embodiment of the vortex emitter
insert member having a plurality of the vortex emitter chambers in
accordance with FIG. 1;
[0018] FIG. 5 is an end view of an embodiment of the vortex emitter
insert member having a plurality of the vortex emitter chambers in
accordance with FIG. 1;
[0019] FIG. 6 is a top view, in elevation of a single vortex
emitter chamber of the present disclosure;
[0020] FIG. 7 is a side view, in elevation, of the vortex emitter
chamber of FIG. 1, in accordance with the present disclosure;
[0021] FIG. 8 is a perspective view of an embodiment of a vortex
emitter assembly in accordance with one embodiment of the present
disclosure;
[0022] FIG. 9 is a top view of an embodiment of the vortex emitter
assembly in accordance with one embodiment of the present
disclosure of FIG. 8;
[0023] FIG. 10 is a side view of an embodiment of the vortex
emitter assembly in accordance with one embodiment of the present
disclosure of FIG. 8;
[0024] FIG. 11 is an end view of an embodiment of the vortex
emitter assembly in accordance with one embodiment of the present
disclosure of FIG. 8;
[0025] FIG. 12 is a bottom view of an embodiment of the vortex
emitter assembly in accordance with one embodiment of the present
disclosure of FIG. 8;
[0026] FIG. 13 is an exploded view of an embodiment of the vortex
emitter assembly in accordance with one embodiment of the present
disclosure of FIG. 8;
[0027] FIG. 14 is a cross sectional view of an embodiment of the
vortex emitter assembly in accordance with one embodiment of the
present disclosure of FIG. 8;
[0028] FIG. 15 is a schematic view of an embodiment of the vortex
emitter assembly positioned within a pipe according to the present
disclosure;
[0029] FIG. 16 is a graph illustrating the average flowrate vs.
grit size tested for several competing emitter devices as well as
the disclosed emitter assembly;
[0030] FIG. 17 is a graph illustrating pressure (P) and flow rate
(Q) data for embodiments of the disclosed emitter assembly
including pressure compensating device; and
[0031] FIG. 18 is a graph illustrating exponent values of the
embodiments of the graph of FIG. 17.
DETAILED DESCRIPTION
[0032] Reference will now be made in detail to exemplary
embodiments, examples of which are illustrated in the accompanying
drawings. It is to be understood that other embodiments may be
utilized and structural and functional changes may be made.
Moreover, features of the various embodiments may be combined or
altered. As such, the following description is presented by way of
illustration only and should not limit in any way the various
alternatives and modifications that may be made to the illustrated
embodiments.
[0033] As used herein, the words "example" and "exemplary" mean an
instance, or illustration. The words "example" or "exemplary" do
not indicate a key or preferred aspect or embodiment. The word "or"
is intended to be inclusive rather an exclusive, unless context
suggests otherwise. As an example, the phrase "A employs B or C,"
includes any inclusive permutation (e.g., A employs B; A employs C;
or A employs both B and C). As another matter, the articles "a" and
"an" are generally intended to mean "one or more" unless context
suggest otherwise.
[0034] Similar reference numerals are used throughout the figures.
Therefore, in certain views, only selected elements are indicated
even though the features of the system or assembly may be identical
in all of the figures. In the same manner, while a particular
aspect of the disclosure is illustrated in these figures, other
aspects and arrangements are possible, as will be explained
below.
[0035] Provided is an embodiment of a clog resistant in-line vortex
irrigation emitter assembly 100 and its components parts. In one
embodiment, the vortex emitter assembly 100 includes a vortex
emitter circuit 110 wherein the assembly defines an inlet, an
outlet and a flow channel therebetween providing fluid
communication between the inlet and the outlet. An embodiment of
the vortex emitter assembly 100 is illustrated in FIGS. 8-15 and
may be configured to include a vortex emitter circuit 110 as
illustrated in FIGS. 1-5. The vortex emitter circuit 110 may be
defined to include a unitary body 120 with a double-sided surface
having a plurality of single or individual vortex chambers 130,
(further illustrated in FIGS. 6 and 7) with flow channel lumen
dimensions optimized to create a pressure drop with large lumen
dimensions and good clog resistance. The vortex circuit or vortex
emitter of the present disclosure may be optimized for a
dimensionless coefficient of emitter efficiency "Ef" wherein
"Ef=(k/Ackt)*Amin." In this equation, k is a unitless head loss
coefficient, Ackt is the total area of the circuit, and Amin is the
minimum cross sectional area of the circuit. This measurement
identifies if there is a relatively large head loss per unit area
of the emitter assembly while achieving relatively good clog
resistance to grit within the fluid.
