Evaporative Cooler Wicking Plate Masks for Scale Buildup Control
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Solution Overview
Problem
Evaporative cooling systems face inefficiency due to scale buildup from mineral residues on wicking surfaces, which is exacerbated by perturbations in wick geometry and air flow, leading to reduced effectiveness and increased maintenance costs as systems become more complex and expensive.
Innovation Solution
Incorporating impermeable masks on wicking surfaces to prevent evaporation through perforations and channel guides, which redirects liquid flow to maintain a higher wick rate than evaporation rate, thereby reducing scale buildup by recirculating liquid and preventing mineral deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If water evaporates through the wicking surface for cooling, then cooling effectiveness is improved, but scale buildup increases
Solution Approach 1:
The wicking surface is segmented into multiple zones with different functions: a first region with high wick rate for active evaporation and cooling, and a second region with reduced wick rate to minimize scale buildup. This segmentation allows the system to maintain cooling effectiveness while reducing harmful scale deposition in specific areas.
Solution Approach 2:
Different regions of the wicking surface are given different local properties - the first region has enhanced wick rate characteristics (through material selection, pore structure, or geometry) to promote evaporation for cooling, while the second region has modified properties to reduce evaporation and consequently reduce scale buildup in that specific location.
2Productivity
If wick rate is increased to maintain cooling efficiency, then evaporation rate exceeds wick rate less often, but scale buildup is reduced only in specific regions
Solution Approach 1:
The wicking surface is divided into functional zones where the first region has increased wick rate to ensure adequate liquid supply for evaporation, preventing the condition where evaporation rate exceeds wick rate. The second region accepts reduced wick rate as a trade-off to minimize scale buildup in areas less critical for cooling performance.
Solution Approach 2:
The wick rate is locally optimized in the first region through material or geometric modifications to ensure high liquid transport capacity where cooling is most needed, while the second region has acceptably lower wick rate where scale buildup is less problematic, achieving a local balance between cooling efficiency and scale reduction.
3Reliability
If evaporative cooling systems are made more complex to improve performance, then cooling effectiveness increases, but maintenance costs increase
Solution Approach 1:
Rather than making the entire system more complex, the invention segments the wicking surface into functional regions with different properties. This localized approach improves cooling effectiveness and reduces scale buildup without requiring complex control systems or additional components, thereby avoiding increased maintenance costs.
Solution Approach 2:
The invention applies local quality modifications to the wicking surface (through material selection, pore structure, or geometric configuration in specific regions) to achieve improved performance and reduced scale buildup, rather than implementing complex system-wide solutions that would increase device complexity and maintenance requirements.
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 solution effectively reduces scale buildup by maintaining a wick rate exceeding evaporation rate potential, preventing mineral deposition and maintaining system efficiency, thus extending the lifespan and reducing maintenance costs of evaporative cooling systems.
Implementation Method 1
a wicking material with at least one exposed surface
Implementation Method 2
one or more masks comprising an impermeable material that prevent a liquid from evaporating through the one or more masks
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
In one embodiment, a plate for an evaporative cooler is disclosed. The plate may comprise a wicking material with an exposed surface and a sealed surface opposite the exposed surface. An impermeable barrier may be coupled to the sealed surface. One or more masks may line a portion of the exposed surface, wherein the masks may comprise an impermeable material. In some embodiments, the mask may be a strip of impermeable material and may be coupled to a flat area of the top surface. In further embodiments, the one or more masks may align with a liquid wick path of the wicking material. In further embodiments, the one or more masks may line the edge of perforations that pass at least partially through the plate.