Patent Publication Number: US-11035016-B2

Title: System and method for improving quench air flow

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 15/177,504, filed Jun. 9, 2016 and now issued as U.S. Pat. No. 10,308,993; which application claims the benefit of U.S. Provisional Patent Application No. 62/174,821, filed Jun. 12, 2015, and U.S. Provisional Patent Application No. 62/197,199, filed Jul. 27, 2015. Each of the above listed patent and applications are incorporated by reference in their entirety herein and for all purposes. 
    
    
     FIELD OF THE INVENTION 
     The present invention generally relates to quench systems for cooling hot metallic components, such as aluminum castings for automotive engine blocks and cylinder heads, after removal from a heat treatment furnace. 
     BACKGROUND 
     Quench systems for cooling hot metallic components after removal from a heat treatment furnace, such as hot forgings or castings made from steel or aluminum alloys, are known in the art. As shown in  FIG. 1 , for instance, a typical forced air quench system  10  can often provide a flow of cooling air  90  from rotating fans located in a lower portion of the quench housing  20 . The cooling air  90  flows upward from the fans and around, and some cases through, a plurality of metallic components  80  that are supported on a casting tray  60 . As known to those of skill in the art, the casting tray  60  is generally a rigid metallic framework having a substantially open construction with large openings  64  defined by support ribs  62 , and which is configured to maintain its shape during repeated thermal cycling through the hot furnace and subsequent cooling quench. The large openings  64  in the casting tray  60  can allow molding sand that falls out of the metallic components  80  during the heat treatment process to pass through the trays to lower sections of the heat treatment furnace (not shown), and then provide minimal obstruction for the cooling air  90  to flow upward, around and through the metallic components  80  after placement into the quench housing  20 . In addition, the casting tray  60  is typically supported on a plurality of support rollers  32  of a roller conveyor  30  that moves the casting tray into and out of the quench housing  20 , with the forced cooling air  90  from the fans flowing upward through gaps  34  between the rollers  32  prior to encountering the casting tray  60  and the metallic components  80  supported thereon. 
     Also illustrated in  FIG. 1 , the cooling air  90  typically flows upward from the fans at a predetermined and substantially uniform flow rate and speed across the entire width of the quench housing  20 , to cool the metallic components  80  that are supported on the casting tray  60  in the center portion  22  of the housing. The flow rate of the cooling air  90  is generally determined by the size and speed of the fans and the cross-sectional area of the quench housing  20 . In some installations the fans can be provided with variable speed drives that allow the flow rate to be increased or decreased depending on operating parameters, so as to quench the metallic components in accordance with a desired temperature profile or within a desired period of time. However, variable speed drives can add significant cost and complexity to the system, which can be undesirable. Although both the constant speed and variable speed versions of this generalized quench system design have proven adequate in many existing heat treatment installations, in some newer applications the flow rate of the cooling air  90  has been found insufficient for cooling larger and/or more complex metallic components within a desired time frame. 
     Consequently, a need exists for an improved forced air quench system and method that allows an operator to more efficiently cool larger and/or complex metallic components with a desired period of time. It is toward such an improved forced quench air system that the present disclosure is directed. 
     SUMMARY 
     Briefly described, one embodiment of the present disclosure comprises a quench system for applying cooling air to a hot metallic component, such as the metallic components described above, that is supported on a component support having a substantially open construction allowing for air flow therethrough. The quench system includes a housing with sidewalls that define a cooling chamber with peripheral portions proximate the sidewalls and a center portion spaced inwardly from the sidewalls. The quench system also includes a conveyance system that is configured to carry the component support with hot metallic component into the center portion of the cooling chamber. The quench system further includes a forced air fan for generating a bulk flow of cooling air through the cooling chamber, as well as a plurality of nozzle baffles extending inwardly from the sidewalls to define a narrowing region within the housing between the forced air fan and the conveyance system, whereby, during operation of the fan, cooling air flowing through the peripheral portions of the cooling chamber is redirected into the center portion of the cooling chamber. This redirection of the cooling air can affect a first stage increase in the average velocity of the cooling air flowing through the cooling chamber prior to encountering the hot metallic components. In one aspect the quench system also includes a plurality of central baffles located within or proximate the gaps between support rollers of the conveyance system, and that are configured to further redirect the cooling air into channels between the central baffles and the support rollers to affect a second stage increase in the average velocity of the cooling air flowing through the cooling chamber prior to encountering the hot metallic components. 