[0036] The vortex emitter circuit 110 as illustrated by FIGS. 1-5
includes various sections including a filter component 210, a
pressure reducing component 220 and a pressure compensating
component 230. However, it should be appreciated that the emitter
assembly 100 may be operable with the pressure reducing component
220 and the remaining portions are illustrated as use in only one
optional embodiment of the present disclosure which is not limited
herein. The filter component 210 may be any structural
configuration that allows fluid to flow therethrough that may catch
debris or other particulate prior to flowing through the assembly
100 and the circuit 110. The filter component 210 may have various
structural configurations and may function to allow fluid to pass
through an inlet of the assembly 100 while preventing relatively
large grit or particulates located within the pressurized fluid
flowing though the tube from entering the assembly 100. The
pressure compensating component 230 may be a moveable device that
modifies the pressure and flow of fluid through the assembly 100 in
a particular manner in an effort to manage pressure of fluid flow
therein. The pressure compensating component 230 may include a
gasket or diaphragm 235 and its operation will be disclosed more
fully herein.
[0037] The vortex emitter circuit 110 particularly includes a
pressure reducing component 220 that includes a plurality of vortex
chambers 130. Each vortex chambers 130 may defined by a wall 132
defining a fluid passageway and be aligned in an interconnecting
pattern along a first surface 112 of the vortex emitter circuit 110
as well as a second opposite surface 114 of the vortex emitter
circuit 110. As illustrated by FIG. 6, each vortex chamber 130
includes an inlet region 140, a power nozzle 150, and an
interaction region 160 with an outlet 170. The inlet region 140 may
include an inlet orifice 180 that is in communication with a
different vortex chamber 130 aligned in series within the circuit
110. The outlet may be in communication with a different vortex
chamber 130 aligned in series within the circuit 110. The inlet
region 140 may be rounded about the inlet orifice 180 (if present)
and be in fluid communication with the interaction region 160
through the power nozzle 150.
[0038] The vortex chamber 130', of a plurality of vortex chambers
130, aligned in direct communication with an assembly outlet or a
pressure compensating component 230 may not include an outlet 170
positioned through the unitary body 120 of the circuit 110 but
otherwise may include a passage 134 in direct communication with
the pressure compensating component 230 or assembly outlet (see
FIG. 3). Similarly, if the vortex chamber 130'' is in communication
with an assembly inlet (such as a pressure compensating component
230 or filter component 210) , the inlet region 140 may not include
an inlet orifice 180 but otherwise include a passage 136 in direct
communication with the pressure compensating component 230 or
filter component 210.
[0039] A convergence angle CA may be measured from an apex 152
aligned along the wall 132 about the perimeter of the vortex
chamber 130 at the power nozzle 150. The convergence angle CA
includes a first side that extends from the wall 132 at the apex
152 along the inlet region 140 and a second side that extends from
the wall 132 at an opposite side of the apex 152 along a generally
straight line aligned with the inlet region 140, power nozzle 150
and interaction region 160 as illustrated by FIG. 6. The convergent
angle CA may be a minimum angle of 45.degree. but may be up to
about 80.degree.. In one embodiment, the convergent angle CA may be
about 55.degree.. If the convergence angle CA is too small and the
pressure drop decreases while the area increases, this may decrease
the emitter efficiency Ef value. If the convergent angle CA exceeds
80.degree., the flow conditioning may be such that the vorticity is
reduced thereby reducing k more than Ackt, resulting in lower Ef
values.
[0040] Further, the convergence angle CA may be modified to change
the overall length of each vortex chamber 130. When arranging a
plurality of vortex chambers 130 together in series, the
convergence angle CA may be configured to allow for the closest
possible spacing that manufacturing processes may allow. These
processes may include molding but may also include others such as
additive manufacturing or the like. The desired placement of vortex
chambers 130 in an efficient use of space along the surfaces 112,
114 may increase the emitter efficiency Ef value of the assembly
100.
