Tunnel Washer Counterflow Switching for Standing-Bath Main Wash
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Solution Overview
Problem
Current continuous batch tunnel washers use a constant counter flow of wash liquor, which dilutes washing chemicals and wastes thermal energy, and require multiple zones and components, increasing water consumption and energy usage.
Innovation Solution
The method involves stopping counter flow during the main wash to create a standing bath, adding chemicals to separate soil, and then resuming flow to remove suspended soil, with intermediate rinsing in the washer and a final rinse using fresh water in a centrifugal extractor or mechanical press, reducing zones and water usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a constant counter flow of wash liquor is used during main wash, then soil removal is continuous, but washing chemicals are diluted and thermal energy is wasted
Solution Approach 1:
The patent applies periodic action by alternating between counter flow operation and standing bath periods. During main wash, the system operates in standing bath mode (no counter flow) to maintain high chemical concentration and thermal energy. During rinse cycles, counter flow is activated to remove suspended soil. This periodic switching resolves the contradiction by providing intensive chemical action when needed and mechanical flushing when soil removal is the priority.
2Manufacturing precision
If multiple zones and components are used for rinsing, then rinsing effectiveness is improved, but water consumption and energy usage increase
Solution Approach 1:
The patent merges the rinsing function into the main wash zone by using the same chamber for both washing and rinsing operations. Instead of requiring separate rinse zones or additional components, the system performs intermediate rinsing by activating counter flow within the existing main wash module. This consolidation achieves effective rinsing while reducing water consumption and eliminating the need for additional zones.
Solution Approach 2:
The main wash zone is designed to perform multiple functions: it serves as both the washing chamber and the rinsing chamber. By making the main wash module multi-functional, the patent eliminates the need for dedicated rinse zones, thereby reducing overall water consumption and energy usage while maintaining rinsing effectiveness.
3Productivity
If counter flow is used during the entire main wash cycle, then soil suspension is continuous, but chemical effectiveness is reduced due to dilution
Solution Approach 1:
The system uses periodic action by switching between two operational modes: standing bath mode during main wash and counter flow mode during rinse. During standing bath, chemicals act intensively on soil without dilution. During rinse periods, counter flow activates to suspend and remove soil. This temporal separation allows both high chemical effectiveness and continuous soil removal capability.
Solution Approach 2:
The patent maintains continuity of useful action by ensuring that while counter flow is stopped during main wash, the washing process continues effectively in standing bath mode. Then during rinse cycles, counter flow resumes to continuously remove suspended soil. This ensures that the useful action of soil removal is maintained throughout the cycle, just distributed across different operational phases.
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 reduces water consumption, preserves chemical effectiveness, and saves energy by minimizing the number of components and zones, while providing effective rinsing and reducing graying of textiles.
Implementation Method 1
a centrifugal extractor or mechanical press
Data Source
AI summary
A method of washing fabric articles in a tunnel washer includes moving the fabric articles from the intake of the washer to the discharge of the washer through first and second sectors that are a pre-wash zone. In the pre-wash zone, liquid is counter flowed in the wash interior along a flow path that is generally opposite the direction of travel of the fabric articles. The fabric articles are transferred to a main wash zone, and a washing chemical is added to the main wash zone. At about the same time, counter flow is reduced or stopped. The main wash zone can be heated as an option. After a period of time (for example, between about 20 and 120 seconds) counter flow is resumed or increased. In the wash zone, this is considered an intermediate rinse. After the wash zone(s), the increased counter flow after chemical treatment amounts to a pre-rinse. This pre-rinse ensures that the fabric articles are substantially free of soil or the majority of any soil and substantially free of chemicals when they are transferred to an extractor for final removal of excess water. A final rinse (second rinse) is conducted during extraction of excess water.