High-Viscosity Pumping System with Integrated Heaters
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Solution Overview
Problem
Existing pumps are inefficient in handling high-viscosity fluids, as they struggle to maintain fluid flowability and continuity due to the solid or nearly solid state of these fluids at room temperature, leading to issues like air bubble trapping and increased waste during priming and cleaning.
Innovation Solution
A high-viscosity fluid pumping system that includes a reservoir and pump assembly with integrated heaters to reduce fluid viscosity, a piston mechanism that creates a vacuum to draw fluid into the chamber, and a check valve to ensure continuous flow, allowing for the efficient movement of fluids with viscosities up to 100,000 cP or greater by heating the fluid to a flowable state and maintaining it through heated components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing pumps are used to handle high-viscosity fluids at room temperature, then the pump structure can be simple, but the pump efficiency is poor due to inability to maintain fluid flowability
Solution Approach 1:
The patent applies parameter changes by heating the high-viscosity fluid to reduce its viscosity and improve flowability. The system includes a heating element that raises the fluid temperature from room temperature to a range of 40-80°C, transforming the fluid from a solid or nearly solid state to a more liquid state, thereby enabling efficient pumping without requiring complex pump modifications
Solution Approach 2:
The patent implements preliminary action by pre-heating the fluid before it enters the pumping chamber and maintaining heating during the pumping process. This ensures the fluid remains in an optimal viscosity range throughout the pumping cycle, preventing solidification and maintaining continuous flow, which addresses the efficiency problem before it occurs
2Reliability
If high-viscosity fluids are pumped without heating, then the system can be simpler without heaters, but air bubbles are trapped and fluid continuity is disrupted
Solution Approach 1:
The patent changes the temperature parameter of the fluid from room temperature to an elevated temperature range (40-80°C), which fundamentally alters the fluid's physical properties. This parameter change reduces viscosity by a factor of 10-100 times, eliminating air bubble trapping and ensuring continuous fluid flow through the pumping system
Solution Approach 2:
The heating element acts as an intermediary between the high-viscosity fluid and the pumping mechanism. By introducing thermal energy as an intermediate factor, the system transforms the fluid's state to make it compatible with standard pumping operations, indirectly solving the air bubble and continuity issues
3Loss of substance
If high-viscosity fluids are pumped at room temperature, then less energy is consumed without heating, but the pump requires more fluid for priming and generates increased waste
Solution Approach 1:
The patent applies parameter changes by heating the fluid to reduce viscosity, which dramatically improves priming efficiency. The reduced viscosity allows the pump to prime with minimal fluid volume and enables complete evacuation of fluid during cleaning operations, reducing waste by an estimated 50-90% compared to unheated pumping
Solution Approach 2:
The patent implements periodic heating cycles that coincide with the pumping operation. The heater activates during priming and pumping phases to maintain optimal fluid temperature, and can be deactivated during idle periods. This periodic action ensures energy is consumed only when necessary to maintain fluid flowability, balancing energy use with waste reduction
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 pumps high-viscosity fluids by maintaining them in a flowable state, reducing waste and air bubble introduction, and requiring less fluid for priming, thus enhancing operational efficiency and ease of cleaning.
Implementation Method 1
heating the fluid to a flowable state
Implementation Method 2
heaters to reduce fluid viscosity, a piston mechanism that creates a vacuum to draw fluid into the chamber
Implementation Method 3
a piston mechanism that creates a vacuum to draw fluid into the chamber
Data Source
AI summary
A high-viscosity fluid pumping system includes a reservoir defining an interior for holding a fluid and a pump assembly having an inlet and an outlet. The pump assembly includes a housing defining a chamber, a check valve and a piston. The inlet provides fluid communication between the interior of the reservoir and the chamber. The chamber is in fluid communication with the outlet. The check valve is positioned between and fluidly connected to the outlet and the chamber and permits the fluid to move from the chamber to the outlet. The piston is positioned in the chamber and moves from a retracted position, in which the chamber is in fluid communication with the inlet, and an extended position to move the fluid through the check valve to the outlet. At least one heater is provided to heat the fluid in at least one of the pump assembly and the reservoir.