Removable Heat Source Drying Unit for Printed Media

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Solution Overview

Problem

Existing printing systems face challenges in efficiently drying printed media while managing heat flow and energy costs, particularly in high-speed printing environments, where the removal of spent air impacts energy efficiency and heat management.

Innovation Solution

A drying unit with a frame, air box, and removably attached heat sources that allow for continuous web processing, incorporating intake and exhaust ports, and insulating panels to minimize heat loss and maximize energy reuse, enabling the heat source to be serviced without stopping the printing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a drying system is incorporated into a printing press, then the print medium can be dried in real time, but the system becomes complex and difficult to service without removing the print medium

Engineering Contradiction:

Improvedrying speedVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The drying system is divided into modular components: a removable heat source unit and a fixed air box unit. This segmentation allows the heat source to be serviced independently without removing the print medium from the web path, resolving the contradiction between integrated drying functionality and ease of maintenance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The heat source is designed to be dynamically removable and reattachable during operation. This dynamic design enables maintenance access while the printing process continues, maintaining productivity while reducing service complexity.

Inventive Principle:

Principle #15Dynamics

2Loss of energy

If spent air is exhausted from the building, then moisture removal is effective, but heat is lost increasing energy costs

Engineering Contradiction:

Improveheat lossVSAvoiddrying effectiveness

Core Design Contradiction:

Loss of energyVSProductivity

Solution Approach 1:

Instead of discarding the heated air directly to the environment, the system recovers it by circulating the spent air back through the heat source. This recovery process allows the heat to be reused for continuing to dry the print medium, reducing energy loss while maintaining drying effectiveness.

Inventive Principle:

Principle #34Discarding and recovering

Solution Approach 2:

The air circulation system maintains continuous useful action by constantly recycling heated air through the print medium path. This ensures uninterrupted drying effectiveness while maximizing heat utilization and minimizing energy waste.

Inventive Principle:

Principle #20Continuity of useful action

3Temperature

If outside air is used in winter, then drying capacity is sufficient, but energy costs increase due to heating requirements

Engineering Contradiction:

Improveair temperatureVSAvoidheating energy

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The system uses its own exhausted heated air to pre-warm incoming outside air through heat exchange. This self-service approach reduces the heating energy required from external sources while maintaining sufficient air temperature for effective drying.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system merges the heating function with the air circulation function by using the heat source to both warm incoming air and dry the print medium simultaneously. This combined approach reduces total energy consumption compared to separate heating and drying systems.

Inventive Principle:

Principle #5Merging (Combining)

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 enables efficient drying of printed media while reducing energy costs by capturing and reusing heat from spent air, maintaining operational efficiency during servicing of components without disrupting the printing process.

Implementation Method 1

passing the continuous web adjacent the heat source

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 2

A heat source is removably attached to the frame

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 3

an airflow that passes resistor-based heating elements, or an airflow coupled to microwave or infrared radiation

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 4

an insulating panel is disposed adjacent the heat source

Methodology Applied

Scientific EffectThermal Insulation: Thermal Insulation

Data Source

PatentUS8322047B2System and method for drying a freshly printed medium

Publication Date: 2012.12.04 R R DONNELLEY & SONS CO

AI summary

A drying unit includes a frame having an air box mounted thereon, wherein the air box includes an intake port and an exhaust port. A plurality of rollers define a web path within the frame and a heat source is removably attached to the frame, wherein removal of the heat source does not require removal of a web from the web path.