Method of washing fabric articles in a continuous batch tunnel washer
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Solution Overview
Problem
Existing continuous batch tunnel washers require multiple modules for effective rinsing, leading to high manufacturing costs and complexity, with counterflow rinsing methods being inefficient and requiring all modules to have outer shells for water flow.
Innovation Solution
Implementing a method that uses high velocity rinsing with fewer modules, where some modules have perforated scoops and outer shells for improved rinsing efficiency, and others do not, allowing for reduced module count and lower manufacturing costs, with booster pumps enhancing rinsing liquid flow rates and allowing for intermittent flow halts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If counterflow rinsing is used in all modules with outer shells, then rinsing function is provided, but manufacturing cost and device complexity increase
Solution Approach 1:
The tunnel washer is divided into distinct functional zones: wash modules without outer shells, rinse modules with outer shells and perforated scoops, and dilution modules with outer shells. This segmentation allows each module type to be optimized for its specific function, reducing the need for all modules to have complex outer shell structures while maintaining effective rinsing through the dedicated rinse zone.
Solution Approach 2:
Outer shells and perforated scoops are applied locally only to modules where they are functionally necessary - specifically in the rinse zone and dilution zone - rather than uniformly across all modules. The wash modules operate without outer shells, reducing overall device complexity and manufacturing cost while the localized rinse modules provide the necessary rinsing function.
2Reliability
If multiple modules with outer shells are used for counterflow rinsing, then rinsing is achieved, but manufacturing cost increases
Solution Approach 1:
The system segments the tunnel washer into wash modules (without outer shells, lower cost) and rinse/dilution modules (with outer shells, higher cost). This allows the expensive outer shell components to be used only where functionally necessary for rinsing and dilution, rather than in all modules, thereby reducing total manufacturing cost while maintaining rinsing effectiveness.
Solution Approach 2:
Outer shells are implemented locally only in the rinse zone and dilution zone where they are needed for containing rinse water and enabling counterflow rinsing. The wash modules operate without outer shells, reducing the quantity of expensive materials and manufacturing steps required, thus lowering overall manufacturing cost while preserving the rinsing function in the dedicated rinse area.
3Productivity
If high velocity rinsing is used, then rinsing efficiency improves, but flow rate requirements increase
Solution Approach 1:
The system uses hydraulic principles to create high velocity rinse water flow through the perforated scoops in the rinse modules. By directing water flow through the specific geometry of the perforated scoop structure, the system generates high velocity rinsing action that effectively removes soil from fabric articles. The dilution modules then add volume to the rinse water to achieve proper dilution of soils and chemicals, separating the velocity generation function from the volume provision function.
Solution Approach 2:
The system changes the flow parameters of rinse water by first creating high velocity flow through the perforated scoops for effective rinsing, then adding volume through the dilution modules to achieve proper dilution. This two-stage parameter adjustment (velocity then volume) allows the system to achieve both high rinsing efficiency and adequate dilution without requiring excessively high flow rates from the beginning.
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 the number of modules needed for effective rinsing and washing, lowers manufacturing costs, and enhances rinsing efficiency with high velocity rinsing, achieving better dilution and washing functions compared to prior art washers.
Implementation Method 1
booster pumps enhancing rinsing liquid flow rates
Implementation Method 2
rinsing by counter flowing liquid in the washer interior at multiple locations along a flow path that is generally opposite the direction of travel of the fabric articles
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 1E
AI summary
A method of washing fabric articles in a continuous batch tunnel washer, comprises providing a continuous batch tunnel washer having an interior, an intake, a discharge, and a plurality of modules that segment the interior. Fabric articles are moved from the intake to the discharge and through the modules in sequence. One or more modules define a wash zone for washing the fabric articles. One or more of the modules are rinse modules that have a perforated scoop. Some of the modules do not have a perforated scoop. After washing fabric articles, the fabric articles can be rinsed by counter flowing liquid in the washer interior at spaced apart modules and along a flow path that is generally opposite the direction of travel of the fabric articles from the intake to the discharge. Velocity rinsing can also replace a continuous counter flow. To improve rinsing and washing, one or more modules may be dilution zone modules, which receives a flow stream from the rinsing modules via a booster pump. A dilution zone module or drum preferably has a perforated scoop to drain the free water when transferring to the next dilution zone module or drum. Drums or modules without shells (carryover modules) have scoops for fabric article (e.g., linen) transfer with no perforations. Thus, the linen and all water go to the next downstream drum at the carryover modules.