Textile Web Heat Treatment with Exhaust Air Recirculation
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Solution Overview
Problem
Existing heat treatment devices for textile material webs face challenges in achieving energy savings and increased efficiency in the drying and fixing processes.
Innovation Solution
The device incorporates successive impingement jet ventilation zones with an upstream aeration zone where the exhaust air from these zones is directed through the material web, using fans to pull or push the air, which cools and concentrates moisture, and includes carrier belts for support and distortion correction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If exhaust air is discharged from impingement jet ventilation zones without further utilization, then the device structure is simple, but energy is wasted and drying efficiency is reduced
Solution Approach 1:
The patent converts the harmful waste heat in exhaust air into a beneficial resource by directing it through the aeration zone to preheat the material web before it enters the impingement jet ventilation zones. This transforms energy that would otherwise be lost into useful thermal energy for the drying process, thereby reducing overall energy consumption without requiring complex additional heating systems
Solution Approach 2:
The patent recovers thermal energy from the exhaust air that would normally be discarded. By routing the exhaust air through the aeration zone, the system captures and utilizes the thermal energy contained in the exhaust stream to preheat the incoming material web, thereby reducing the energy burden on subsequent drying zones
2Productivity
If material web is supported by traditional means (metal sheets or conveyor belts) in aeration zone, then support is provided, but ironing effects occur and drying efficiency is reduced
Solution Approach 1:
The patent replaces traditional mechanical support systems with a pneumatic support system using an air support table. Compressed air is directed through nozzles to create an air cushion that supports the material web, allowing it to remain suspended and maintain its natural wave profile without contact with solid surfaces. This eliminates ironing effects while providing adequate support for the web during the aeration process
Solution Approach 2:
The air cushion created by the air support table acts as a flexible, conforming support surface that adapts to the natural wave profile of the material web. Unlike rigid metal sheets or conveyor belts, the air cushion provides support without imposing a fixed geometry, thereby preventing distortion and ironing effects while maintaining web stability
3Loss of energy
If treatment gas is circulated and repeatedly heated, then energy is saved compared to continuous fresh air heating, but moisture concentration in exhaust air increases reducing drying efficiency
Solution Approach 1:
The patent divides the drying system into distinct functional zones: an aeration zone for initial moisture removal and conditioning, followed by multiple impingement jet ventilation zones for intensive drying. This segmentation allows the circulated treatment gas to be used effectively in the impingement zones while the aeration zone handles the moisture-laden exhaust air separately, preventing saturation issues in the main drying path
Solution Approach 2:
The aeration zone performs preliminary drying and conditioning of the material web before it enters the impingement jet ventilation zones. By removing excess surface moisture and equilibrating the web moisture content in advance, the subsequent impingement zones can operate more efficiently with circulated air, as the web is better prepared to accept and release moisture in controlled amounts
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 approach enhances drying performance, saves energy, and ensures even heating, allowing for quicker and more efficient drying and fixing processes while correcting non-linear distortions in the material web.
Implementation Method 1
a fan which is arranged in the area of the ventilation zone in such a way that it pulls the exhaust air through the web of material or pushes the exhaust air through the web of material
Implementation Method 2
The treatment gas, for example heated air, is circulated, i.e. repeatedly heated, applied to the web and returned. The treatment gas absorbs the moisture.
Implementation Method 3
By directing the exhaust gases through the material web in the upstream aeration zone, the exhaust air can continue to cool down to the cooling limit temperature, with energy being supplied to the material web.
Implementation Method 4
the web of material being in contact in the aeration zone with at least one carrier belt aligned in the direction of transport of the web of material
Data Source
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AI summary
An initial treatment zone (1) in the direction (21) of web transport, is designed to force air through the textile web (7). Equipment removing used air from the air jet zones, is connected to this initial treatment zone, such that outgoing air is directed through the web. A fan (12) induces the outgoing air and is located near the initial zone, in order to draw it through the web, or force it through under pressure. First and second fans (11, 12) are used, the initial treatment zone being located between them. An independent claim is included for the corresponding method.