[0041] The power nozzle 150 may include a width Pw and a radius Pr.
The dimension of the power nozzle radius Pr is desirable to be
smaller to maintain a high velocity of fluid flow through the power
nozzle 150. In one embodiment, this dimension may be as small as
manufacturing constraints permit, such as between about 0.05 mm to
about 0.3 mm or, in one embodiment, 0.07 mm. The power nozzle width
Pw may be a minimum of 0.8 mm to avoid clogging. The configuration
of the vortex chambers 130 may depend on the dimensions of the
power nozzle 150 and incorporate ratios relative to the power
nozzle width Pw. The outlet 170 (as well as the inlet 180) may
include a throat diameter Td wherein the throat diameter Td may be
at least 0.8 mm, but it is desired not to be much larger as
otherwise vorticity may be reduced. The interaction region 160
includes an interaction region diameter IRD. In one embodiment the
ratio of the throat diameter Td to the power nozzle width Pw may be
about 1:1 additionally, the minimum interaction region diameter IRD
to power nozzle width Pw ratio may be about 2:1 and the minimum
interaction region diameter IRD to throat diameter Td ratio may
also be about 2:1. In one embodiment, the interaction region
diameter IRD to throat diameter Td ratio may be about 2.69:1 and
include a range of 2.69 +/-1.2 to 1.
[0042] The interaction region diameter IRD may be designed to be
small enough that the area is reduced, but large enough the circuit
130 and fluid flowing therein creates a vortex in the interaction
region 160. In one embodiment, the ratio for the dimension of the
interaction region diameter IRD relative to the power nozzle width
Pw is about 2.15:1 IRD:Pw. The range of this ratio may be 2.15 from
about minus 0.15 to about plus 0.85 to 1.
[0043] The inlet region 140 may include an exit diameter ED. The
exit diameter ED may be the same size as the interaction region
diameter IRD. It may cause a small pressure drop as the flow goes
from the inlet to the expanded area within the inlet region 140. A
large exit diameter ED may allow the vortex chamber 130 to include
a large convergence angle CA going into the subsequent vortex
chamber 130 which may assist to keep the flow conditioning going
into the vortex chambers 130.
[0044] FIG. 7 illustrates a side view, in elevation, of the vortex
emitter chamber 130 of FIG. 6, in accordance with the present
disclosure. The power nozzle 150 includes a depth Pd that extends
from a surface 132 of the circuit to a floor 134 of the circuit
110. In one embodiment, the circuit 110 may adopt the depth Pd of
the power nozzle 150 to be about equal to the depth of the other
component parts including the interaction region 160 and the inlet
region 140. This configuration may provide a smooth transition of
fluid flow from power nozzle 150 to interaction region 160.
However, the depth of each component part may be varied and this
disclosure is not limited in this regard. In one embodiment, the
power nozzle depth Pd may also be equal to the power nozzle width
Pw. The ratio of the power nozzle width Pw to the power nozzle
depth Pd may be about 1:1 but may be in the range of 1+/-0.25 to 1.
The power nozzle 150 may include a cross sectional shape formed
into a square which may provide preferred flow conditioning into
the interaction region 160 and may provide a preferred minimum
dimension for the area of the power nozzle 150. Also illustrated is
a throat length TL that extends from the floor 134 of the vortex
chamber 130 to an opposing side of the circuit 110 which may be
connected to another vortex chamber 130 positioned along the second
side 114 of the circuit 110 described herein or may be a further
pattern to allow for the fluid flow to communicate with either a
filter component 210, a pressure compensating component 230 or an
outlet/nozzle to spray fluid to environment.
[0045] The vortex emitter assembly 100 of the present disclosure
works by taking the flow of fluid and passing it through a
converging passage defined by a series of vortex chambers 130
aligned in series along either side of the circuit 110. This
configuration has been found to increase the velocity of the flow
and condition it to produce a better spin or vorticity. It has been
found that the larger the power nozzle's initial linear velocity,
the larger the interaction regions rotational or angular velocity.
