Optical Particle Sensor Exhaust-Cooled Source

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Solution Overview

Problem

Optical particle sensors face challenges in effectively cooling high-energy optical sources, leading to reduced operating lifetimes and increased contamination risks in clean-room environments, as existing cooling methods are often complex, energy-intensive, or incompatible with these settings.

Innovation Solution

The use of exhausted sample fluid to establish thermal contact with heat-producing elements, such as optical sources, for passive cooling, reducing the need for active power-consuming cooling devices and minimizing contamination risks by integrating cooling mechanisms within the sensor system.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If high-energy optical sources are used to detect sub-micron particles at higher sampling rates, then measurement precision and productivity are improved, but the optical sources generate substantial heat that reduces their operating life and reliability

Engineering Contradiction:

Improvefluid sampling rateVSAvoidoptical source operating life

Core Design Contradiction:

ProductivityVSDuration of action of stationary object

Solution Approach 1:

The patent converts the harmful heat generated by the optical source into a beneficial cooling mechanism by using the same heat to drive convection currents that draw cooler ambient air through heat sinks positioned near the optical source, thereby extending its operating life while maintaining high sampling rates

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent employs fluid dynamics by utilizing natural convection currents created by the heated air rising from the optical source to drive airflow through the cooling system, eliminating the need for active mechanical cooling components

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Temperature

If active cooling systems are used to cool optical sources, then temperature control is improved, but device complexity and energy consumption increase

Engineering Contradiction:

Improveoptical source temperatureVSAvoidcooling system complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent implements a self-cooling mechanism where the optical source's own heat generation drives the cooling process through natural convection, eliminating the need for external active cooling systems and reducing overall device complexity

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces mechanical active cooling systems with a passive thermal management approach that uses natural convection and conduction through heat sinks, eliminating moving parts and mechanical complexity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Temperature

If active cooling systems are used to cool optical sources, then temperature control is improved, but energy consumption increases

Engineering Contradiction:

Improveoptical source temperatureVSAvoidcooling system power consumption

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The patent converts the wasted thermal energy from the optical source into a useful cooling mechanism by harnessing the temperature differential to drive natural convection currents that actively remove heat without requiring additional energy input

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The cooling system is self-powered by the heat generated from the optical source itself, using the temperature differential to drive convection currents that continuously remove heat without external energy input

Inventive Principle:

Principle #25Self-service

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 approach extends the operating life of optical sources, reduces noise, and enhances detection reliability while maintaining low power consumption, making it suitable for clean-room applications without excessive design or expense.

Implementation Method 1

flowing the sample fluid through the sample chamber and the outlet passage... to provide thermal exchange between exhaust flow of sample fluid flowing through the outlet passage and the optical source

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 2

exhaust flow of sample fluid... to provide thermal exchange between exhaust flow of sample fluid flowing through the outlet passage and the optical source

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS7796255B2Optical particle sensor with exhaust-cooled optical source

Publication Date: 2010.09.14 PARTICLE MEASURING SYSTEMS INC

AI summary

The invention relates to particle sensors that are capable of passively cooling high-powered optical sources within the sensor, thereby extending the optical source lifetime without requiring additional power. The sensor detects particles within a sample fluid by optical interaction of the optical source with flowing sample fluid in the sample chamber. Sample fluid that exits the sample chamber is directed into thermal contact with the optical source, thereby cooling the optical source. Sample fluid that has come into thermal contact with the optical source is continuously removed from the sensor to ensure the optical source is adequately cooled. A variety of elements are used to facilitate thermal contact between the optical source and sample fluid including plenums, heat sinks, and airflow cavities. Provided are related methods for cooling a one or more heat-producing device within a particle sensor.