Condenser for Gravure Plating Mist Recovery
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Solution Overview
Problem
Conventional fully automatic gravure plate-making processing systems face issues with processing solution vaporization leading to reduction and jamming in exhaust gas cleaning systems, particularly in copper sulfate plating processes.
Innovation Solution
A processing unit with a condenser is introduced, which condenses vaporized processing solution mist back into liquid for reuse, utilizing an air-cooled condenser with a mist collector to efficiently collect and return the solution to the processing bath, reducing the need for constant solution replenishment and minimizing exhaust gas load.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If the processing solution vaporized into mist is exhausted as is and filtrated with a filter, then the processing solution can be removed from the processing chamber, but the processing solution amount is reduced and the vapor jams in the middle of the passage
Solution Approach 1:
The patent applies phase transition by using a condenser to convert the vaporized processing solution mist back into liquid form. The condenser cools the vapor, causing it to condense and collect in a collection tank, preventing both jamming in the exhaust passage and loss of the processing solution. This resolves the contradiction by transforming the harmful vapor phase into a reusable liquid phase.
Solution Approach 2:
The patent converts the harmful effect of vaporized processing solution (which causes jamming and loss) into a beneficial outcome by condensing it back into liquid form. The condensed liquid is then returned to the processing bath through a return pipe, transforming what was previously a waste problem into a resource recovery solution.
2Quantity of substance
If the processing solution is added after the plate-making process by an amount corresponding to the vaporization amount, then the processing solution amount can be maintained, but the operation complexity increases
Solution Approach 1:
The patent implements self-service by creating a closed-loop system where the condenser automatically condenses the vaporized processing solution and the return pipe automatically returns it to the processing bath. This eliminates the need for manual monitoring and replenishment operations, as the system self-regulates the processing solution quantity through automatic condensation and return.
Solution Approach 2:
The system establishes a feedback loop where vaporized processing solution is continuously monitored, condensed, and returned to the processing bath. This automatic feedback mechanism maintains the processing solution amount without requiring external intervention or complex replenishment operations.
3Object-generated harmful factors
If a mist scrubber is mounted to clean the exhaust gas, then the exhaust gas can be cleaned, but the vapor is still jammed in the middle of the passage
Solution Approach 1:
The patent introduces a condenser as an intermediary device between the processing chamber and the exhaust system. The condenser acts as a mediator that removes the vaporized processing solution before it reaches the exhaust gas cleaning system, preventing jamming in the passage while still allowing the mist scrubber to effectively clean the remaining exhaust gas.
Solution Approach 2:
The patent applies preliminary action by condensing the vaporized processing solution before it enters the exhaust gas cleaning system. This preliminary condensation step prevents the vapor from reaching the mist scrubber and causing jamming, while the mist scrubber continues to handle the cleaned exhaust gas effectively.
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 reuses the processing solution, reducing costs and environmental impact by minimizing solution loss and exhaust gas volume, thereby alleviating the burden on exhaust gas cleaning systems and improving system efficiency.
Implementation Method 1
a condenser (22) provided between the processing bath (12) and the exhaust port (20)... capable of condensing, during a plate-making process, a processing solution vaporized into the form of mist
Implementation Method 2
utilizing an air-cooled condenser with a mist collector to efficiently collect and return the solution
Data Source
Figure 1
Figure 2
AI summary
Provided is a processing unit including a condenser, which is capable of condensing, during a plate-making process to be performed by the processing unit in a fully automatic gravure plate-making processing system, a processing solution vaporized into the form of mist so as to reuse the resultant as the processing solution, and to provide a fully automatic gravure plate-making processing system using the processing unit including a condenser. The processing unit includes a condenser, which is to be used for a fully automatic gravure plate-making processing system for manufacturing a plate-making roll by performing a series of processes on an unprocessed plate-making roll. The processing unit includes: a processing bath; chuck means for holding a gravure cylinder inside the processing bath; an intake port for taking in air, which is provided in a part of the processing bath; an exhaust port for exhausting gas, which is provided in another part of the processing bath; a condenser provided between the processing bath and the exhaust port; and a processing solution return pipe for returning, to the processing bath, a processing solution obtained by the condenser that liquefies a part of the gas to be exhausted.