The larger the angular velocity, the larger the head loss Kl. This
loss is due to the dissipation of kinetic energy by shear stress
occurring between layers of rotating fluid. The dimensions of the
convergence angle CA, the power nozzle width PW, the interaction
region diameter IRD and the throat diameter Td have been identified
to optimize pressure drop through the circuit 100. A series of
design experiments were conducted to identify the optimal values
and ratios of these dimensions wherein the ratios were identified
to maintain optimal emitter efficiency Ef.
[0046] The more efficient the circuit can turn linear flow in to
rotational flow, the larger the pressure drop. The convergence
angle CA should be somewhere between 45.degree. to 70.degree. or
80.degree.. Between these angles, the k value used to calculate the
emitter efficiency Ef does not change a great deal. The spatial
efficiency of the circuit, the aim of the flow, and conditioning
are all affected by the convergence angle CA. The convergence angle
CA and interaction region diameter IRD may affect the overall
circuit length as it may be desirable to place a plurality of
vortex chambers 130 along a surface of the circuit 110 in close
proximity to one another. In one embodiment, it may be desirable to
fit the largest number of vortex chambers 130 allowable on the
circuit 110. In this embodiment, the convergence angle CA may be
sufficiently large enough that the total length of the vortex
chamber 130 is short. The spacing between chambers 130 may be set
by the length of each chamber 130 so the angle may be as large as
possible without placing the chambers 130 too close to each
other.
[0047] The convergence angle CA may be large enough so that the aim
and conditioning are such that the highest pressure attenuation for
the package size may be achieved. Small angles (below 45.degree.)
and large angles (80.degree.) may reduce the pressure attenuation
of the circuit. Small angles may not aim the flow enough towards
the wall of the vortex chamber 130 and away from the power nozzle
150 and throat 170. Small angles also may have a much larger
footprint decreasing the emitter efficiency Ef value. Large angled
may slow the flow down and force it too much to the outside and the
vortex may not be as powerful.
[0048] The inlet region 140 may converge towards the power nozzle
150 along the chamber walls 132 defined by the convergence angle
CA. The power nozzle 150 may have the same depth as width (Pw=Pd).
A square power nozzle may provide the largest minimum dimension for
the area, and has better flow conditioning. A power nozzle width Pw
that is larger makes it harder to avoid losing vorticity as the
flow may be directed straight into the throat. A power nozzle width
Pw that is smaller may affect the flow conditioning going into the
chamber 130, reducing its efficiency. In one embodiment, the power
nozzle 150 may have no straight length to it. Having a large
convergence angle CA may allow for a corresponding large region on
the exit of the throat 170. The sudden expansion may have a small,
but not insignificant pressure drop. One wall of the converging
angle CA meets with the interaction region 160 tangentially at the
power nozzle 150. The other side of the power nozzle 150 is a round
apex 152 where the convergent angle CA and the interaction region
160 meet. This round portion or apex 152 may be as small as
manufacturing processes constraints such as molding or additive
manufacturing may allow as a small apex 152 may provide a higher
velocity and give improved system performance.
[0049] The inlet region 140 may be considered a converging passage
that communicates with the interaction region 160 which may be a
circular chamber with a hole or throat 170 in the center. The
converging passage aims the flow of the circuit 130 mostly
tangentially with some aim towards the wall 132 to create a vortex
in the interaction region 160 that creates pressure attenuation by
dissipating energy through the angular momentum of the vortex flow
created by the geometry of the chamber walls 132. This
configuration may also be responsible for the pressure regulation.
As the pressure increases, the loss of pressure due to the angular
momentum increases and reduces the measured exponent of the circuit
110. The interaction region diameter IRD to power nozzle width Pw
may be about 2:1 to 3:1 but more specifically may be about
2.15:1.
[0050] If the interaction region diameter IRD were smaller than
about (2:1) the vorticity may be lost, and a larger ratio than
about (3:1) may make the area increase at a faster rate than the
pressure drop. The small circuit size may be space efficient and
allow a larger number of vortex chambers 130 to be configured in a
small package. The throat 170 may be a minimum dimension of 0.8 mm
in diameter to avoid clogging. It may be small enough that the flow
doesn't directly enter the throat 170 lowering the vorticity of the
circuit 110.
