Flexographic Washing Liquid Treatment Unit
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Solution Overview
Problem
Current methods for treating water-based washing liquids used in flexographic printing face challenges such as the need for frequent filter cleaning, high water management volumes, and increased construction and management costs, particularly when separating monomers or polymers from water, which limits the effectiveness and efficiency of the washing process.
Innovation Solution
A washing station with a treatment unit comprising two tanks and movable barrier means, where the washing liquid is allowed to rest and separate monomers or polymers from water based on density, with the separated phase overflowing into a second tank, allowing for subsequent distillation to recover the water, reducing the volume of liquid to be managed and eliminating the need for mechanical filters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical filters are used to separate monomer from water-based washing liquid, then separation effectiveness is improved, but filter cleaning frequency increases and downtime increases
Solution Approach 1:
The patent replaces mechanical filtration systems with a thermal separation system. The washing liquid is heated to evaporate water, leaving monomer behind, or condensed from vapor to separate phases. This substitution eliminates mechanical filters and their associated cleaning downtime, resolving the contradiction between separation effectiveness and productivity.
Solution Approach 2:
The invention utilizes phase transitions (evaporation and condensation) to separate monomer from water. By heating the washing liquid to the evaporation point of water, the water transforms from liquid to vapor, leaving monomer in liquid phase. The vapor is then condensed back to liquid form for reuse. This phase-based separation achieves effective separation without mechanical filters, maintaining continuous operation.
2Loss of substance
If distillation process is used to separate monomer from water, then water recovery is improved, but construction costs and management costs increase
Solution Approach 1:
The patent modifies the distillation process by controlling temperature parameters to match the evaporation point of water rather than using full industrial distillation systems. By heating to specific temperature thresholds and utilizing simple condensation, the system achieves water recovery with minimal infrastructure, significantly reducing construction and management costs while maintaining effective separation.
3Reliability
If solvent-based liquid is used for washing plates, then washing effectiveness is improved, but volatile organic compounds are released and disposal becomes complicated
Solution Approach 1:
The invention changes the chemical composition parameter of the washing liquid from solvent-based to water-based. This fundamental parameter change eliminates volatile organic compounds and their associated environmental and disposal problems. The water-based liquid achieves effective washing through the combination of thermal softening and mechanical brushing actions.
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 effectively separates monomers or polymers from water without mechanical filters, reduces the volume of liquid to be managed, and lowers construction and management costs, enhancing the efficiency and reliability of the washing process.
Implementation Method 1
the washing liquid is allowed to rest and separate monomers or polymers from water based on density
Implementation Method 2
allowing for subsequent distillation to recover the water
Data Source
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AI summary
The present invention relates to a unit (100) and a method for treating the water-based washing liquid used in or by a washing station of flexographic plates. The unit (100) comprises a first tank (8) in which the liquid is collected and in which the monomer or polymer contained in the liquid itself surfaces. The unit (100) further comprises a second tank (10) into which part of the liquid contained in the second tank (10) overflows following the opening of barrier means (12). Such means in closing condition isolate the two tanks (8,10). By means of such overflow, a volume of liquid is collected in the second tank (10), which contains the polymer or monomer previously surfaced in the first tank.