Cylindrical Suction Box With Dual Pressure Chambers
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Solution Overview
Problem
Existing cylindrical suction boxes with a single suction pressure lead to uneven water distribution in textured fabrics, as air follows the path of least resistance, causing thicker areas to retain more water and requiring longer drying times, increasing production costs.
Innovation Solution
A cylindrical suction box assembly with two or more suction chambers operating at different pressures, where a lower suction pressure chamber is used for texturing and a higher suction pressure chamber for de-watering, with an embossing roller and fluid injectors to evenly distribute water and facilitate de-watering while the fabric is still supported.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single suction pressure is used in the cylindrical suction box, then the structure is simple and easy to operate, but the water distribution becomes uneven with thicker areas retaining more water
Solution Approach 1:
The suction box is divided into multiple suction chambers, each with independent suction pressure control. This segmentation allows different regions to operate at different suction pressures, enabling uniform water distribution across the fabric while maintaining a relatively simple overall structure.
Solution Approach 2:
Different suction chambers are assigned different suction pressures based on local requirements. Chambers dealing with thicker fabric areas use lower suction pressure, while thinner areas use higher suction pressure, achieving uniform water distribution through localized pressure optimization.
2Productivity
If air follows the path of least resistance through thinner fabric areas, then the suction process is efficient, but thicker areas retain more water requiring longer drying times
Solution Approach 1:
The suction pressure parameter is varied across different chambers to optimize both suction efficiency and water distribution. By adjusting pressure parameters locally, the system achieves efficient water removal from thin areas while preventing excessive water loss from thick areas, thereby reducing overall drying time.
3Productivity
If higher suction pressure is applied to remove more water, then de-watering efficiency increases, but the fabric structure may be damaged and energy consumption increases
Solution Approach 1:
Higher suction pressure is applied only in chambers handling thinner fabric areas that require aggressive de-watering, while lower pressure is used in chambers handling thicker areas. This localized pressure application maintains fabric structure integrity while achieving efficient overall de-watering.
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 solution ensures uniform water distribution and reduces energy consumption by removing excess water during the de-watering process, enhancing fabric quality and reducing production costs by drying thicker regions more efficiently.
Implementation Method 1
a cylindrical suction box having at least one lower suction pressure suction chamber and at least one higher suction pressure suction chamber
Data Source
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AI summary
The present invention provides a cylindrical suction box assembly with a suction box having two or more suction chambers that operate at different suction pressures. A lower suction pressure suction chamber is configured to provide lower suction pressure suction and is used in conjunction with the texturing process. At least one higher suction pressure suction chamber is configured to provide higher suction pressure suction and is used in conjunction with the de-watering process of the present invention. Therefore, according to the present invention two processes that are traditionally performed on two different devices are performed on a single cylindrical suction box assembly.