Atomized Steam Web Treatment With Negative-Pressure Plenum
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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 dislodgment, and insufficient heating of the web material, which can result in product contamination and equipment maintenance issues, while also being costly and complex.
Innovation Solution
An apparatus using a permeable belt with a fluid source and receipt plenum to apply atomized steam to the web substrate, ensuring intimate contact and condensation onto the substrate, enhancing its temperature and moisture content for improved plastic deformation during downstream processing.
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 receives steam treatment, but steam condenses on processing equipment causing rust and equipment lifespan reduction
Solution Approach 1:
A controlled enclosure or hood structure is introduced as an intermediary between the steam boom and the ambient environment. This enclosure directs steam flow onto the web material while preventing steam from contacting surrounding processing equipment, thereby eliminating rust-causing condensation on equipment while maintaining effective steam treatment of the material.
Solution Approach 2:
The harmful element (steam) is extracted from the general ambient environment and confined to a specific treatment zone. By using localized enclosures or directed steam delivery systems, steam is separated from areas where it would cause rust on equipment, allowing steam treatment to occur only where needed without the harmful side effects.
2Temperature
If steam is applied to passing web material, then the web material is heated and moisturized, but debris on the web material dislodges and deposits on damp processing equipment
Solution Approach 1:
A controlled enclosure or localized treatment zone serves as an intermediary that contains the steam-debris interaction. This enclosure prevents dislodged debris from escaping into the ambient environment and depositing on processing equipment, while still allowing the steam treatment to effectively heat and moisturize the web material.
Solution Approach 2:
The steam that would otherwise cause harmful debris dislodgment is converted into a beneficial plasticizing agent by controlling its application. By using atomized steam delivery and controlled enclosures, the steam softens the web material for improved downstream processing without causing excessive debris generation, effectively converting a potentially harmful effect into a useful one.
3Speed
If steam particles are released from the steam boom with sufficient momentum, then the steam can reach the web material, but the steam particles rebound off or pass through the web material without providing heating effects
Solution Approach 1:
The steam delivery system transitions from a static steam boom to a dynamic atomized steam delivery system. Atomized steam particles are delivered at controlled velocities that optimize penetration into the web material. The dynamic control of particle size and velocity ensures steam particles have sufficient momentum to penetrate the material while maintaining enough contact time for effective heat transfer and condensation.
Solution Approach 2:
The physical parameters of steam delivery are changed from high-velocity molecular flow to atomized droplet flow. By controlling droplet size, velocity, and distribution, the steam delivers both sufficient momentum for penetration and adequate residence time for condensation and heat transfer. This parameter optimization resolves the contradiction between reaching the material and effectively heating it.
4Productivity
If complex steam processing systems with steam boxes and chambers are used, then steam application efficiency is improved, but device complexity and cost increase significantly
Solution Approach 1:
The complex steam box and chamber system is segmented into simpler, modular components. Instead of large enclosed chambers, the system uses distributed atomized steam delivery points along the web path. Each atomized delivery point is a simple component that can be independently controlled and maintained, achieving high efficiency without the complexity of large-scale enclosed systems.
Solution Approach 2:
The system replaces complex mechanical steam box structures with pneumatic/atomized steam delivery mechanisms. Atomized steam is delivered through controlled pressure systems that create fine droplet sprays, eliminating the need for large steam boxes, complex flow paths, and extensive condensation management infrastructure while maintaining or improving steam application efficiency.
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 effectively increases the web substrate's temperature and moisture content, enhancing its susceptibility to plastic deformation, leading to improved embossment quality and tensile efficiency without the drawbacks of existing methods.
Implementation Method 1
The receipt plenum provides a source of negative pressure to the second surface of the web material
Implementation Method 2
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
Implementation Method 3
the impingement of steam upon the passing web material can cause debris resident upon the web material to dislodge
Data Source
AI summary
An apparatus for the application of atomized fluid to a web material having a first surface and a second surface opposed thereto is disclosed. The apparatus is provided with a fluid source disposed adjacent to the first surface of the web material and a receipt plenum disposed adjacent to the second surface of the web material. The receipt plenum provides a source of negative pressure to the second surface of the web material. A fluid disposed from the fluid source contacts the first surface of the web material and is caused to traverse therethrough by the source of negative pressure. A portion of the fluid contacting the first surface of the web material is contained by the receipt plenum.