Smoke Device Baffle Cooling and Spark Suppression
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Solution Overview
Problem
Existing smoke devices produce flames, hot ash, and sparks during operation, posing fire and injury risks when used on flammable materials and without proper protective equipment.
Innovation Solution
A smoke device design featuring a container with multiple baffles and chambers that redirect smoke, reducing the exit velocity of hot particles and using a choke mechanism to control smoke exit, made from various materials like cardboard, plastic, or metal, to prevent direct smoke emission and cool the smoke, thereby minimizing flames and sparks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-chamber container with direct exit hole is used, then the device structure is simple, but hot ash, sparks and flames are projected out causing fire and injury risks
Solution Approach 1:
The single-chamber container is divided into multiple chambers by introducing baffles with multiple holes. This segmentation allows the smoke generation process to be separated into distinct zones: a lower chamber for chemical combustion and an upper chamber for smoke cooling and particle separation. The multiple chambers enable the smoke to traverse different path lengths and cool progressively, effectively reducing hot particle projection while maintaining structural feasibility
Solution Approach 2:
The baffles with multiple holes act as intermediary structures between the chemical blend and the exit hole. These baffles redirect the smoke flow multiple times, forcing hot particles to change direction and cool down before exiting. The intermediary baffles serve as a buffer zone that separates the high-temperature combustion region from the exit region, preventing direct projection of hot ash and sparks
2Productivity
If smoke is forced out at high pressure through a small aperture, then smoke projection is greater, but flames and hot gas are also projected out
Solution Approach 1:
The smoke is cooled and particles are separated before reaching the exit hole through preliminary action in the lower chamber. The baffles with multiple holes force the smoke to undergo multiple directional changes and cooling processes before it can exit. This preliminary cooling and particle separation occurs in advance of the exit, allowing high-pressure projection of cooled smoke without projecting flames and hot gas
Solution Approach 2:
The smoke flow is redirected from a direct linear path to a multi-dimensional path through the baffles. Instead of moving straight from the chemical blend to the exit hole, the smoke must navigate through multiple chambers and baffle holes, effectively increasing the path length and cooling time. This dimensional redirection allows maintained projection pressure while reducing harmful particle exit
3Ease of operation
If a plate with exit hole is used to reduce container diameter, then smoke exit is controlled, but smoke cooling is insufficient
Solution Approach 1:
The single plate with exit hole is segmented into multiple baffles with multiple holes distributed across different levels. This segmentation creates multiple cooling stages within the chamber, allowing smoke to cool progressively as it passes through each baffle layer. The segmented structure increases the effective cooling surface area and extends the smoke residence time in the cooling zone, achieving better temperature reduction while maintaining exit control
4Temperature
If multiple baffles and chambers are introduced to cool smoke, then smoke cooling improves, but device complexity increases
Solution Approach 1:
The baffles are designed to perform multiple functions simultaneously: they redirect smoke flow, provide cooling surfaces, separate hot particles from smoke, and maintain structural integrity of the chamber. Each baffle serves as a multi-functional element that accomplishes several objectives in one component, reducing the need for additional separate parts and justifying the structural complexity through functional consolidation
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 design significantly reduces the emission of hot ash, sparks, and flames, enhancing safety by preventing fires and injuries while producing richer, less bleached smoke colors due to increased cooling and redirection of smoke within the device.
Implementation Method 1
as the generated smoke passes through baffles or chambers and cools more than in devices with a single chamber or no chamber
Implementation Method 2
The plate acts to reduce the diameter of the container at the exit hole(s)... the container is said to be choked
Data Source
AI summary
A smoke device comprises a container, a base/base plate, a plate having at least one exit hole, a blend of chemicals contained in the container and a mechanical means by which generated smoke is prevented from directly exiting through the at least one exit hole without first being redirected in one or more directions. The mechanical means by which generated smoke is prevented from directly exiting through the at least one exit hole without first being redirected in one or more directions may include a plurality of baffles which have at least one hole therein and a plurality of chambers formed by the plurality of baffles. Each baffle has holes offset from holes in an adjacent baffle. The plurality of baffles may be spaced apart by using support posts and/or can be supported by support rings and/or can be supported by support pins and/or can be supported by support brackets.