Ultrasonic Transducer Spacing for Faster Industrial Component Cleaning

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Solution Overview

Problem

Existing methods for cleaning fouled industrial components, such as heat exchangers and valves, are inefficient, hazardous, and time-consuming, particularly due to the complexity of the components and the nature of the contaminants, and often result in damage to the components or incomplete removal of contaminants.

Innovation Solution

An apparatus using ultrasonic transducers secured at specific spacings and frequencies to generate a non-uniform energy field within a cleaning liquid, combined with suitable cleaning fluids, effectively dislodges contaminants from industrial components by enhancing ultrasonic energy penetration and reducing cavitation damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If high pressure water jetting is used to clean industrial components, then cleaning effectiveness is improved, but cleaning time increases and safety hazards increase

Engineering Contradiction:

Improvecleaning effectivenessVSAvoidcleaning time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent applies ultrasonic vibration to the cleaning process, where ultrasonic transducers generate high-frequency vibrations in a cleaning fluid. These vibrations create cavitation bubbles that collapse against the contaminated surfaces, providing effective cleaning without requiring prolonged high-pressure water jetting. This mechanical vibration approach reduces cleaning time while maintaining effectiveness.

Inventive Principle:

Principle #18Mechanical vibration

Solution Approach 2:

The patent replaces traditional mechanical water jetting systems with an ultrasonic field-based cleaning system. Instead of using high-pressure water streams that require extensive exposure time, the system uses ultrasonic energy to generate cavitation and micro-jetting effects, significantly reducing the cleaning duration while maintaining or improving cleaning effectiveness.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If high pressure water jetting is used to clean industrial components, then cleaning effectiveness is improved, but safety hazards increase

Engineering Contradiction:

Improvecleaning effectivenessVSAvoidsafety hazards

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent substitutes high-pressure water jetting with ultrasonic field-based cleaning. The ultrasonic transducers operate at frequencies that generate cavitation and mechanical vibration effects without requiring the extreme pressures associated with water jetting. This eliminates the safety hazards of high-pressure water injection while maintaining effective cleaning capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If traditional mechanical cleaning methods are used, then cleaning effectiveness is improved, but device complexity increases

Engineering Contradiction:

Improvecleaning effectivenessVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical cleaning systems (such as abrasive blasting equipment, high-pressure water jetting systems, and chemical cleaning systems) with a relatively simple ultrasonic field-based system. The core components are ultrasonic transducers, a cleaning fluid reservoir, and power supply, which is significantly simpler than traditional mechanical cleaning apparatus while achieving comparable or superior cleaning effectiveness.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If chemical cleaning methods are used, then cleaning effectiveness is improved, but harmful chemical substances are introduced

Engineering Contradiction:

Improvecleaning effectivenessVSAvoidhazardous chemicals

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent substitutes chemical cleaning methods with physical ultrasonic field-based cleaning. The ultrasonic transducers generate mechanical vibrations and cavitation effects that remove contaminants through physical means rather than chemical dissolution. This eliminates the need for hazardous cleaning chemicals while maintaining effective removal of various types of contaminants including scale, rust, and organic deposits.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 apparatus significantly reduces cleaning time and enhances the effectiveness of removing contaminants from complex industrial components, while minimizing potential damage to the components and reducing the need for hazardous chemicals.

Implementation Method 1

ultrasonic transducers having an operating frequency and a wavelength in the cleaning liquid

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Implementation Method 2

enhancing ultrasonic energy penetration and reducing cavitation damage

Methodology Applied

Scientific EffectCavitation: Cavitation

Data Source

PatentUS12365012B2Apparatus for cleaning industrial components

Publication Date: 2025.07.22 TECH SONIC LLP

AI summary

An apparatus for cleaning industrial components has a liquid container defining a liquid enclosure for containing a cleaning liquid and ultrasonic transducers having an operating frequency and a wavelength in the cleaning liquid and secured to at least a portion of the liquid container at a spacing of between 2 and 10 wavelengths. In operation, the transducers generate a larger power density in the component-receiving area of the liquid container than an average power density of the liquid container.