Irrigation spray nozzle and mold assembly and method of forming nozzle

A nozzle comprising:

• a nozzle base including a mounting portion defining an inlet;
• and a nozzle cap in mating engagement with the nozzle base, the nozzle cap comprising:
• at least one port reducing fluid flowing through the nozzle body from the inlet to a predetermined precipitation rate;
• at least one deflector contoured to deliver fluid radially outwardly from the nozzle through a predetermined arcuate span, the at least one deflector comprising a surface having a profile forming part of the at least one deflector and wherein the profile includes at least two sets of flow channels that subdivide fluid into a plurality of fluid streams with at least two different elevations;
• and
• at least one transition surface intermediate of the at least one port and the profile guiding flow directed through the at least one port to the at least two sets of flow channels, the at least one transition surface aligned with and expanding smoothly in the direction of the profile.

A mold assembly for making a spray nozzle body having a bottom end with a mounting portion defining an inlet and at least one deflector contoured to deliver fluid radially outwardly from the nozzle body through a predetermined arcuate span and at least one port, the at least one deflector comprising a profile including at least two sets of flow channels that subdivide fluid into a plurality of fluid streams with at least two different elevations, the at least one port comprising at least one opening with a cross-sectional shape corresponding to the shape of the predetermined arcuate span, the mold assembly comprising:

• a cavity block defining in part a mold cavity and having a plurality of openings;
• a first core unit having a first surface with a profile to mirror the top of the nozzle body and moveable through one opening between an advanced position protruding into the cavity block and a retracted position substantially withdrawn from the cavity block;
• a second core unit having a second surface with a profile to mirror the bottom end mounting portion of the nozzle body and configured for insertion through a second opening;
• and
• a third core unit having a third surface with a profile to mirror at least in part the at least one deflector profile and moveable through a third opening between an advanced position protruding into the cavity block and a retracted position substantially withdrawn from the cavity block.

A method of forming a molded, unitary, one-piece spray nozzle body having a bottom end with a mounting portion defining an inlet and at least one deflector contoured to deliver fluid radially outwardly from the nozzle body through a predetermined arcuate span and at least one port, the at least one deflector comprising a profile including at least two sets of flow channels that subdivide fluid into a plurality of fluid streams with at least two different elevations, the at least one port comprising at least one opening with a cross-sectional shape corresponding to the shape of the predetermined arcuate span, the method comprising:

• forming a cavity block defining in part a mold cavity and having a plurality of openings;
• inserting a first core unit having a first surface with a profile to mirror the top of the nozzle body through a first opening in the cavity block;
• inserting a second core unit having a second surface with a profile to mirror the bottom end mounting portion of the nozzle body through a second opening in the cavity block;
• inserting a third core unit having a third surface with a profile to mirror at least in part the at least one deflector profile through a third opening in the cavity block;
• injecting plastic material into the mold cavity to form the nozzle body;
• and
• retracting at least two of the core units from the cavity block.