     In accordance with another embodiment, the present disclosure also includes a quench system for applying cooling air to one or more hot metallic components supported on a component support having a substantially open construction allowing for air flow therethrough. The quench system includes a housing having sidewalls that define a cooling chamber with peripheral portions proximate the sidewalls and a center portion spaced inwardly from the sidewalls. The quench system also includes a porous platform located within the cooling chamber that is configured to position the component support and hot metallic components proximate the center portion of the cooling chamber, as well as a forced air fan for generating a bulk flow of cooling air through the cooling chamber at a first average velocity. The quench system further includes a first set of flow directing elements, such as a set of fixed nozzle baffles, located upstream of the hot metallic components, and which first set of flow directing elements is configured to increase the flowrate of the cooling air to a second average velocity greater than the first average velocity. The quench system also includes a second set of flow directing elements, such as a set of movable center baffles, located between the first set of baffles and the hot metallic components, and which second set of flow directing elements is configured to further increase the flowrate of the cooling air to a third average velocity that is greater than the first and second average velocities. 
     In accordance with yet another embodiment, the present disclosure also includes a method for applying cooling air to a hot metallic component that includes supporting one or more hot metallic components on a component support having a substantially open construction allowing air flow therethrough. The method also includes positioning the component support within the cooling chamber of a quench system, and generating a bulk flow of cooling air through the cooling chamber at a first average velocity. The method further includes affecting a first stage increase in the flowrate of the cooling air to a second average velocity that is greater than the first average velocity, followed by affecting a second stage increase in the flowrate of the cooling air to a third average velocity that is greater than the first average velocity, and then directing the cooling air against the hot metallic components to increase the heat transfer away from the components. 
     The invention will be better understood upon review of the detailed description set forth below taken in conjunction with the accompanying drawing figures, which are briefly described as follows. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic side view of a quench system for cooling metallic components, as generally known in the art 
         FIG. 2  is a schematic side view of a quench system for cooling metallic components, in accordance with one representative embodiment of the present disclosure. 
         FIGS. 3 and 4  are schematic side views of a quench system for cooling metallic components, in accordance with another representative embodiment of the present disclosure. 
         FIGS. 5A and 5B  are plan and side elevation schematic views of a casting tray for supporting metallic components in a forced air quench system, in accordance with yet another representative embodiment of the present disclosure. 
         FIG. 6  is a schematic side view of the casting tray of  FIG. 5  being used within a forced air quench system, in accordance with another representative embodiment of the present disclosure. 
         FIG. 7  is a schematic side view of a quench system for cooling metallic components, in accordance with yet another representative embodiment of the present disclosure 
         FIGS. 8 and 9  are schematic side views of a quench system for cooling metallic components, in accordance with another representative embodiment of the present disclosure. 
     
    
    
     Those skilled in the art will appreciate and understand that, according to common practice, various features and elements of the drawings described above are not necessarily drawn to scale, and that the dimensions of the various features and elements may be expanded or reduced to more clearly illustrate the embodiments of the present disclosure described therein. 
     DETAILED DESCRIPTION 
     The following description, in conjunction with the accompanying drawings described above, is provided as an enabling teaching of exemplary embodiments of a system for improving quench air flow, and one or more methods for improving the flow of cooling air within a forced quench air system. As described below, the improved forced air quench system can provide several significant advantages and benefits over other forced-air type quench systems. However, the recited advantages are not meant to be limiting in any way, as one skilled in the art will appreciate that other advantages may also be realized upon practicing the present disclosure. 
     Furthermore, those skilled in the relevant art will recognize that changes can be made to the described embodiments while still obtaining the beneficial results. It will also be apparent that some of the advantages and benefits of the described embodiments can be obtained by selecting some of the features of the embodiments without utilizing other features, and that features from one embodiment may be combined with features from other embodiments in any appropriate combination. For example, any individual or collective features of method embodiments may be applied to apparatus, product or system embodiments, and vice versa. Accordingly, those who work in the art will recognize that many modifications and adaptations to the embodiments described are possible and may even be desirable in certain circumstances, and are a part of the disclosure. Thus, the present disclosure is provided as an illustration of the principles of the embodiments and not in limitation thereof, since the scope of the invention is to be defined by the claims. 
     Referring now in more detail to the drawing figures, wherein like parts are identified with like reference numerals throughout the several views,  FIG. 2  illustrates a forced air quench system  100  for cooling metallic components  180 , in accordance with one representative embodiment of the present disclosure. While the hot metallic components can be forgings or castings made from steel or aluminum alloys, and the like, for the purpose of convenience and brevity the components will generally be referenced herein as castings made from aluminum alloy. 
