Air-Drying Module with Segmented Exhaust Flow for Uniform Drying
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Solution Overview
Problem
Conventional infrared dryer systems for substrates lack reproducibility and efficiency in terms of homogeneity and speed of drying, particularly for solvent-based and water-based dispersions, due to undefined air flow interactions and potential vortex formation leading to inefficient moisture removal.
Innovation Solution
The method involves splitting the exhaust air flow into multiple sub-flows through individual intake channels and positioning the supply air flow either upstream or downstream of the exhaust air flow relative to the substrate movement, with a controlled angle of incidence to break through flow boundary layers and minimize vortex formation, using a compact air dryer module design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional infrared dryer systems use heating devices and ventilation systems to generate air flow, then the substrate can be dried, but the drying homogeneity and speed are not reproducible due to undefined air flow interactions
Solution Approach 1:
The exhaust air flow is divided into multiple sub-flows by introducing several intake channels instead of a single exhaust channel. This segmentation allows each sub-flow to be extracted independently, preventing vortex formation and ensuring uniform drying across the substrate surface, thereby improving both drying homogeneity and reproducibility
Solution Approach 2:
The air flow direction is changed from a single-dimensional extraction to a multi-dimensional extraction pattern. By positioning intake channels at different locations and orientations, the system creates a three-dimensional air flow pattern that effectively removes moisture from the substrate surface without forming vortices, improving drying uniformity
2Productivity
If a single exhaust air flow is used to remove moisture-laden air, then the system is simple, but vortex formation occurs leading to inefficient moisture removal
Solution Approach 1:
The single exhaust air flow is segmented into multiple sub-flows by introducing multiple intake channels. This segmentation prevents vortex formation by distributing the extraction points, thereby improving moisture removal efficiency without creating a complex system
Solution Approach 2:
The potential harmful effect of vortex formation is converted into a beneficial effect by using the vortex tendency to drive the segmented air flows through the intake channels. The segmented structure harnesses the natural flow patterns to improve moisture removal while preventing the formation of harmful large-scale vortices
3Manufacturing precision
If supply air flow is directed onto the substrate to break through flow boundary layers, then mass transfer is enhanced, but energy consumption increases
Solution Approach 1:
The supply air flow continuously breaks through flow boundary layers along the substrate surface, maintaining optimal drying conditions throughout the drying process. This continuous action ensures uniform drying while minimizing energy consumption by avoiding the need for high-temperature heating
Solution Approach 2:
The system changes the flow parameters by directing supply air at specific angles and velocities to optimize boundary layer disruption. By controlling air flow parameters rather than relying on high temperature, the system achieves uniform drying with lower energy consumption
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 achieves rapid and effective drying with low energy consumption by controlling air turbulence and ensuring uniform drying across the substrate, reducing vortex formation and enhancing mass transfer, thus improving drying efficiency and reducing environmental contamination.
Implementation Method 1
controlling air turbulence and ensuring uniform drying across the substrate, reducing vortex formation and enhancing mass transfer
Implementation Method 2
the supply air flow is directed onto the substrate surface... breaking through flow boundary layers
Implementation Method 3
Physical drying processes comprise the evaporation of solvents (in particular water) and the diffusion of solvents into the print substrate
Implementation Method 4
generating an exhaust air flow leading away from the substrate... moisture-laden air is removed as exhaust air
Implementation Method 5
Conventional infrared dryer systems have other functional components besides infrared lamps
Implementation Method 6
The infrared lamp is arranged within a process space for the print substrate... heated in the space using a heating device
Implementation Method 7
potential vortex formation leading to inefficient moisture removal... reducing vortex formation
Data Source
AI summary
A method for at least partially drying a substrate. The method includes: (a) directing a supply air flow onto the substrate with a direction component in either the transport direction, or the opposite direction and (b) directing an exhaust air flow away from the substrate. The method is reproducible and effective and achieves an improved result with respect to the homogeneity and speed of drying because the exhaust air flow is split into a plurality of sub-flows by supplying each of the sub-flows to an individual intake channel, and because, in the event of a supply air flow in the transport direction of movement of the substrate, the supply air flow is arranged spatially upstream of the exhaust air flow and, in the event of a supply air flow in the opposite direction, the supply air flow is arranged spatially downstream of the exhaust air flow.