Dry fog diffuser for cold service case
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing humidification systems for cold service cases, such as those using air atomizing nozzles or ultrasonic nebulization, face issues with noise, bacterial contamination, and high maintenance costs, while also failing to effectively maintain humidity levels, leading to product shrinkage and reduced shelf life.
Innovation Solution
A dry fog diffuser system utilizing a stainless-steel elbow with a No. 4 finish and an aluminum oxide nozzle, connected to a high-pressure water supply, which produces a fine water vapor and diffuses it to create a dry fog, maintaining humidity levels and minimizing bacterial issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If air atomizing nozzles are used to produce fine vapor fog, then humidity levels are increased, but noise levels become undesirable due to the compressor
Solution Approach 1:
The patent replaces the mechanical compressor-based air atomizing system with a high-pressure water supply system operating at 600-1000 psi. This substitution eliminates the noisy compressor while achieving the same fine vapor fog production through pure hydraulic pressure, resolving the noise issue while maintaining effective humidification
Solution Approach 2:
The invention uses high-pressure hydraulics (600-1000 psi water supply) to directly drive the atomizing nozzle without any mechanical compressor. The hydraulic pressure alone is sufficient to atomize the water into fine vapor, eliminating the need for pneumatic compression and its associated noise
2Object-affected harmful factors
If ultrasonic nebulization transducers are used to produce dry fog, then noise levels are reduced, but bacterial contamination issues arise due to the warm water bath
Solution Approach 1:
The patent changes the operating parameters by using high-pressure cold water (600-1000 psi) instead of warm water in ultrasonic systems. This parameter change eliminates the bacterial growth environment while maintaining effective atomization through pressure-driven nozzle design, resolving the contamination issue without sacrificing noise reduction
Solution Approach 2:
The invention extracts and eliminates the problematic warm water bath component from the system. By using cold high-pressure water directly in the nozzle, the system removes the medium that supports bacterial growth, achieving contamination-free operation while keeping the system quiet
3Object-affected harmful factors
If ultrasonic nebulization systems are used, then noise is reduced, but maintenance costs increase due to frequent cleaning requirements
Solution Approach 1:
The patent employs inexpensive, easily replaceable nozzle components that can be quickly swapped without extensive disassembly or cleaning. The simple high-pressure nozzle design is more durable and easier to maintain than complex ultrasonic transducers, reducing maintenance costs while preserving quiet operation
Solution Approach 2:
The high-pressure cold water system naturally resists bacterial growth and mineral deposition compared to warm water systems, reducing the frequency and complexity of maintenance. The system essentially maintains itself by using conditions (cold, high-pressure flow) that prevent contamination in the first place
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively maintains humidity levels, reduces product shrinkage, and minimizes bacterial contamination, providing a quiet and cost-effective solution for maintaining fresh and marketable food products in cold service cases.
Implementation Method 1
a base having an adapter for connection to a high-pressure water supply in a range of 600 to 1,000 psi. The nozzle has an orifice in the range of 0.003-0.012 inches to produce a fine water vapor
Implementation Method 2
An inner surface of the diffuser has a roughness of at least Ra25, where water vapor from the nozzle is diffused in the elbow and the diffuser produces a dry fog exiting at the outlet end
Data Source
AI summary
A dry fog diffuser assembly for use in a refrigerated space comprises a base having an adapter for connection to a high-pressure water supply in a range of 600 to 1,000 psi. The nozzle has an orifice in the range of 0.003-0.012 inches to produce a fine water vapor. A riser operatively connects the nozzle to the adapter to space the nozzle from the base. A housing is mounted to the base and encloses the nozzle. The housing defines an open space below the nozzle providing an air inlet to the interior of the housing. A diffuser comprises a stainless-steel elbow having an inlet end and an outlet end. The inlet end is mounted to the housing. An inner surface of the diffuser has a roughness of at least Ra25, where water vapor from the nozzle is diffused in the elbow and the diffuser produces a dry fog exiting at the outlet end.