Continuous Batch Tunnel Washer Dual-Use Modules for Counterflow Rinsing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Continuous batch tunnel washers with constant counterflow dilute washing chemicals, reducing their effectiveness, and require additional modules for rinsing, leading to increased water consumption and operational inefficiencies.
Innovation Solution
Implementing an interrupted counterflow method with booster pumps to maintain high velocity and pressure of rinse water in selected modules, allowing for dual-use modules that function as both wash and rinse, and using a water extraction device to minimize water usage and chemical dilution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If constant counterflow is used during the entire wash cycle, then rinsing is continuous, but washing chemicals are diluted and their effectiveness is reduced
Solution Approach 1:
The patent implements periodic counterflow by alternating between washing phases (with chemicals) and rinsing phases (with counterflow). During washing phases, counterflow is minimized or stopped to maintain chemical concentration. During rinsing phases, counterflow is activated to rinse the fabric. This periodic operation allows both effective washing and effective rinsing without continuous chemical dilution.
2Productivity
If additional modules are added for dedicated rinsing, then rinsing capacity is increased, but device complexity and water consumption increase
Solution Approach 1:
The patent makes the washing modules multi-functional by enabling them to perform both washing and rinsing operations. During rinsing phases, the same modules that were used for washing are utilized for rinsing by activating counterflow. This eliminates the need for separate dedicated rinsing modules, reducing device complexity while maintaining rinsing capacity.
3Productivity
If additional modules are added for dedicated rinsing, then rinsing capacity is increased, but water consumption increases
Solution Approach 1:
The patent implements water recovery by collecting rinse water from downstream modules and reusing it in upstream modules through the counterflow system. This recycling approach reduces fresh water consumption while maintaining effective rinsing capacity across all modules.
4Speed
If high velocity counterflow is applied throughout, then rinsing speed is increased, but chemical dilution occurs during washing phases
Solution Approach 1:
The patent applies high velocity counterflow only during dedicated rinsing phases when chemicals are not being added. During washing phases, counterflow is reduced or stopped to prevent chemical dilution. This timing-based approach ensures that high-speed rinsing occurs only when it is most effective, without compromising washing chemical performance.
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 enhances chemical performance, reduces water consumption, and increases throughput by allowing chemicals to work at full concentration, achieving faster rinsing with less water and fewer modules required, while maintaining high-velocity recirculation for effective cleaning.
Implementation Method 1
Multiple booster pumps are placed at intervals to increase the pressure and/or velocity of counter flowing rinse water
Implementation Method 2
fabric articles can be transferred to a liquid extraction device (e.g., press or centrifuge) that removes excess water
Implementation Method 3
fabric articles can be transferred to a liquid extraction device (e.g., press or centrifuge) that removes excess water
Data Source
Figure 1
Figure 2
AI summary
A method of washing fabric articles in a tunnel washer that includes moving the fabric articles from the intake of the washer to the discharge of the washer and through multiple modules or sectors. Liquid can be counter flowed in the washer interior along a flow path that is generally opposite the direction of travel of the fabric articles. A dual use zone includes multiple of the modules or sectors. In a dual use zone, a module or modules can be used to both wash and thereafter rinse the fabric articles. While counterflow rinsing, the flow rate can be maintained at a selected flow rate or flow pressure head. One or more booster pumps can optionally be employed to maintain constant counterflow rinsing flow rate or constant counterflow rinsing pressure head.