[0051] The vortex assembly 100 may include the circuit 110 and
additional components to sufficiently communicate pressurized fluid
from a tube 300 through the vortex emitter assembly 100 and to
spray fluid at a desired rate to the environment. FIGS. 8-15
illustrate the vortex emitter assembly 100 that includes the
described vortex circuit 110. In one embodiment, the circuit 110 is
attached to a backing plate 250 along a fluid facing side within
the tube 300 and a support place 260 along the opposite side of the
circuit 110 to support the vortex emitter assembly 100 along an
inner surface 302 of the tube 300.
[0052] The backing place 250 may be attached to the circuit 110
with a plurality of fasteners that may extend through bore holes
252 and establish the fluid passages defined by the vortex chambers
130 in the circuit 110. In one embodiment, the filter component 210
may be a three dimensional configuration that may protrude from the
circuit 110 and be exposed to interior of the tube 300 (as
illustrated by FIG. 1). Here the filter component 210 may be in
direct communication with the pressure compensating component 230
and subsequently, the pressure reducing component 220 (i.e. the
plurality of vortex chambers 130). Alternatively, the filter
component 210 may be positioned along the support plate 250 as
illustrated by FIGS. 8-15. The filter component 210 may allow for
fluid communication with the circuit 110 from fluid that flows
through the tube 300. The filter component 210 may be in fluid
communication with an inlet portion along the support place 250 to
communicate with the circuit and plurality of vortex chambers 130.
A protruding 3D filter component may keep the fluid entrance to the
circuit towards the interior of the pipe and away from a level at
which grit and debris settle when the system is not running. The
filter component 210 may protrudes through the backing plate 250 in
this configuration (not shown) or may be positioned along the
backing plate 250 towards the bulk flow region that has a higher
velocity flow than at the edges of the tube 300. This helps prevent
debris from entering the system.
[0053] In operation, fluid may flow through the assembly 100 from
an assembly inlet at the filter component 210, the pressure
reducing element 220 and the pressure compensating device 230 prior
to being sprayed from the outlet 270 to the environment. FIG. 14
illustrates one example of the operation of the instant application
wherein arrows identify the flow of fluid through the assembly 100.
Fluid may first enter through the filter component 210 to remove
debris or grit from the fluid. The fluid may then flow to abut
against the fluid facing side (top) of the diaphragm 235 of the
pressure compensating component 230. The fluid then enters the
pressure reducing component 220 that comprises the series of vortex
chambers 130 aligned along the first side 112 and second side 114
of the circuit 110. The flow may travel through the inlets 180 and
throats 170 of the plurality of vortex chambers 130 through the
inlet regions 140, power nozzles 150 and interaction regions 160
therein creating vorticity flow and reducing fluid pressure by
providing some head loss k. Once through the plurality of vortex
chambers 130 the flow may enter into the pressure compensating
component 230 at an opposite (bottom) side of the diaphragm 235.
The pressure compensating component 230 may provide a pressure
difference that results in the deformation of the diaphragm to form
a small opening between the deformed diaphragm and an exit hole 238
which is designed to supply a remainder of the head loss to achieve
a desired flow rate. The flow may then be distributed through the
outlet 270 to environment.
[0054] The performance of the disclosed assembly has been optimized
based on the coefficient of emitter efficiency Ef. This parameter
is maximized by geometry which produces a large head loss Kl
despite having a large minimum flow area Amin and a small total
area Ackt. The vortex chambers 130 function by accelerating fluid
through its passage defined by the convergence angle CA, leading to
a minimum cross-sectional area referred to as the power nozzle 150.
The linear velocity of the fluid exiting the power nozzle 150 is
forced to rotate within the circular interaction region 160 before
exiting through a concentrically located circular throat 170 and
then entering into a subsequent inlet region 140 of the next vortex
chamber 130.
