Evaporative Media Geometry for Lower Pressure Drop
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Solution Overview
Problem
Existing evaporative cooling systems face issues with excess cooling capacity leading to unnecessary energy and water usage due to unneeded pressure drop, requiring frame redesigns when scaling down cooling capacity, which increases costs.
Innovation Solution
Replace evaporative media with new media having dimensions complementary to the housing and a lower pressure drop factor, maintaining similar external dimensions and efficiency, using corrugated sheets with different inclination angles and amplitudes to reduce pressure drop.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If evaporative media with high cooling capacity is used, then cooling efficiency is improved, but pressure drop increases leading to excess energy and water usage
Solution Approach 1:
The patent applies parameter changes by modifying the corrugation geometry parameters of the evaporative media. Specifically, it changes the inclination angles (α and β) and amplitudes (a and b) of the corrugated sheets to optimize the balance between cooling efficiency and pressure drop. By adjusting these geometric parameters, the media provides adequate cooling while reducing unnecessary pressure drop that leads to excess fan energy consumption and water usage.
2Reliability
If evaporative media with high cooling capacity is used, then cooling efficiency is improved, but water consumption increases due to excess cooling capacity
Solution Approach 1:
The patent modifies the geometric parameters of the corrugated sheets (inclination angles and amplitudes) to achieve optimal water consumption. The adjusted parameters ensure that water evaporates efficiently for cooling purposes without being forced through excessive pressure drop, thereby reducing unnecessary water loss and improving overall system efficiency.
3Loss of energy
If cooling capacity is scaled down by using smaller cassette, then energy and water usage is reduced, but frame redesign is required increasing costs
Solution Approach 1:
The patent applies local quality by modifying only the internal geometric characteristics of the evaporative media (corrugation angles and amplitudes) while maintaining the same external cassette dimensions. This allows the existing frame structure to be retained, avoiding costly redesigns, while the localized changes in media geometry provide the desired reduction in cooling capacity and associated energy and water usage.
4Loss of energy
If corrugated sheets with different inclination angles and amplitudes are used, then pressure drop is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent segments the evaporative media into multiple sets of corrugated sheets (first set with parameters α and a, second set with parameters β and b). Each set can be manufactured independently with specific geometric parameters, allowing for optimized performance while maintaining relatively simple manufacturing processes for each individual sheet type. The segmented approach enables modular assembly and facilitates quality control during production.
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
Achieves energy and water savings by reducing fan usage and water consumption while maintaining acceptable cooling efficiency without frame modifications.
Implementation Method 1
Water or another suitable cooling liquid is recirculated from a reservoir 110 through a supply line 112 to a distributor 116 using a pump 114. Distributor 116 evenly distributes the supplied water over a heat exchanger, such as evaporative pad 118. The water fed from distributor 16 flows down and through the pad and evaporates as it meets the warm supply air 124.
Implementation Method 2
direct evaporative coolers, where water is evaporated into the air stream via an engineered pad to provide adiabatic cooling
Implementation Method 3
indirect evaporative coolers, where evaporating water is used to cool a scavenger airstream passing through a heat exchanger
Data Source
AI summary
A method and system of replacing evaporative media is usable with an evaporative cooling apparatus including a media housing having predetermined dimensions. The method and system include removing first evaporative media from the media housing, and installing second evaporative media in the media housing. The second evaporative media has dimensions complementary to predetermined dimensions of the media housing and substantially equal to the dimensions of the first evaporative media. The second evaporative media has a pressure drop factor that differs from a first pressure drop factor.