Impingement Freezer Ejector Plates for Stable Conveyor Freezing

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Solution Overview

Problem

Existing freezers using the impingement principle for freezing products on conveyor belts face inefficiencies in freezing capacity and product stability due to high airspeeds, which can cause products to be blown off the belt, and are difficult to clean.

Innovation Solution

The design incorporates transverse return air ducts with specific cross-sectional shapes, such as triangular or mushroom-shaped, on the ejector plates to manage airspeed and facilitate efficient airflow perpendicular to the conveyor belt, combined with a heat exchanger/evaporator system for recirculated air, allowing for increased contact time and improved cooling efficiency while maintaining easy cleaning access.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If high airspeed is used for impingement freezing, then freezing efficiency is improved, but products may be blown off the conveyor belt

Engineering Contradiction:

Improvefreezing efficiencyVSAvoidproduct stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The ejector plates are designed with different functional zones: central areas with ejector holes for high-velocity impingement freezing, and peripheral areas with return air ducts for low-velocity air return. This local differentiation allows high airspeed to be applied only where freezing efficiency is needed, while maintaining product stability in other areas.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The return air ducts are arranged to conduct air transversely to the conveying direction, creating a two-dimensional airflow pattern. This transverse return path allows the air to be redirected perpendicular to the conveyor belt motion, preventing lateral air forces that would blow products off the belt while maintaining effective impingement in the freezing zone.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Reliability

If traditional air cooling is used, then product stability is maintained, but freezing capacity is insufficient

Engineering Contradiction:

Improveproduct stabilityVSAvoidfreezing capacity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The invention merges the impingement freezing principle with traditional air cooling by integrating return air ducts into the ejector plate structure. The system combines high-velocity impingement air flow for rapid freezing with low-velocity return air flow for stable product transport, achieving both high freezing capacity and product stability simultaneously.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The return air ducts act as intermediaries that redirect the cooling air flow. Instead of allowing air to escape laterally and lose momentum, the ducts capture and redirect the air transverse to the conveyor direction, maintaining a controlled airflow environment that supports both efficient freezing and product stability.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If ejector plates with holes are used for impingement freezing, then freezing efficiency is improved, but cleaning difficulty increases

Engineering Contradiction:

Improvefreezing efficiencyVSAvoidcleaning ease

Core Design Contradiction:

ProductivityVSEase of repair

Solution Approach 1:

The ejector plate is segmented into distinct functional zones with ejector holes in central areas and return air ducts in peripheral areas. This segmentation allows different cleaning approaches for different zones, and the modular design facilitates access to cleaning surfaces without requiring disassembly of the entire plate structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of having complex internal passages that are difficult to access for cleaning, the return air ducts are designed with external access points and transverse orientation that allows cleaning personnel to access and clean the duct interiors from the sides, reversing the traditional difficult-to-reach configuration.

Inventive Principle:

Principle #13The other way round (Inversion)

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

This configuration enhances freezing efficiency by maintaining product stability and increasing cooling capacity by 13% compared to traditional designs, while also simplifying maintenance through easy access and reduced blower energy demand.

Implementation Method 1

The exhaust ducts from the freezing zone are connected to a heat exchanger/evaporator where the air is cooled for subsequent recirculation via the blower back to the injection side of the ejector plates

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Implementation Method 2

upper ejector plates are provided above the conveyor belt and lower ejector plates are provided below the conveyor belt for inflow of air into the freezing zone while applying an impingement principle

Methodology Applied

Scientific EffectImpingement principle: Impact Force

Data Source

PatentUS7823409B2Freezing system

Publication Date: 2010.11.02 SCANICO

AI summary

A freezer housing for a freezer for cooling and/or freezing of products lying on a conveyor belt, and which are conveyed through a freezing zone for the freezing, where upper ejector plates are provided above the conveyor belt and lower ejector plates are provided below the conveyor belt for inflow of air into the freezing zone while applying an impingement principle, where the ejector plates are provided with transverse air return ducts.