Variable Exposure Gap Infusion for On-Demand Linear Substrate Coloring
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Solution Overview
Problem
Existing methods for adding color or other characteristics to linear polymeric substrates, such as hose or wire jackets, require extensive time, manual labor, and equipment cleaning, and struggle with consistent color control between runs and locations, necessitating a rapid and cost-effective solution for on-demand customization.
Innovation Solution
A linear substrate infusion compartment with a reconfigurable infusion chamber and fluid system that allows for the infusion of additives like dyes or weatherability enhancers into the substrate, enabling quick and consistent color or characteristic changes by adjusting the exposure gap and using a reconfigurable processing barrel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If color is added to linear polymeric substrates by compounding into the plastic mixture, then color is distributed throughout the polymeric material, but color determination must be made at the time of manufacture and requires maintaining large selection of colored material in stock
Solution Approach 1:
The invention separates the substrate manufacturing process from the color addition process. The linear substrate is manufactured without color (or with base color), then color is added separately through infusion after manufacturing. This segmentation allows the substrate to be produced once and then customized with different colors on demand, eliminating the need to maintain large inventories of pre-colored materials while ensuring consistent color distribution through the infusion process.
Solution Approach 2:
The substrate is prepared in advance without color (or with base color) and stored in a neutral state. The color infusion is performed as a preliminary action before the substrate is put into service, allowing customers to request specific colors that can be infused on demand. This preliminary preparation of the substrate in a neutral state enables both consistent manufacturing and flexible color selection.
2Manufacturing precision
If extensive equipment cleaning is performed between color changes, then consistent color control is achieved, but production time and equipment downtime increase significantly
Solution Approach 1:
The invention extracts the color addition step from the main substrate manufacturing process. By using a separate infusion system that adds color after the substrate is formed, the system eliminates the need for extensive cleaning between color changes. The infusion system can be quickly reconfigured with different colored materials without contaminating the substrate manufacturing equipment, thus maintaining color consistency while dramatically reducing downtime and increasing productivity.
Solution Approach 2:
The invention introduces an intermediary infusion system that acts as a bridge between the substrate manufacturing process and the final colored product. This intermediary system handles all color addition operations, allowing the substrate manufacturing equipment to remain dedicated and clean while the infusion system manages color changes. The intermediary infusion process ensures consistent color application without requiring the main manufacturing equipment to be cleaned between color runs.
3Manufacturing precision
If separate production lines are used for each color, then color consistency is maintained, but device complexity and manufacturing costs increase
Solution Approach 1:
The invention creates a universal substrate manufacturing line that can produce colored substrates on demand by infusing different colors into a single type of substrate. Instead of having separate production lines for each color, one production line produces the base substrate which can then be infused with any color through the infusion system. This multi-functional approach maintains color consistency through controlled infusion while eliminating the need for multiple dedicated production lines, thereby reducing device complexity and manufacturing costs.
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 and cost-effective on-demand customization of linear substrates with consistent coloring and physical/chemical characteristics, reducing production time and equipment downtime.
Implementation Method 1
infusing one or more components of an infusion fluid into a linear substrate
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.