[0055] In one embodiment, as illustrated by FIGS. 2, 3, and 14, the
circuit 110 may include a portion of the pressure compensating
component 230 defined within the unitary body 120 and in
communication with the plurality of vortex chambers 130. The
pressure compensating component 230 may include a recessed area 232
with a shoulder 236 for receiving the diaphragm 235. The diaphragm
235 may separate the recessed area 232 into a first zone 330 in
communication with the first side 112 of the circuit 110 and a
second zone 332 in communication with the second side 114 of the
circuit 110. A base surface 334 may exist along the second zone 332
and include a plurality of radially positioned apertures 236 that
are spaced from an exit hole 238 that is aligned with the outlet
270. Here, the outlet 270 may be defined in the support plate 260
and the support plate 260 may be attached to the opposite side of
the circuit 110 than the backing plate 250. The diaphragm 235 may
deflect towards the exit hole 238 within the second zone 332 of the
recessed area 232 during operation and may throttle the flow of
fluid and pressure level as fluid egress through the exit hole 238.
The exit hole 238 may be positioned within a pedestal 336 on the
base surface 334 within the second zone 332 and a channel or weir
338 may be defined within the pedestal 336 to allow fluid
communication between the second zone 332 and the exit hole 238.
This may assist with pressure and fluid flow regulation when the
diaphragm 235 has been deflected to abut against the exit hole 238.
This configuration may allow for the proper function and regulation
of fluid flow and pressure through the assembly 100 and provide an
exponent value of about 0.
[0056] The plurality of radially positioned apertures 236 may allow
for fluid to flow within the second zone 332 between the bottom
side of the diaphragm 235 and the support plate 260 to allow fluid
to find its way through the weir 338 and exit hole 238. The outlet
270 of the support plate 260 may be aligned with the exit hole 238
and a hole (not shown) along the tube 300 for fluid to be sprayed
to environment.
[0057] FIG. 16 illustrates a graph resembling test data identifying
an average flow rate vs. grit size for four different irrigation
emitter assemblies. This "grit test" is an industry standard
performance test measuring the pressure and flow relationships and
clog resistance. It involved recirculating fluid through a sample
of emitters and sequentially adding larger particles of grit having
a grit concentration of 250 PPM at a time wherein the fluid to
eventually achieved a final concentration of about 2750 PPM while
operating at 1.5 LPH at 15 psi flow range. The first three graph
lines represent tests performed using irrigation emitter assemblies
that are known assemblies labeled "Competing Emitters No. 1, No. 2,
and No. 3." These assemblies are currently available on the market
today and do not include the features described in the present
disclosure including the vortex circuit 110. The fourth and fifth
graph lines represent two tests performed of the instant emitter
assembly including the vortex circuit 110 described above and
labeled "Disclosed Emitter Tests No. 1, and No. 2." The graph
represents the average flowrate measured through the assemblies as
various sizes of grit or particulate have been added to the fluid
over time. The y-axis represents average flow rate Q in liters per
hour (LPH) and the x-axis represent girt size wherein the smaller
number illustrates a coarser grit value. As shown by the graph of
FIG. 16, the graph lines identify that as the grit size increased
grew coarser for competing emitters No. 1, 2, and 3, the average
flowrate Q dropped precipitously after about 140 to about 70 grit
size. Comparatively, the Disclosed Emitter Tests No. 1 and No. 2
illustrate that the average flowrate for the instant emitter
assembly 100 that includes the vortex circuit 110 of the instant
application performed having a relatively constant average flow
rate as grit size increased over time. The measured average flow
rate Q was measured to be about 1 LPH to about 1.4 LPH over time.
Notably, measurements were taken every 30 minutes as additional
grit having an increasingly coarser measurement was introduced into
the flow of fluid during these tests.
[0058] FIG. 17 illustrates a graph that displays various tests of
the vortex emitter assembly 100 that includes the vortex circuit
110 of the present disclosure and includes the pressure
compensating component 230. This graph is a P-Q graph that
identifies pressure and average flow rate of the measured
assemblies 100. This data illustrates that for nine (9) different
tests of various prototypes of the present assembly 100 the level
pressure (psi) measured at the outlet of the assembly 100 was able
to be maintained at a relative constant level over a broad range of
flow rates Q (mL/min). Here, each of the measured prototypes
maintained a flowrate between about 23 psi to 28 mL/min as pressure
increased from about 5 psi to about 40 psi.
