Spray nozzle and method of manufacturing same

An assembly, comprising:

• a flat metal sheet and a plurality of spray nozzles formed in said sheet, each of said spray nozzles including:
• a metal disk member having a first side and a second side;
• said first side of each disk member having a bowl-shaped swirl chamber therein shaped by etching such that liquid to be sprayed from the nozzle can move therein in a vortex motion toward the center of the swirl chamber;
• a spray orifice in fluid communication with the center of the swirl chamber and extending substantially co-axial therewith such that liquid to be sprayed from the nozzle can move from the swirl chamber to said spray orifice and then exit the spray orifice in an active thin film, and
• at least one feed slot in fluid communication with the swirl chamber and extending in non-radial relation thereto for supplying liquid to be sprayed through said nozzle, and wherein said sheet includes a plurality of circular slots, each of which surrounds a respective disk, and at least one bridge extending from each disk to the sheet which enables each disk to be separated from said sheet by breaking the bridge.

A thin-film spray nozzle comprising:

• a sheet formed of etchable material having a first side and a second side;
• said first side of said sheet having a swirl chamber therein shaped by etching with smooth, generally vertical side walls and a smooth, generally horizontal end wall, with a smooth and continuous surface extending between and interconnecting the side walls and end wall, said swirl chamber having a shape such that fluid to be sprayed from said nozzle can move therein in a vortex motion toward the center of the chamber,
• a spray orifice in fluid communication with the center of the swirl chamber and extending substantially co-axial therewith such that fluid to be sprayed from the nozzle can move from the swirl chamber to said spray orifice and then exit the spray orifice in a conically-shaped film, and
• at least one feed slot shaped by etching in fluid communication with the swirl chamber, said at least one feet slot having smooth, trough-shaped walls in non-radial relation to said swirl chamber and having a smooth, continuous junction between said trough-shaped walls of said at least one feed slot and said side walls and end wall of said swirl chamber for supplying fluid to be sprayed through said nozzle.

An assembly comprising:

• an etchable flat sheet having a first side and a second side, and a plurality of spray nozzles formed in said sheet, each of said spray nozzles including:
• a swirl chamber formed in a first side of the sheet shaped by etching, said swirl chamber having a configuration such that fluid to be sprayed from the nozzle can move therein in a vortex motion toward the center of the chamber;
• a spray orifice in fluid communication with the center of the swirl chamber and extending substantially co-axial therewith, and
• at least one feed slot in fluid communication with the swirl chamber and extending in non-radial relation thereto, and wherein said sheet includes a plurality of slots, each of which surrounds a respective nozzle, and at least one bridge extending from each nozzle to the sheet.

A thin-film spray nozzel, comprising;

• a disk member formed of etchable material having a first side and a second side;
• said first side of said disk member having a generally round swirl chamber therein shaped by etching with smooth, rounded, generally vertical side walls and a smooth, generally horizontal end wall, with a smooth and continuous surface extending between and interconnecting the side walls and end wall;
• a spray orifice in fluid communication with the center of the swirl chamber and extending substantially co-axial therewith, and
• at least one feed slot shaped by etching in fluid communication with the swirl chamber, said at least one feed slot having smooth, trough-shaped walls extending in non-radial relation to said swirl chamber and having a smooth, continuous junction between said trough-shaped walls of said at least one feed slot and said side walls and end wall of said swirl chamber .