Concentric Web Conditioning Modules in Print Dryers
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Solution Overview
Problem
Conventional drum dryers in printing systems have limited options for conditioning the web and are not efficient in energy use, especially for high heat applications, due to their fixed path length and limited adaptability.
Innovation Solution
A concentric arrangement of web conditioning modules around a drum, including semi-circles of rollers and conditioners that direct air or heat towards the web, creating a spiral-like path for enhanced conditioning and efficient energy use, with adjustable components for precise control and maintenance accessibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional drum dryer with fixed path length is used, then the structure is simple, but the adaptability for different web conditioning options is limited
Solution Approach 1:
The dryer is divided into multiple independent conditioning modules arranged in a concentric pattern around the drum. Each module can be independently configured with different components (heaters, air knives, rollers) to provide various web conditioning functions, enabling high adaptability while maintaining modular simplicity
Solution Approach 2:
The concentric modular architecture allows the same physical structure to support multiple web conditioning functions simultaneously. Different modules can perform different functions (drying, cooling, embossing, etc.) and can be selectively activated based on the specific printing application requirements
2Use of energy by moving object
If a conventional drum dryer with limited path length is used, then the device complexity is low, but the energy use efficiency for high heat applications is poor
Solution Approach 1:
The concentric circular arrangement of conditioning modules around the drum creates a curved web path that naturally extends the drying path length without increasing the physical footprint. This curved geometry allows the web to pass through multiple conditioning zones, improving energy efficiency by maximizing heat transfer time
Solution Approach 2:
The web path transitions from a simple linear or planar path to a three-dimensional concentric circular path around the drum. This dimensional change allows the web to traverse a longer effective path length through the heating zones, improving energy efficiency without proportionally increasing device complexity
3Manufacturing precision
If multiple web conditioning components are added to improve adaptability, then the web conditioning control precision improves, but the difficulty of installation and maintenance increases
Solution Approach 1:
Each web conditioning function is implemented as a separate modular component that can be independently installed, adjusted, and maintained. The modular design allows technicians to access and service individual modules without disassembling the entire dryer system, maintaining ease of repair while achieving precise control through multiple specialized components
Solution Approach 2:
Each conditioning module is designed to perform a specific function with optimized local characteristics (e.g., localized heating zones, targeted air knife positions). This localized specialization enables precise web conditioning control in different areas of the web path while keeping each individual module relatively simple and easy to maintain
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 configuration allows for improved web drying efficiency, increased adaptability, and efficient energy use, enabling precise control of web conditioning and facilitating easier installation and maintenance operations.
Implementation Method 1
a hollow metal drum heated with a radiant energy source such as a lamp. The lamp heats the surface of the drum to a desired temperature and the web contacts the heated rotating surface of the drum to dry ink on the web
Implementation Method 2
The conditioning modules may include various combinations of components that eject air or heat toward a web of print media
Data Source
AI summary
Systems and methods for concentric arrangement of web conditioning modules in a dryer of a printing system. In one embodiment a dryer includes a drum, first rollers positioned in an arc around the drum to define a web path between an entrance of the dryer and the drum, and second rollers positioned along the arc between the first rollers and the drum that reverse the web path between the drum and an exit of the dryer. The dryer further includes first web conditioners positioned along the arc and beyond the first rollers from the drum that direct energy toward a portion of the web path that is between the entrance of the dryer and the drum. The dryer further includes second web conditioners positioned along the arc between the second rollers and the drum that direct energy toward a portion of the web path that wraps around the drum.