     The forced air quench system  100  generally includes a quench enclosure or housing  120  with sidewalls  124  that define a quench or cooling chamber  122  having peripheral portions  123  proximate the sidewalls  124  and a center portion  121  spaced inwardly from the sidewalls. The quench system  100  also includes a conveyance system that carries a component support, such as casting tray  160 , into the center portion  121  of the cooling chamber  122 . In one aspect the conveyance system can be a roller conveyor system  130  having a plurality of support rollers  132  extending across the center portion  121  of the cooling chamber  122 , and that serve as a platform that positions the component support within or proximate to the center portion  121  the cooling chamber  122  during the quench process. Force air fans (not shown) can be located within a lower portion of the quench housing  120  for providing a stream of cooling air  190  that flows upward through the cooling chamber  122  to exit through one or more openings (also not shown) in the upper portion of the quench housing. The roller conveyor system  130  is configured to move one or more casting trays  160  loaded with metallic components  180  into the center portion  121  of the cooling chamber  122  where it will encounter the cooling air  190  provided by the forced air fans. 
     Although in  FIG. 2  the conveyance system is shown as a roller conveyor system  130  and the component support is shown as a casting tray  160 , it will be appreciated that other types of conveyance systems and component supports are also possible and considered to fall within the scope of the present disclosure. For instance, the component support could also be a rack, a basket, and the like, with each having a substantially open construction allowing cooling air to flow therethrough. Likewise, the conveyance system could also be a chain conveyor, a slotted belt conveyor, a robotic manipulator, and the like, with each being capable of carrying the component support, or even the hot metallic component directly in some embodiments, into the center portion  121  of the cooling chamber  122 . In addition, in other aspects the conveyance system may include a platform located within cooling chamber upon which the component support is deposited, and which platform is configured to position the component support within or proximate the center portion of the cooling chamber. 
     As illustrated in  FIG. 2 , the forced air quench system  100  can include a plurality of nozzle baffles  140  that extend inward from sidewalls  124  of the quench housing  120  to the inside of the outermost rollers  132  of the roller conveyor  130 , and that define a narrowing region within the housing between the forced air fan and the platform. During operation of the fan, the nozzle baffles  140  can operate to redirect those portions  192  of the cooling air  190  that flow upward through the peripheral portions  123  of the cooling chamber  122  away from the sidewalls  124  and toward the center portion  121  of the cooling chamber  122 , thereby affecting a first stage increase in the velocity of the forced cooling air  190  as it flows upward through the casting tray  160 . In one aspect the nozzle baffles  140  can include fixed upwardly and inwardly sloped portions  142  that curve aerodynamically into vertical lips  144  that extend upward and adjacent to the inside of the outermost rollers  132  of the conveyance system  130 , without contacting the rollers  132 , so as to maximize the first stage increase in the average velocity of the cooling air  190  while minimizing pressure losses. However, other configurations and/or shapes for the nozzle baffles  140  are possible and considered to fall within the scope of the present disclosure. 
     Although not shown in the schematic side view of  FIG. 2 , it is to be appreciated that similar nozzle baffles can also extend inward from the sidewalls of the quench housing  120  that are perpendicular to the sidewalls  124  shown in the drawing (i.e. into or out of the paper of the drawing). In this case the nozzle baffles can include notches or cutouts that fit around the support rollers  132 . Thus, in some aspects the set of nozzle baffles  140  can redirect and focus the forced cooling air  190  into an area that substantially corresponds to the footprint of the casting tray  160 , or even the footprint of the portion of the casting tray  160  that supports the metallic components  180 , and which will generally be much smaller than the total cross-sectional area of the quench closure  120 . Thus, the set of nozzle baffles  140  can provide a first redirection or concentration of the forced air flow and a corresponding first stage increase in the average flow rate or velocity of the cooling air  190 . 
