Continuous batch tunnel washer and method
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Solution Overview
Problem
Current continuous batch tunnel washers dilute washing chemicals due to constant counterflow, reducing their effectiveness, and require additional modules for rinsing, leading to higher water consumption and increased costs.
Innovation Solution
Implementing a method with booster pumps to maintain constant pressure and velocity of counterflow rinse water, using dual-use modules for both washing and rinsing, and interrupting counterflow for most of the cycle to create standing baths, allowing chemicals to work at full concentration, followed by high-velocity counterflow for efficient rinsing, which reduces water usage and module requirements.
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 applies periodic action by interrupting the counterflow during the wash cycle to allow chemicals to work at full concentration, then restoring counterflow for rinsing. The counterflow is stopped for about the first 65-75% of each transfer cycle and then applied at high velocity for the final 25-35% of the cycle, creating periodic intervals of chemical action and rinsing action.
2Productivity
If additional modules are added for dedicated rinsing, then rinsing capacity is increased, but water consumption and costs increase
Solution Approach 1:
The patent applies universality by making modules dual-use, capable of functioning as both wash modules and rinse modules. The counterflow can be directed to different modules depending on whether they are in wash or rinse mode, eliminating the need for separate dedicated rinse modules and reducing overall water consumption.
3Speed
If counterflow velocity is increased for faster rinsing, then rinsing time is reduced, but water pressure requirements and energy consumption increase
Solution Approach 1:
The patent applies periodic action by using high-velocity counterflow only during the final 25-35% of the transfer cycle when rinsing is needed, rather than maintaining high velocity continuously. This reduces overall energy consumption while achieving fast rinsing when required.
Solution Approach 2:
The patent applies parameter changes by varying the counterflow velocity and duration based on process requirements. The counterflow is applied at very fast rates (300-400% of normal rate) for short intervals during rinsing, optimizing the balance between rinsing effectiveness and 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 enhances chemical performance, reduces water consumption, and increases throughput by allowing chemicals to work undiluted for most of the cycle, achieving faster rinsing with less water and fewer modules, while maintaining high-velocity counterflow for effective contaminant removal.
Implementation Method 1
Booster pumps can be placed at intervals to increase the pressure and/or velocity of counter flowing rinse water
Implementation Method 2
After a final module, fabric articles can be transferred to a liquid extraction device (e.g., press or centrifuge) that removes excess water
Data Source
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. During rinsing, extracted water or reuse water is first used to rinse followed by a clean water rinse.