System and a method for in-line treatment of two or more threads for use with thread consuming device
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Solution Overview
Problem
Existing thread consuming devices, such as embroidery machines, require multiple threads of different colors for multi-colored patterns, which is costly and space-consuming, and existing in-line coloration systems can only handle one thread at a time.
Innovation Solution
A system with a treatment unit that includes multiple nozzles divided into separate dispensing zones, allowing independent control for simultaneous treatment of multiple threads with different coating substances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate threads of different colors are used for multi-colored patterns, then color variety is achieved, but device complexity and space requirements increase
Solution Approach 1:
A single thread is used to perform multiple functions by applying different coating substances (colors) in-line during processing. The treatment unit with multiple nozzles can apply different colors to the same thread sequentially, replacing the need for multiple pre-colored threads and simplifying thread management while maintaining color variety.
Solution Approach 2:
The coating substances are applied to the thread in advance before the thread reaches the consuming device. This preliminary coloring action allows the thread to be prepared with specific color patterns beforehand, eliminating the need for complex real-time thread switching and management during the consuming process.
2Productivity
If a single treatment unit treats multiple threads simultaneously, then productivity increases, but control complexity increases
Solution Approach 1:
The treatment unit is divided into multiple dispensing zones, with each zone containing nozzles dedicated to treating specific threads. This segmentation allows independent control of each zone, enabling simultaneous treatment of multiple threads while maintaining simple control logic for each individual zone. The control unit can activate specific zones based on which threads need treatment, managing complexity through modular organization.
3Manufacturing precision
If in-line coloring is applied to improve color quality, then color consistency improves, but the system can only handle one thread at a time
Solution Approach 1:
Multiple treatment functions are merged into a single treatment unit. The unit combines multiple nozzles distributed in different dispensing zones, allowing it to treat multiple threads simultaneously while maintaining the in-line coloring advantage of consistent color application. This merging preserves color consistency while increasing processing capacity.
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 efficient and cost-effective simultaneous application of different coating substances, such as colors, to multiple threads, reducing the need for multiple threads and improving pattern complexity.
Implementation Method 1
each nozzle being configured to dispense one or more coating substances at least onto one of the at least two threads when activated
Data Source
Figure 1a~1b
Figure 2
Figure 3
AI summary
A system (10) for in-line treatment of one or more threads (20a-b) for use with a thread consuming device (15) is provided. The system comprises a treatment unit (100) having a plurality of nozzles (152a-f) being distributed in at least a first and a second dispensing zone (154a-b), the dispensing zones (154a-b) being separated in a direction being perpendicular to the longitudinal direction of the at least one thread (20a-b), said thread (20a-b) being in motion in use, each nozzle (152a-f) being configured to dispense one or more coating substances at least onto the at least one thread (20a-b) when activated, and a control unit (190) being configured to control activation of each dispensing zone (154a-b) of nozzles (152a-f) independently. A method is further provided.