Variable Exposure Gap for Consistent Linear Substrate Coloration
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Solution Overview
Problem
Existing systems face challenges in consistently and cost-effectively adding customer-requested colors and physical or chemical characteristics to linear polymeric substrates, such as hose or wire jackets, due to difficulties in achieving color consistency between runs and locations, and the time-consuming process of switching between colors.
Innovation Solution
A linear substrate infusion compartment with a reconfigurable processing barrel that allows for on-demand infusion of components into the substrate, enabling quick and efficient addition of colors or characteristics by varying the exposure gap and configuration of the infusion chamber, allowing for rapid switching between colors without the need for extensive cleaning or manual labor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If color is added by compounding into the plastic mixture during manufacture, then color distribution throughout the polymeric material is achieved, but color determination must be made at the time of manufacture and extensive time and manual labor are required for switching between colors
Solution Approach 1:
The system employs a movable inner processing vessel that can be repositioned along the longitudinal axis of the outer processing vessel, allowing dynamic adjustment of the exposure gap length. This enables the linear substrate to be exposed to different infusion fluids (different colors) by simply changing the position of the inner vessel, eliminating the need for extensive cleaning and manual labor during color switching.
Solution Approach 2:
The invention changes the physical parameter of the exposure gap length by moving the inner processing vessel to different positions. This parameter change allows control over the extent of substrate exposure to infusion fluid, enabling rapid color changes and customization without reconfiguring the entire system or performing extensive cleaning operations.
2Manufacturing precision
If separate lines are used for each color, then color consistency within each line is maintained, but device complexity increases and extensive cleaning is required between colors
Solution Approach 1:
The single processing barrel is designed to handle multiple colors and infusion fluids through the reconfigurable exposure gap mechanism. The inner processing vessel can be moved to expose different portions of the linear substrate to different infusion fluids circulating in the same barrel, making the system universal and eliminating the need for separate dedicated lines for each color.
Solution Approach 2:
The processing barrel is segmented into an inner movable processing vessel and an outer stationary processing vessel. This segmentation allows the inner vessel to be independently repositioned to create variable exposure gaps, enabling a single barrel to function as multiple dedicated lines would, thereby reducing device complexity while maintaining color consistency.
3Productivity
If the exposure gap is increased, then more of the linear substrate is exposed to the infusion fluid, but the volume of infusion chamber decreases
Solution Approach 1:
The inner processing vessel is designed to move dynamically along the longitudinal axis, allowing the exposure gap length to be adjusted based on production requirements. When higher productivity is needed, the inner vessel is repositioned to increase the exposure gap, temporarily reducing infusion chamber volume but increasing substrate exposure efficiency. This dynamic adjustment optimizes the trade-off between productivity and infusion chamber volume.
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 rapid, cost-effective, and consistent coloration and customization of linear substrates, reducing waste and improving customer service by allowing for immediate color changes and maintaining color consistency across different manufacturing locations.
Implementation Method 1
contacting the linear substrate with the infusion fluid 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.