[0059] Although applicant's testing data shows that in a single
vortex 130 the emitter efficiency Ef value may be larger for a
larger interaction region diameter IRD, the minor head losses of
the circuit may occur as flow through the power nozzle 150 entering
the interaction region 160, flow going from the interaction region
160 to the throat 170, flow going from the throat 170 to the exit
diameter and either various static bends that flow must go through
to exit the assembly or to a pressure compensating device 230--each
of which may add up to a non-insignificant pressure drop. The
circuit may be a balance of all these effects, not just the
vorticity of the circuit, but additional head losses.
[0060] As noted above, the vortex emitter assembly 100 of the
present disclosure may be created as an injection molded component.
It may be static, with no moving parts or may be dynamic, having a
pressure compensating device to assist with pressure manipulation.
The vortex emitter assembly 100 may be attached to an inner side of
the tube 300 and may be inserted and attached as the tube is
extruded as part of a drip irrigation system. The drip irrigation
assembly's tube 300 may be placed in a farm field and water may be
pumped in. The emitter assemblies 100 may take the high pressure
flow inside the tube and produce a desired flowrate (selectable
depending on the requirements of the environment, terrain or plant
being irrigated).
[0061] The vortex emitter assembly 100 of the present disclosure
and the disclosed pressure reducing elements 220 provide a higher
efficiency than traditional pivot or sprinkler systems. The
emitters 100 not only provide the appropriate pressure attenuation;
they resist clogging from the grit and debris in available ground
water. In accordance with the present disclosure, newly developed
prototype clog resistant in-line vortex element irrigation emitter
gives a greater pressure attenuation for its physical dimensions
than comparable devices in the prior art (as described above). The
large dimensions and the vortex created in each chamber 130 help
flush debris and grit through the system. The smaller circuit
package along with the natural coring that occurs with the vortex
circuit of the present disclosure saves on circuit size. This saves
irrigation assembly cost, and allows for parts to be used in
thinner walled tubing as the inner wall tubing requires a smaller
mass to heat for bonding circuits.
[0062] The vortex circuit of the present disclosure naturally
pressure regulates. The circuit 110 optimizes exponent rating. The
exponent of an optimized vortex circuit of the present disclosure
can reach as low as 0.3 versus a standard (prior art) orifice which
has an exponent of 0.5. What this means for the flow is that as the
pressure increases, the change of flow only increases a small
amount.
[0063] FIG. 18 illustrates a graph that displays the measured
Exponent values that corresponds to the various tests of the
prototypes of the vortex emitter assembly 100 identified by FIG.
17. Here each of the tested prototypes were identified to include
an exponent value that was less than about 0.14 and was as low as
about 0.04. The addition of the pressure compensation component 230
to the pressure reducing component 220 of the instant disclosure
gives an exponent of about 0 so that for any change in pressure,
the circuit doesn't increase in flow. The vortex circuit 110 of the
present disclosure may be used in communication with a pressure
compensation PC component 230 that includes a diaphragm 235.
However, the circuit 110 may also be used in an assembly 100
without pressure compensation PC component 230 in which the
relevant range of irrigation fluid pressures and flows, the 0.3
exponent range should be sufficient to prevent over-watering the
desired environment. This device does allow for pressure
compensation to be added, but for naturally flowing circuits with
no PC, the low exponent of the vortex circuit 110 offers a blend of
flow control and cost in a non-PC part.
[0064] While in accordance with the patent statutes the best mode
and certain embodiments of the disclosure have been set forth, the
scope of the disclosure is not limited thereto, but rather by the
scope of the attached. As such, other variants within the spirit
and scope of this disclosure are possible and will present
themselves to those skilled in the art.
[0065] Although the present embodiments have been illustrated in
the accompanying drawings and described in the foregoing detailed
description, it is to be understood that the vortex emitter
assemblies are not to be limited to just the embodiments disclosed,
but that the systems and assemblies described herein are capable of
numerous rearrangements, modifications and substitutions. The
exemplary embodiment has been described with reference to the
preferred embodiments. Obviously, modifications and alterations
will occur to others upon reading and understanding the preceding
detailed description. Accordingly, the present specification is
intended to embrace all such alterations, modifications and
variations that fall within the spirit and scope of the appended
claims. Furthermore, to the extent that the term "includes" is used
in either the detailed description or the claims, such term is
intended to be inclusive in a manner similar to the term
"comprising" as "comprising" is interpreted when employed as a
transitional word in a claim.
* * * * *