     Also illustrated in  FIG. 2 , in some embodiments the forced air quench system  100  can further include a plurality of movable central baffles  150  that are located within or near to the gaps  134  between support rollers  132  in the center portion  121  of the quench enclosure or housing  120 . Although viewed from their ends in the drawing, it is to be appreciated that the set of central baffles  150  can be elongate, vane-shaped structures that can substantially span the length of the support rollers. In addition, the central baffles  150  can be supported, either at their ends or at one or more mid-span locations, with an actuated support system that can move or rotate the central baffles  150  from the substantially horizontal orientation shown in  FIG. 2  to a substantially vertical orientation, as well as any desired angular orientation therebetween. As indicated in  FIG. 2 , when moved into a horizontal or angled orientation, the set of central baffles can function to further redirect and concentrate the upwardly-flowing forced cooling air into narrow gaps or channels  136  between the central baffles  150  and the outer circumferential surfaces of the support rollers  132  to form directed streams of cooling air, thereby further increasing the velocity of the cooling air  190  within the directed streams as it flows around and through the metallic components  180 . This second and more localized redirection and concentration of the forced air flow can comprise a second stage increase in the average flow velocity, leading to a corresponding increase in the rate at which heat is collected and drawn away from the hot surfaces of the metallic components being quenched. 
     Although not visible in  FIG. 2 , in one aspect the width of the individual central baffles  150  may vary along the length of the vane-shaped structure (i.e. while moving perpendicular to the plane of the drawing) so as to define channels of varying size and shape that can be optimized to better define and shape the directed streams of cooling air  190 . For example, in some aspects the profile of the central baffles  150  can be shaped to match large openings  182  formed through the metallic components  180  themselves (for example, empty cylinder bores or crank shaft bores), so that a high velocity stream of cooling air can be directed to flow upward through the interior of the metallic components in addition to the high velocity streams of cooling air flowing across the exterior surfaces of the metallic components  180 . In this way a greater proportion of the cooling air provided by the forced air fans can be utilized to cool the metallic components, thereby increasing the effectiveness, efficiency and cooling rates of the quench system  100 . 
     As shown in  FIG. 2 , in one embodiment the roller conveyor system  130  extending across the center portion  121  of the cooling chamber  122 , together with the plurality of nozzle baffles  140  and movable central baffles  150  associated with that roller conveyor system  130 , can define a quench station having a two stage increase in the average velocity of the cooling air. Alternatively, other embodiments having a conveyance system configured to carry a component support into the center portion of the cooling chamber, but without one of the set of nozzle baffles or the set of movable central baffles, may also define a quench station having only a single stage increase in the velocity of the cooling air. 
       FIGS. 3 and 4  are schematic side views of another representative embodiment of the improved forced air quench system  200  that includes two roller conveyor systems  230 ,  235 , with a second or upper roller conveyor  235  positioned directly above the first or lower roller conveyor  230  in the center portion  221  of the cooling chamber  222  of the quench enclosure or housing  220  so that the stream of cooling air provided by the forced air fans (not shown) flows upward through both quench stations. Adding the second roller conveyor  235  can be useful for minimizing the switch out time between a first casting tray  260  loaded with a first group of metallic components  280  and a second casting tray  266  loaded with a second group of metallic components  286  ( FIG. 4 ), as the upper casting tray  266  can be moved into position on the upper quench station without interfering with the simultaneous withdrawal of the lower casting tray  260  from the lower quench station. 
     Both quench stations in the forced air quench system  200  can include a set of nozzle baffles  240 ,  246  and a set of movable central baffles  250 ,  256  that are positioned in the gaps  234 ,  238  between the support rollers  232 ,  236 . As described above, the nozzle baffles  240 ,  246  can serve to redirect and focus the forced cooling air into areas that substantially correspond with the footprints of the portions of the lower and upper casting trays  160 ,  166 , respectively, that support the metallic components  180 ,  186 . As these flow areas will generally be much smaller than the total cross-sectional area of the quench closure  220 , the nozzle baffles  240 ,  246  can provide a first redirection or concentration of the forced air flow and a corresponding first stage increase in flow velocity. 
     Also as described above, the movable central baffles  250 ,  256  that are positioned in the gaps  234 ,  238  between the support rollers  232 ,  236  can provide a second and more localized redirection or concentration of the forced air flow and a corresponding second stage increase in flow velocity. The central baffles can function to further redirect and concentrate the upwardly-flowing forced cooling air into narrow gaps or channels  235  between the central baffles  150  and the outer circumferential surfaces of the support rollers  232 , and in one aspect can include shaped profiles that define and shape the directed streams of cooling air to correspond with openings and/or other structures formed into the metallic components above. In this way the cooling streams can be tailored to provide improved cooling for specific metallic components. 
