Device and method for drying a textile web
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Solution Overview
Problem
Existing drying technologies for hydroentangled nonwoven fiber fleeces are inefficient in terms of energy and resource usage, and require significant construction effort, as they rely solely on thermal drying methods without effective mechanical dehumidification.
Innovation Solution
The integration of a suction device that uses a suction stream to mechanically detach and remove liquid from the web material in conjunction with thermal drying, allowing for simultaneous mechanical and thermal drying processes on the same conveyor, thereby enhancing dehumidification and reducing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If only thermal drying is used, then the drying process is simple in design, but energy consumption is high and drying efficiency is low
Solution Approach 1:
The patent combines mechanical suction drying with thermal drying into a hybrid system. The suction device mechanically removes liquid from the web while the thermal drying system simultaneously evaporates moisture, achieving synergistic drying effects that improve productivity while reducing energy consumption compared to thermal drying alone.
Solution Approach 2:
The patent replaces part of the thermal drying function with a mechanical suction system. The suction device uses mechanical forces (suction pressure, centrifugal force) to remove liquid, substituting for what would otherwise require thermal energy, thereby reducing overall energy consumption while maintaining or improving drying efficiency.
2Ease of manufacture
If thermal drying alone is used, then the construction is simple, but construction costs and space requirements are high
Solution Approach 1:
The suction device is integrated with the existing conveyor belt system, merging two functions (mechanical drying and material transport) into one system. This integration avoids the need for separate complex construction while achieving faster drying speeds through the combined mechanical-thermal drying approach.
3Productivity
If mechanical suction drying is added, then dehumidification efficiency is improved, but device complexity increases
Solution Approach 1:
The suction device serves multiple functions: it mechanically removes liquid, generates suction flow, and the suction stream is reused for hydroentangling. This multi-functionality justifies the added complexity by delivering significant improvements in dehumidification efficiency while performing additional process functions.
Solution Approach 2:
The suction stream that would otherwise be waste is recovered and reused for hydroentangling the web. This recovery approach offsets the added device complexity by improving overall process efficiency and reducing waste, making the additional complexity worthwhile.
4Loss of energy
If suction stream is not regenerated, then system operation is simple, but energy and resource balance deteriorates
Solution Approach 1:
The suction stream is recovered from the drying process and reused for hydroentangling. This recovery system improves energy and resource balance by eliminating waste, and the patent acknowledges that this adds complexity but justifies it through significant resource conservation and process efficiency improvements.
Solution Approach 2:
The suction stream is fed back into the process for hydroentangling, creating a closed-loop system. This feedback mechanism improves overall energy efficiency by reusing the suction stream's energy and cooling capacity, justifying the additional complexity through enhanced resource utilization.
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 significantly reduces the energy required for thermal drying, accelerates the drying process, and improves the resource balance by recovering heat and liquid for reuse, while minimizing construction and operational costs.
Implementation Method 1
The suction device (5) has at least one suction element (7) arranged on the conveyor (23) for generating a suction flow (6) acting on the web of material (4) at one or more suction points (53) in the web of material (4)
Implementation Method 2
The suction device (5) can further comprise a vacuum generator (8) connected to the suction element (7) for generating the suction flow (6)
Implementation Method 3
The suction device (5) can further comprise a separator (9) connected to the suction element (7) for separating the liquid from the suction flow (6). The flow energy of the suction flow (6) can be advantageously used for separation, particularly in a rotary flow or vortex flow in a centrifugal separator or cyclone separator
Implementation Method 4
The web is transported in a drying chamber with a rotating drum and dried by a ventilation system with heated air
Implementation Method 5
This mechanical drying takes place in addition to the thermal drying of the aeration system
Implementation Method 6
The suction device (5) can also include a heat exchanger, e.g., for the suction flow (6) and/or the dehumidified gas flow emitted by the vacuum generator (8)
Data Source
Figure 1
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AI summary
The invention relates to a drying method and to a drying device (2) for a moist material web (4) which is composed of a textile fibrous material and which has for example been compacted using liquid jets (45). The drying device (2) comprises a drying chamber (22) with an aeration device (29) and an inlet (18), an outlet (19) and a fluid-permeable conveying means (23) for the running material web (4). The material web (4) is transported within the drying chamber (22) by the conveying means (23) and is dried using a heated gas, in particular air. The drying device (2) additionally has a suction device (5) which locally suctions and discharges liquid, in particular water, which is contained in the material web (4) by means of a suction flow (6) at one or more suction locations (53) at the material web (4).