Variable Exposure Gap Infusion for Consistent Linear Substrate Coloring
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Solution Overview
Problem
Existing systems face challenges in consistently adding customer-requested colors and physical or chemical characteristics to linear polymeric substrates, such as hose or wire jackets, in a rapid and cost-effective manner, with difficulties in achieving consistent color control between runs and at different manufacturing locations.
Innovation Solution
A linear substrate infusion compartment with a processing barrel and infusion chamber that allows for the dimensional reconfiguration of an exposure gap, enabling on-demand infusion of components into the substrate, along with a system incorporating a fluid loop and additive sources for rapid color changes and physical/chemical property enhancements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If color is added to linear polymeric substrates by compounding a color into the plastic mixture, then color is distributed throughout the polymeric material, but color determination must be made at the time of manufacture and maintaining a large selection of colored material in stock incurs associated costs
Solution Approach 1:
The system preps the polymeric substrate in a neutral base color and prepares multiple colorant reservoirs in advance. When a customer order arrives, the system immediately infuses the required color without needing to have pre-manufactured and stored that specific colored material, thus reducing inventory costs while maintaining color selection flexibility.
Solution Approach 2:
The patent introduces an intermediary colorant reservoir system between the base polymer and the final colored product. Neutral-colored substrate passes through an infusion chamber where colorants are added on-demand, acting as a mediator that enables rapid color changes without requiring separate production lines for each color.
2Manufacturing precision
If separate lines for each color are used, then color consistency can be maintained, but the device complexity increases and requires multiple monitoring systems
Solution Approach 1:
The patent creates a universal processing line that can handle multiple colors through a single infusion chamber. The system uses interchangeable colorant reservoirs and a single substrate processing line that can be quickly reconfigured between colors, eliminating the need for multiple dedicated production lines while maintaining color consistency through controlled infusion parameters.
Solution Approach 2:
The system dynamically switches between different colorants by replacing reservoirs rather than physically reconfiguring the entire production line. The infusion chamber maintains consistent operational parameters while the colorant source changes, allowing rapid color transitions without the complexity of multiple static production lines.
3Manufacturing precision
If infusion chamber volume is increased to ensure complete substrate exposure to infusion fluid, then consistent coloring is achieved, but the time required for color changes and equipment cleaning increases
Solution Approach 1:
The patent segments the infusion system into a modular reservoir-chamber-discharge arrangement. The infusion chamber is designed with specific geometric features (such as tapered entrances and controlled exit points) that ensure complete substrate exposure to the infusion fluid while maintaining a compact volume. This segmentation allows the chamber to be quickly emptied and refilled with different colorants, reducing color change preparation time while preserving coloring consistency.
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 quick and cost-effective addition of colors and characteristics to linear substrates, ensuring consistent coloring between runs and locations, reducing production time and material waste, and improving customer service by allowing for rapid product customization.
Implementation Method 1
contacting the linear substrate with the infusion fluid within the infusion chamber... the infusion time and the infusion temperature being sufficient to infuse the one or more components of the infusion fluid into the linear substrate
Implementation Method 2
infuse the one or more components of the infusion fluid into the linear substrate
Implementation Method 3
the linear substrate inlet and the linear substrate outlet are moveable between a plurality of relative positions... different configurations of length of an exposure gap defined within the infusion chamber
Data Source
AI summary
An apparatus and method for modifying an aspect of an exterior polymer material or polymer type material of a linear substrate with a fluid. The apparatus include a variable exposure gap within which the linear substrate is exposed to the fluid. The width of the exposure gap is varied with the speed of the linear substrate traversing the exposure gap to maintain a constant exposure time of the linear substrate with the modifying fluid.