     As illustrated in  FIG. 3 , when the first casting tray  260  loaded with a first group of metallic components  280  is positioned within the lower quench station, the central baffles  250  that are associated with the first station can be moved or rotated to their active orientations (in this case, a horizontal orientation) that redirects and concentrates the upwardly-flowing forced cooling air into narrow gaps or shaped channels  235  that correspond with the openings  282  and/or other structures formed into the metallic components  280  above. At the same time, the central baffles  256  that are associated with the second station can be moved or rotated to their vertical or inactive orientations so as to reduce the backpressure generated by the overlying structures. 
     For similar reasons, when the first casting tray  260  is withdrawn from the lower quench station and the second casting tray  266  loaded with a second group of metallic components  286  is positioned within the upper quench station, as shown in  FIG. 4 , the central baffles  250  that are associated with the first station can be moved or rotated to their vertical or inactive orientations so as to reduce the pressure losses generated by the underlying structures. At the same time, the central baffles  256  that are associated with the second station can be moved or rotated to their active orientations (e.g. a horizontal orientation) that redirects and concentrates the upwardly-flowing forced cooling air into narrow gaps or shaped channels that correspond with the openings  288  and/or other structures formed into the metallic components  286  above. 
     In another embodiment of the forced air quench system shown in  FIGS. 5A-5B  and  FIG. 6 , the component support (i.e. casting tray  360 ) can be modified to include one or more additional flow directing elements (i.e. tray baffles  370 ) that serve to cover or block portions  366  of the large openings  364  located around the perimeter of the castings  380 , while leaving uncovered the portions of the large openings  364  that are underneath the metallic components  380 . Depending on its construction, in some embodiments the casting tray  360  can also include a plurality of smaller openings  368  formed through the thickness of the tray, and which smaller openings  368  may not be covered by the tray baffles  370  to allow a portion of the cooling air to continue to pass around the outside of the metallic components. Once positioned within the forced air quench system  300 , as shown in  FIG. 6 , the tray baffles  370  can align with the nozzle baffles  340  and the gaps  334  between the support rollers  332  to further redirect and concentrate the upwardly-flowing forced cooling air into the footprints of the metallic components  380 . 
     As shown in  FIG. 5B , in one aspect the tray baffles  370  can be positioned at a mid-height level between the ribs  362 , so that the casting tray is reversible and can be flipped between loadings without any change in contact between successive groups of metallic components  380 . Alternatively, the tray baffles  370  can be mounted to either an upper surface or lower surface of the casting tray  360 , and in one aspect (not shown) can also be curved upward out-of-plane relative to the plane of the casting tray  360  to provide a more aerodynamic redirection of the cooling air flow. 
     In yet another embodiment of the improved forced air quench system illustrated in  FIG. 7 , the movable central baffles  450 ,  456  in the upper and lower quench stations can be configured as part of modular and interchangeable baffle units  452 ,  458 , respectively. In this way each of the central baffles  450 ,  456  in the modular baffle units  452 ,  458  can be customized for a particular type or size of casting, so as to define and shape the direct streams of cooling air and provide improved cooling for specific metallic components. In addition, each of the modular baffle units  452 ,  458  may be configured for mounting with a support frame  434 ,  438  that is located between or at the ends of the support rollers  432 ,  436 . As describe above, the movable central baffles  450 ,  456  can operate together with the generally-fixed nozzle baffles  440 ,  446  extending inward from the sidewalls  424  of the quench enclosure or housing  420  to provide at least a two-stage increase in the flow rate or velocity of the cooling air. 
       FIGS. 8 and 9  are schematic side views of another representative embodiment of the improved forced air quench system  500  that includes two roller conveyor systems  530 ,  535 , with a second or upper roller conveyor  535  positioned directly above the first or lower roller conveyor  530  in the center portion  522  of the cooling chamber  522  defined by the sidewalls  524  of the quench housing  520 . However, in this embodiment the forced air fans (not shown) are located above the quench stations, so that the stream of cooling air  590  provided by the fans flows downward through both roller conveyor systems  530 ,  535 . As described above, the second roller conveyor  535  can be useful for minimizing the switch out time between a first casting tray  560  loaded with a first group of metallic components  580  ( FIG. 8 ) and a second casting tray  566  loaded with a second group of metallic components  586  ( FIG. 9 ), as the upper casting tray  566  can be moved into position on the upper quench station without interfering with the simultaneous withdrawal of the lower casting tray  560  from the lower quench station. 
