High Pressure Spray Cooling System for Ultra-Fast Heat Transfer
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Solution Overview
Problem
Current spray cooling technologies, such as gas atomization, achieve slow cooling rates of 20-100° C./s, which are insufficient for ultra-fast cooling applications, and there is a need for methods that can achieve higher cooling rates like 558.71° C./s, 289.11° C./s, 160.02° C./s, and 156.95° C./s.
Innovation Solution
A high pressure, high temperature spray cooling system and method utilizing a multi-phase spray cooling system with a supply tank, high pressure pump, spray chamber, and nozzle, along with control valves and a gas supply system, which includes copper or aluminum nano-particles in water to achieve ultra-fast cooling rates of up to 2.5 MPa and 600° C. to 1,000° C., using nitrogen gas and nano-particles to enhance cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If gas atomization spray cooling is used, then the cooling system can operate at temperatures below 100°C, but the cooling rate is slow (20-100°C/s)
Solution Approach 1:
The patent changes the operating parameters from conventional gas atomization (below 100°C, low pressure) to high-pressure water spray (600-1000°C, up to 2.5 MPa). This parameter transformation enables ultra-fast cooling rates by increasing both temperature and pressure, fundamentally resolving the contradiction between operating temperature and cooling rate.
Solution Approach 2:
The patent utilizes phase transition of water from liquid to vapor during spray cooling. The water absorbs heat from the workpiece through evaporation and phase change, achieving ultra-fast cooling rates. This phase transition mechanism is key to achieving high cooling rates while maintaining system efficiency.
2Productivity
If traditional laminar quenching is used, then the process is simple, but the cooling rate is slow and insufficient for ultra-fast cooling applications
Solution Approach 1:
The patent segments the cooling system into multiple functional components: supply tank with heater, high-pressure pump, control valves, mass flow meters, spray chamber, and nozzle. This segmentation allows each component to be optimized for its specific function, achieving ultra-fast cooling rates while maintaining controllable system complexity through modular design.
Solution Approach 2:
The patent incorporates mass flow meters and temperature/pressure monitoring to provide feedback control. The controller adjusts the system parameters based on real-time measurements, enabling precise control of cooling rates. This feedback mechanism resolves the contradiction by making the complex system controllable and adaptable.
3Productivity
If high pressure (up to 2.5 MPa) and high temperature (600-1000°C) spray cooling is implemented, then ultra-fast cooling rates are achieved, but the system complexity increases
Solution Approach 1:
The patent employs a multi-functional integrated system where the high-pressure pump serves both pressure generation and flow control functions, the heater provides temperature regulation, and the nozzle performs both atomization and spray distribution. This multi-functionality reduces the number of separate components needed, managing system complexity while achieving ultra-fast cooling.
Solution Approach 2:
The patent uses control valves and mass flow meters as intermediary devices between the power sources (pump, heater) and the spray chamber. These intermediaries provide precise control and measurement, enabling the system to achieve high cooling rates while maintaining manageable complexity through standardized control components.
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 achieves ultra-fast cooling rates, effectively cooling materials from high temperatures, reaching cooling rates significantly higher than traditional methods, making it suitable for high-pressure, high-temperature applications.
Implementation Method 1
A supply tank having a heater
Implementation Method 2
a high pressure pump... reaches pressures of up to 2.5 MPa
Implementation Method 3
Gas atomization cooling is a type of spray cooling... A cooling rate of 20-100°C./s can be achieved with gas atomization
Implementation Method 4
spray cooling is a technology where a liquid is dispersed into droplets onto an object to cool
Implementation Method 5
The supply line further includes a control valve and a bypass valve to adjust the pressure of the contents in the supply line
Implementation Method 6
A gas regulating valve is further included to adjust the pressure of the gas supply in the gas line
Data Source
AI summary
A high pressure, high temperature spray cooling system for heat transfer. The system includes: a supply tank having a heater and a high pressure pump; and a spray chamber spaced apart from the supply tank. The spray chamber has a workpiece receiving bed and a nozzle spaced apart from the workpiece receiving bed. The supply line has a first supply line end and a second supply line end. The first supply line end is connected to the supply tank and the second supply line end is connected to the nozzle so that the contents within the supply tank are supplied to the nozzle through the supply line at a high pressure to cool a workpiece on the workpiece receiving bed.