Compact Fabric Pretreatment Sprayer for Uniform DTG Coating

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Solution Overview

Problem

Existing methods for applying pretreatment liquids in direct-to-garment printing, such as brushes, rollers, and large automated sprayers, often fail to provide a smooth, even, and uniform application, making them unsuitable for at-home businesses due to size and cost constraints.

Innovation Solution

A compact spray device that positions a fabric on a substrate, activates a pump-driven sprayer, and adjusts height, velocity, and pressure to apply pretreatment liquid uniformly as it moves from one position to another, allowing for precise control over the application rate.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If large automated mechanical sprayers are used to apply pretreatment liquid, then uniform application is achieved, but device size and cost increase making them unsuitable for at-home businesses

Engineering Contradiction:

Improveuniformity of pretreatment liquid applicationVSAvoidsize and cost of spray device

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system divides the fabric treatment process into discrete spray zones along the conveyance path, with multiple spray heads positioned at different locations to treat different sections of the fabric sequentially, enabling uniform application without requiring a single large complex device

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A fabric conveyance system acts as an intermediary mechanism, transporting the fabric through the spray zone while maintaining proper positioning and tension, allowing the spray device to remain compact while still achieving uniform pretreatment application across the entire fabric width

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If hand application methods (brushes, rollers, hand sprayers) are used, then device size and cost are reduced, but smooth and uniform application of pretreatment liquid cannot be achieved

Engineering Contradiction:

Improvesize and cost of spray deviceVSAvoiduniformity of pretreatment liquid application

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The system replaces manual mechanical application methods with an automated spray system that uses controlled liquid delivery mechanisms, pumps, and spray nozzles to achieve uniform application without requiring manual operation, thereby maintaining simplicity while improving precision

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The spray system is designed to automatically regulate its operation through the interaction of spray heads, fabric conveyance, and liquid delivery mechanisms, maintaining consistent application parameters without requiring continuous manual adjustment or intervention

Inventive Principle:

Principle #25Self-service

3Productivity

If spray device moves quickly from first position to second position, then productivity increases, but uniform application rate cannot be maintained

Engineering Contradiction:

Improvespray device movement speedVSAvoiduniformity of pretreatment liquid application rate

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system employs dynamic control of the spray device movement and liquid delivery rate, adjusting parameters in real-time based on position and fabric speed to maintain consistent application rate even during accelerated movement between positions

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The spray system maintains continuous liquid delivery and fabric conveyance during movement between positions, ensuring that the pretreatment application process never interrupts or varies in quality, thereby maintaining uniformity while enabling rapid repositioning

Inventive Principle:

Principle #20Continuity of useful action

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

Enables a controlled and uniform application of pretreatment liquid to fabrics, optimizing the printing surface while minimizing overspray and ensuring consistent wash durability, suitable for use in at-home settings.

Implementation Method 1

activating a pump-driven sprayer

Methodology Applied

Scientific EffectPump: Pump

Implementation Method 2

spraying the pretreatment liquid onto the fabric material

Methodology Applied

Scientific EffectSpray: Spray

Data Source

PatentUS11486071B2Spray device and method for use thereof

Publication Date: 2022.11.01 WALKER BRIAN A

AI summary

A spray device and a method of using the spray device are provided. The spray device facilitates the application of a liquid such as a pretreatment liquid to an area of a fabric material. The spray device can be positioned on or adjacent portions of the fabric material and/or a substrate supporting the fabric material. The spray device can be activated to spray the pretreatment liquid and move the spray device on portions of the fabric material and/or the substrate supporting the fabric material.