     Both quench stations in the forced air quench system  500  can include a set of nozzle baffles  540 ,  546  and a set of movable central baffles  550 ,  556 . The nozzle baffles  540 ,  546  can be fixed, and can serve to redirect those portions  592  of the cooling air  590  that flow downward through the peripheral portions  523  of the cooling chamber  522  away from the sidewalls  524  and toward the center portion  521  of the cooling chamber  522 , thereby focusing and increasing the speed of the forced cooling air  590  as it flows downward through and around the metallic components that are supported on the casting trays. In this embodiment, however, the nozzle baffles  540 ,  546  can extend inward from the sidewalls  524  at locations above the roller conveyors  530 ,  535  of each quench station and by a distance  526  that allows a component support  560 ,  566  loaded with metallic components  580 ,  586  to roll in under the nozzle baffles, which in one aspect can include the lower vertical lips  544 ,  548  shown in the illustrated embodiment. In addition, since the nozzle baffles are located above the quench stations, the size and shape of the nozzle baffles  540 ,  546  is not constrained by the roller conveyers. This can allow the nozzle baffles to be configured or customized, if so desired, to more accurately conform to the footprint of the metallic components  580 ,  586  that are loaded on their respective casting trays  560 ,  566 . As these flow areas will generally be much smaller than the total cross-sectional area of the quench closure  220 , the nozzle baffles  240 ,  246  can provide a first redirection or concentration of the forced air flow and a corresponding first stage increase in flow velocity. 
     Similar to the embodiments of the forced air quench system described above, the movable central baffles  550 ,  556  that are positioned near or within the mouth of the nozzle baffles  540 ,  546  can provide a second and more localized redirection or concentration of the forced air flow and a corresponding second stage increase in flow velocity. The central baffles  550 ,  556  can also be provided with shaped profiles that can define and shape the streams of cooling air to correspond with openings and/or other structures formed into the metallic components below, and in this way can be used to tailor the cooling stream to provide improved cooling for specific metallic components. However, since the movable central baffles  550 ,  556  are also located above the quench stations and not constrained by the roller conveyers  530 ,  535 , the number, size and shape of the central baffles  550 ,  556  can be substantially different than those movable baffle designs that are intermixed with the rollers (see, for example, the embodiments of  FIGS. 3-4  or  FIG. 7 ) 
     With reference to  FIG. 8 , when the first casting tray  560  loaded with a first group of metallic components  580  is positioned within the lower quench station ( FIG. 8 ), the central baffles  550  that are associated with the first station can be moved or rotated to their active orientations (in the depicted case, a horizontal orientation) that redirects and concentrates the downwardly-flowing forced cooling air into narrow gaps or shaped channels  535  that correspond with openings or other structures formed into the metallic components  580  below. At the same time, the central baffles  556  that are associated with the second quench station (that is now upstream of the first quench station) can be moved to their vertical or inactive orientations so as to reduce any drag and pressure loses caused by the overlying structures. 
     When the first casting tray  560  is withdrawn from the lower quench station and the second casting tray  566  loaded with a second group of metallic components  586  is positioned within the upper quench station ( FIG. 9 ), the central baffles  550  that are associated with the first station can be moved to their vertical or inactive orientations so as to reduce the backpressure generated by the structures that are now downstream of the metallic components being quenched. At the same time, the central baffles  556  that are associated with the second quench station can be moved or rotated to their active orientations (e.g. a horizontal orientation) that redirects and concentrates the downwardly-flowing forced cooling air into narrow gaps or shaped channels  535  that correspond with the openings or other structures formed into the metallic components  586  immediately below. 
     As indicated above, the invention has been described herein in terms of preferred embodiments and methodologies considered by the inventor to represent the best mode of carrying out the invention. It will be understood by the skilled artisan, however, that a wide range of additions, deletions, and modifications, both subtle and gross, may be made to the illustrated and exemplary embodiments of the composite substrate without departing from the spirit and scope of the invention. For instance, in some embodiments the nozzle baffles may not be fixed structures extending inward from the sidewalls of the quench system housing, but instead may be movable and/or reconfigurable flow directing elements that can be adjusted to accommodate differently-sized component supports. And in other embodiments where the conveyance system is not a roller conveyor, such as, for instance, a robotic manipulator, it will be appreciated that the number, size and shape of the central baffles can be substantially different than those movable baffle designs that are intermixed with the rollers, while still affecting a second stage increase in the average flow velocity. These and other revisions might be made by those of skill in the art without departing from the spirit and scope of the invention that is constrained only by the following claims.