Dual-Solvent Component Cleaning for Faster Complete Degreasing
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Solution Overview
Problem
Existing cleaning methods for industrially manufactured metal and plastic parts are time-consuming and inefficient, often requiring multiple solvent applications and energy-intensive drying processes, leading to contamination and increased effort, while also producing significant wastewater.
Innovation Solution
A method using a mixture of at least two organic solvents and water as a cleaning agent, where a first solvent is water-insoluble and a second solvent is water-soluble, allowing for simultaneous removal of both non-water-soluble and water-soluble contaminants in a single step, followed by solvent vapor condensation at reduced pressure and temperature to enhance cleaning efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple solvent applications and drying processes are used sequentially, then cleaning completeness is improved, but processing time and energy consumption increase significantly
Solution Approach 1:
The patent combines multiple cleaning functions into a single integrated cleaning bath containing both water-soluble and water-insoluble solvents. This allows simultaneous removal of both water-soluble and water-insoluble contaminants in one step, eliminating the need for sequential solvent applications and intermediate drying processes that were required in conventional multi-step methods.
Solution Approach 2:
The cleaning composition serves multiple functions simultaneously: it removes water-soluble contaminants through the water-soluble solvent component, removes water-insoluble contaminants through the water-insoluble solvent component, and eliminates the need for separate drying steps. This multi-functional approach replaces several sequential operations with a single comprehensive cleaning process.
2Reliability
If multiple solvent applications and drying processes are used sequentially, then cleaning completeness is improved, but energy consumption increases due to repeated drying
Solution Approach 1:
The patent merges multiple cleaning and drying operations into a single integrated process. By using a dual-solvent system that handles both water-soluble and water-insoluble contaminants simultaneously, the need for repeated drying cycles is eliminated, thereby significantly reducing energy consumption associated with heating and evaporating solvents in sequential steps.
Solution Approach 2:
The cleaning process maintains continuous action without interruption for drying steps. The dual-solvent system allows the cleaning to proceed continuously in one bath, eliminating idle time and energy-intensive drying phases that would otherwise be required between solvent applications in conventional sequential processes.
3Reliability
If water is applied first in hybrid cleaning systems, then water-soluble contaminants are removed, but water becomes heavily contaminated and service life decreases
Solution Approach 1:
The patent introduces water-insoluble solvents as intermediaries that handle the removal of water-insoluble contaminants (oils, greases) before the water component acts on water-soluble contaminants. This intermediary action prevents water from becoming heavily contaminated with organic substances, thereby extending the service life of the water in the cleaning system.
Solution Approach 2:
The cleaning composition is designed with different components having specific local functions: the water-insoluble solvent component targets water-insoluble contaminants while the water component targets water-soluble contaminants. This localized functionality ensures that water is primarily exposed to water-soluble contaminants rather than becoming heavily contaminated with organic substances, thus extending its usable life.
4Loss of substance
If evaporator is used to purify process water in hybrid cleaning systems, then water is recovered, but considerable energy is required or large amounts of wastewater are produced
Solution Approach 1:
The patent extracts water-insoluble contaminants from the cleaning composition using the water-insoluble solvent component, which forms a separate phase that can be easily removed. This extraction approach allows water to be recovered and reused without requiring energy-intensive evaporation processes, as the contamination is separated physically rather than through thermal evaporation.
Solution Approach 2:
The cleaning system enables easy separation and recovery of the water component from used solvents through phase separation. The water-insoluble solvent and water form distinct layers that can be separated by decantation or phase separation equipment, allowing water to be recovered and reused without the need for evaporators, thereby avoiding both high energy consumption and wastewater generation.
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 process achieves improved cleaning results in less time with reduced effort, eliminating the need for repeated drying processes and minimizing wastewater production, while effectively separating and recovering solvents for reuse.
Implementation Method 1
subsequently, the solvent vapor is fed into the cleaning chamber at a pressure of 200 mbar or below and at a temperature at or above the solvent's flash point. This allows the cleaning of the objects to be completed by condensation of the solvent vapor onto the objects.
Implementation Method 2
A method according to the invention for cleaning industrially manufactured parts made of metal and/or plastic using a cleaning agent is characterized in that a mixture of at least two organic solvents and water is used as the cleaning agent, the mixture comprising at least a first water-insoluble organic solvent and at least a second water-soluble organic solvent.
Data Source
Figure 1
AI summary
The invention relates to a method and to a device for cleaning industrially produced metal and/or plastic components using a cleaning agent, characterised in that a mixture of at least two organic solvents and water is used as the cleaning agent, said mixture comprising at least one non-water soluble organic solvent and at least one water-soluble organic solvent. The invention also relates to a device (1) which is suitable for carrying out the method, comprising a working chamber (2) for the components to be cleaned and at least one tank (3, 4) for feeding the working chamber (2) with a solvent mixture by means of at least one supply means (5, 11) for cleaning the components.