Intelligent Manifold Assemblies for Light Source Cooling

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Solution Overview

Problem

Existing cooling fluid distribution systems for light sources, such as UV LEDs, fail to adequately address issues like maintaining uniform fluid flow, controlling pressure spikes during startup, detecting leaks, and shutting off fluid flow when not needed, leading to potential damage, safety hazards, and energy wastage.

Innovation Solution

An intelligent manifold assembly with sensors and a microprocessor that monitors cooling fluid characteristics like pressure, temperature, and flow rate, and controls valve operations to maintain optimal conditions, ramp startup pressure, detect leaks, and shut off fluid flow when necessary, using a printed circuit board with EEPROM for data storage and communication.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If cooling fluid flow is continuously maintained to cool light producing devices, then cooling effectiveness is improved, but energy wastage occurs when light source is not in use

Engineering Contradiction:

Improvecooling effectivenessVSAvoidenergy wastage

Core Design Contradiction:

TemperatureVSLoss of energy

Solution Approach 1:

The manifold assembly autonomously controls cooling fluid flow based on operational status detection. The system automatically shuts off flow when the light source is not in use and resumes flow when operation is detected, eliminating the need for manual intervention and preventing energy wastage while maintaining cooling effectiveness when needed.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system incorporates sensors that monitor operational status and provide feedback to the control mechanism. This feedback loop enables the manifold assembly to adjust cooling fluid flow dynamically based on actual cooling needs, ensuring energy efficiency without compromising cooling performance.

Inventive Principle:

Principle #23Feedback

2Temperature

If cooling fluid flow rate is increased to improve cooling, then cooling performance is improved, but pressure spikes during startup occur

Engineering Contradiction:

Improvecooling performanceVSAvoidpressure spikes

Core Design Contradiction:

TemperatureVSStress or pressure

Solution Approach 1:

The manifold assembly gradually ramps up the cooling fluid flow rate during startup rather than immediately delivering full flow. This preliminary gradual increase prevents pressure spikes while still achieving the required cooling performance, as the system prepares the fluid distribution network incrementally.

Inventive Principle:

Principle #10Preliminary action

3Extent of automation

If sensors and control mechanisms are added to monitor and control cooling fluid, then system intelligence and control capability are improved, but device complexity increases

Engineering Contradiction:

Improvesystem intelligenceVSAvoiddevice complexity

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The control electronics, including microprocessor and EEPROM, are integrated directly into the manifold assembly housing. This merging of control functions with the fluid distribution system eliminates the need for separate control units and reduces overall system complexity while maintaining high automation capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The microprocessor-based control system performs multiple functions including monitoring operational status, controlling valve operations, ramping flow rates, and preventing pressure spikes. This multi-functional approach reduces the need for separate dedicated components for each function, thereby reducing overall device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Loss of energy

If cooling fluid flow is shut off to conserve energy, then energy efficiency is improved, but risk of damage from unmonitored conditions increases

Engineering Contradiction:

Improveenergy efficiencyVSAvoidrisk of damage

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

Sensors continuously monitor cooling fluid characteristics and system conditions, providing feedback to the control system. This enables the manifold assembly to safely shut off flow when energy conservation is needed while maintaining reliability through real-time detection of potential issues such as leaks or abnormal conditions.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system replaces manual monitoring and control mechanisms with electronic sensors and microprocessor-based control. This substitution enables automated detection of harmful conditions and intelligent decision-making regarding flow control, improving both energy efficiency and reliability simultaneously.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentEP3245446B1Intelligent manifold assemblies for a light source, light sources including intelligent manifold assemblies, and methods of operating the same

Publication Date: 2020.10.28 HERAEUS NOBLELIGHT AMERICA LLC

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AI summary

A manifold assembly for distribution of a cooling fluid configured for use with a light source is provided. The manifold assembly includes a fluid manifold for providing a cooling fluid to a lamp head assembly of the light source, at least one sensor for sensing at least one characteristic of the cooling fluid in the fluid manifold, and a microprocessor for receiving information related to the at least one characteristic from the at least one sensor.