Atomized Steam Roll and Plenum for Web Heating Without Condensation
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Solution Overview
Problem
Existing methods for applying steam to web substrates are inefficient, leading to steam condensation on processing equipment, debris dislodgement, and insufficient heat transfer to the web material, resulting in reduced product quality and increased maintenance costs.
Innovation Solution
An apparatus using a positively pressured permeable roll with apertures to deliver atomized steam directly to the web material, combined with a negatively pressured receipt plenum to enhance steam impingement and retention, ensuring effective heating and moisturization of the web substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If steam is applied to web material in an ambient environment using a steam boom, then the web material can be heated and moisturized, but steam condenses on processing equipment causing rust and equipment degradation
Solution Approach 1:
The patent introduces a controlled enclosure or hood system as an intermediary between the steam application point and the ambient environment. This enclosure captures steam molecules before they can escape and condense on equipment, directing them instead toward the web material while protecting surrounding equipment from harmful condensation
Solution Approach 2:
The patent converts the potentially harmful escaping steam into a beneficial resource by using the enclosure to redirect it. The steam that would otherwise condense on equipment and cause rust is now channeled to effectively treat the web material, turning a harmful side effect into an enhanced processing benefit
2Temperature
If steam is applied to web material using conventional methods, then heating can occur, but debris on the web material dislodges and deposits on damp equipment
Solution Approach 1:
The enclosure acts as an intermediary barrier that traps debris-laden steam within a controlled zone. This prevents dislodged debris from traveling freely to equipment surfaces, while still allowing the steam to effectively heat and moisturize the web material within the enclosed space
Solution Approach 2:
The patent converts the harmful debris contamination issue into a manageable situation by using the enclosure to contain and control debris movement. The debris remains within the enclosed processing zone where it can be managed through proper exhaust or collection systems, rather than contaminating equipment
3Ease of manufacture
If steam is applied using stainless steel pipe booms, then steam delivery is simple, but insufficient steam impingement occurs due to molecular rebound and passing through the web
Solution Approach 1:
The patent segments the steam delivery system into multiple components: the steam boom, the enclosed processing chamber, and controlled exhaust. This segmentation allows each component to perform its specific function - the boom delivers steam, the enclosure traps and directs it, and the exhaust removes excess - thereby improving overall steam utilization efficiency
Solution Approach 2:
The patent adds the spatial dimension of an enclosed chamber around the steam application point. This creates a three-dimensional controlled environment that confines steam molecules in the processing zone, increasing the probability of multiple impingements on the web material rather than simple rebound or pass-through
4Loss of energy
If complex steam processing systems with steam boxes and chambers are used, then steam efficiency increases, but device complexity and cost increase significantly
Solution Approach 1:
The patent extracts only the essential elements needed for efficient steam processing - specifically the enclosure/hood and controlled exhaust - while eliminating unnecessary complex components. This creates a streamlined system that achieves high steam efficiency without the complexity of full steam boxes and chambers
Solution Approach 2:
The patent applies complexity only where needed - the enclosure and exhaust controls are concentrated at the steam application zone - while leaving the rest of the processing system simple. This localized approach to complexity achieves high efficiency without requiring complex systems throughout the entire processing line
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 increases the web material's temperature and moisture content, making it more susceptible to plastic deformation, thereby improving embossment quality and tensile efficiency while minimizing equipment contamination and maintenance.
Implementation Method 1
fluid source has atomized fluid disposed therein that is disposable from the inner portion to the surface through the apertures
Implementation Method 2
a portion of the atomized fluid contacting the first surface of the web material is then contained by the receipt plenum
Implementation Method 3
The receipt plenum provides a source of negative pressure to the second surface of the web material
Implementation Method 4
condensation on the web material, due to the impingement of steam thereon, effectively increases the temperature of the web material and its effective moisture content. This is believed to effectively plasticize the web
Data Source
AI summary
An apparatus for the application of atomized fluid to a permeable web material is disclosed. The apparatus has a fluid source and a receipt plenum. The fluid source is disposed in proximate fluid contact with the first surface of the web material. The fluid source has a positively pressured permeable roll having atomized fluid and at least one aperture disposed therein. The apertures provide fluid communication between an inner portion of the roll and a surface thereof. The fluid is disposable from the inner portion to the surface through the apertures into contacting engagement with the permeable web material. The receipt plenum has an opening disposed adjacent to the second surface of the web material that provides a source of negative pressure to the second surface of the web material that causes the fluid to traverse through the web.