Electrospraying Coating Device for Thread Dyeing to Reduce Clogging
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Solution Overview
Problem
Current embroidery techniques require frequent thread changes for color variations, leading to inefficiencies and limitations in expressing continuous color transitions, and existing ink jet printing devices face issues with ink coverage, clogging, and complexity.
Innovation Solution
A coating device using an electrospraying unit with emitters, thread guiding means, voltage supply, and a counter electrode to dynamically apply ink to a thread, featuring a diversion electrode for improved ink distribution and a capillary tube design to reduce clogging and increase precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a small ink jet nozzle is used to obtain small droplets and optimized ink coverage, then manufacturing precision and ink distribution quality improve, but the risk of clogging increases and device reliability decreases
Solution Approach 1:
The patent replaces the mechanical ink jet nozzle system with an electrospraying system that uses electrical fields to generate and control ink droplets. The electrospraying unit employs an emitter with a capillary tube and voltage supply means to create charged droplets through electrostatic forces, eliminating the mechanical nozzle that is prone to clogging while maintaining precise ink distribution control
Solution Approach 2:
The patent changes the physical parameters of ink application by using electrospraying technology that controls droplet formation through voltage and electrical field parameters rather than mechanical nozzle dimensions. The capillary tube diameter (0.1-1.0 mm) and voltage (1-20 kV) are optimized parameters that enable precise ink distribution without the clogging issues of traditional small nozzles
2Object-generated harmful factors
If a small ink jet nozzle is used to maintain ink inside the head when no discharge is wanted, then ink leakage is reduced, but the nozzle is more susceptible to clogging and has shorter lifespan
Solution Approach 1:
The patent replaces the mechanical ink jet nozzle with an electrospraying emitter that uses electrical fields to control ink discharge. The emitter with capillary tube and voltage supply means allows precise control of droplet formation and discharge timing through electrostatic forces, eliminating the mechanical nozzle that requires small openings for ink retention, thereby preventing clogging while maintaining leak-free operation
Solution Approach 2:
The electrospraying system uses the electrical field itself to control both ink discharge and ink retention within the emitter. The voltage supply means enables the system to self-regulate ink flow and droplet formation without mechanical components, allowing the emitter to maintain ink internally through electrostatic control rather than mechanical constriction
3Ease of manufacture
If traditional ink jet printing is used to dye threads, then color application is achieved, but the device complexity increases and ink coverage is unsatisfactory
Solution Approach 1:
The patent extracts the core ink discharge function from the complex ink jet printing system and implements it through a simplified electrospraying unit. By removing the unnecessary mechanical complexity of traditional ink jet heads and retaining only the essential droplet generation and discharge functions through electrical fields, the patent achieves simpler device construction with superior ink coverage on threads
Solution Approach 2:
The patent changes the fundamental parameters of ink application from mechanical spray to electrospraying, using voltage and electrical field strength as control parameters instead of mechanical pressure and nozzle geometry. This parameter change enables better ink coverage on threads while simplifying the overall device structure
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
The solution provides better ink coverage, reduces the risk of clogging, and extends the device's lifespan, enabling more precise and efficient color application with reduced mechanical complexity and increased color range.
Implementation Method 1
a coating device using an electrospraying unit with emitters, thread guiding means, voltage supply, and a counter electrode to dynamically apply ink to a thread
Implementation Method 2
voltage supply means and a counter electrode arranged at opposite sides of the thread in use, such that an electric field created between each respective emitter and the counter electrode means
Data Source
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AI summary
A device and system for dynamically applying liquid to a single thread for a thread consuming device as said thread moves relative to the device along a path of movement. The device is configured to apply liquid to said thread by means of an electrospraying unit. A method for applying liquid to a single thread for a thread consuming device as said thread moves relative to the device along a path of movement is also provided.