US20220056626A1

US20220056626A1 - A system and method for in-line treatment of one or more threads for use with thread consuming device

Info

Publication number: US20220056626A1
Application number: US17/275,768
Authority: US
Inventors: Martin Eklind; Joakim Staberg
Original assignee: Coloreel Group AB
Current assignee: Coloreel Group AB
Priority date: 2018-09-15
Filing date: 2019-08-27
Publication date: 2022-02-24
Also published as: IL281386A; KR20210057164A; AR116386A1; ZA202102275B; WO2020055300A1; EP3850134A1; CA3112827A1; AU2019337356A1; CN113039320A; SE543831C2; SE1851097A1; JP2021535968A; CN113039320B; TW202030394A; EP3850134A4

Abstract

A system for in-line treatment of one or more threads for use with a thread consuming device is provided. The system includes a treatment unit having a plurality of nozzles being distributed in at least a first and a second dispensing zone, the dispensing zones being separated in a direction being perpendicular to the longitudinal direction of the at least one thread, said thread being in motion in use, each nozzle being configured to dispense one or more coating substances at least onto the at least one thread when activated, and a control unit being configured to control activation of each dispensing zone of nozzles independently. A method is further provided.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

The instant application is a U.S. National Stage application of and claims priority to PCT/SE2019/050794, filed on Aug. 27, 2019, which is a PCT application of and claims priority to SE Application No. 1851097-4, filed on Sep. 15, 2018, the subject matter of both aforementioned applications are hereby incorporated by reference in their entireties.

TECHNICAL FIELD

The present invention relates to the technical field of thread consuming devices. In particular, the present invention relates to a system comprising a treatment unit to be used in association with such thread consuming device.

BACKGROUND

It has been suggested to provide thread consuming devices, such as embroidery machines or the like, with in-line apparatuses designed to provide the thread with a certain treatment. Such in-line apparatuses could e.g. be used to colour the thread, whereby multiple colour nozzles could replace the current use of multiple pre-coloured threads when producing multi-coloured patterns using embroidery machines. In prior art systems where threads of different colours are used, one thread, having a first specified colour, is used for some stitches while another thread, having a second specified colour, is used for other stitches.
In order to eliminate the obvious drawbacks of the requirement of multiple threads of different colours, the present applicant has filed several patent applications on the technique of in-line colouring of thread, such as WO2016204687 and WO2016204686. The proposed solutions provide improvements in terms of colour quality and also reduces the complexity of the thread consuming device.
However, in order to further improve the quality and efficiency of the in-line colouring of threads it would be advantageous if the in-line colouring apparatus could be able to handle more than one thread simultaneously.

SUMMARY

An object of the present invention is therefore to provide a solution overcoming the disadvantages of prior art. More specifically, the present invention provides a solution where the system for in-line treatment of a thread is configured to handle more than one thread simultaneously by dividing the nozzles into different dispensing zones that can be controlled individually.
In a first aspect, a system for in-line treatment of one or more threads for use with a thread consuming device. The system comprises a treatment unit having a plurality of nozzles being distributed in at least a first and a second dispensing zone, the dispensing zones can be separated in a direction being perpendicular to the longitudinal direction of the at least one thread, said thread being in motion in use, each nozzle being configured to dispense one or more coating substances at least onto the at least one thread when activated, and a control unit being configured to control activation of each dispensing zone of nozzles independently.
Some thread consuming devices needs to use a plurality of separate threads simultaneously. A solution having separate systems for each thread is not beneficial since it would be both costly and space consuming. Hence, having a single system that is capable of treating a plurality of threads with coating substance simultaneously has several benefits. With the system described herein the plurality of threads can for example be applied with different coating substances (such as different colour) simultaneously.
The plurality of nozzles may be arranged in one or more nozzle arrays. In one embodiment, the plurality of nozzles arranged in one nozzle array and wherein the nozzle array is arranged at an angle in relation to the direction of the at least one thread.
The plurality of nozzles may be arranged in at least two nozzle arrays. The at least two nozzle arrays may be parallel to each other.
The nozzle arrays may be arranged at an angle in relation to the direction of the at least one thread.
In one embodiment, at least a part of the nozzles of the first nozzle array are distributed in the first dispensing zone and at least a part of the nozzles of the second nozzle array are distributed in the second dispensing zone.
In one embodiment, all of the nozzles of the first nozzle array are distributed in the first dispensing zone and all of the nozzles of the second nozzle array are distributed in the second dispensing zone.
In one embodiment, the system is arranged for in-line treatment of at least a first thread and a second thread, and wherein the control unit is configured to control activation of the nozzles of each dispensing zone independently such that the first thread can be treated by the first dispensing zone, while the second thread can be simultaneously treated by the second dispensing zone.
In one embodiment, the control unit is configured to control activation of each dispensing zone by transmitting trigger signals to the nozzles being arranged in the specific dispensing zone.
The control unit may be configured to activate the nozzles of one dispensing zone individually.
The control unit may be configured to activate the nozzles of one dispensing zone individually with a predetermined offset from receiving the trigger signal.
In one embodiment, the first thread and a second thread are different from each other.
In one embodiment the nozzles are inkjet nozzles.
In one embodiment, the system further comprises a thread consuming device. The thread consuming device may be an embroidery machine, a sewing machine, a knitting machine, a weaving machine, a tufting machine, a thread winding machine, and or any combination thereof.
In a second aspect, a method for in-line treatment of at least one thread is provided. The method comprises providing a treatment unit having a plurality of nozzles being distributed in at least a first and a second dispensing zone, the dispensing zones being separated in a direction being substantially perpendicular to the longitudinal direction of the at least one thread, said thread being in motion in use, each nozzle being configured to dispense one or more coating substances at least onto the at least one thread when activated, and providing a control unit being configured to control activation of each dispensing zone of nozzles independently.

Definitions

Thread consuming device is in this context any apparatus which in use consumes thread. It may e.g. be an embroidery machine, weaving machine, sewing machine, knitting machine, weaving machine, a tufting machine, a thread winding machine or any other thread consuming apparatus which may benefit from a surface treatment or coating or any other process involving subjecting the thread to a substance, such as dying.
Treatment is in this context any process designed to cause a change of the properties of a thread. Such processes include, but are not limited to, colouring, wetting, lubrication, cleaning, fixing, heating, curing, dying, etc.
Thread is in this context a flexible elongate member or substrate, being thin in width and height direction, and having a longitudinal extension being significantly greater than the longitudinal extension of any parts of the system described herein, as well as than its width and height dimensions. Typically, a thread may consist of a plurality of plies being bundled or twisted together. The term thread thus includes a yarn, wire, strand, filament, etc. made of various materials such as glass fibre, wool, cotton, synthetic materials such as polymers, metals, polyester, viscos, or e.g. a mixture of wool, cotton, polymer, or metal or any combination thereof.
Within this specification, all references to upstream and/or downstream should be interpreted as relative positions during normal operation of the thread consuming device, i.e. when the device is operating to treat an elongated substrate, such as a thread, continuously moving through the device in a normal operating direction. Hence, an upstream component is arranged such that a specific part of the thread passes it before it passes a downstream component.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will be described in the following description of the present invention; reference being made to the appended drawings which illustrate non-limiting examples of how the inventive concept can be reduced into practice.

FIG. 1a is a schematic view of a system for in-line treatment of thread according to an embodiment;

FIG. 1b is a perspective view of a system having a thread consuming device and a treatment unit according to an embodiment;

FIG. 2 is a schematic view of a treatment unit for use with a system according to an embodiment;

FIG. 3 is a schematic view of a discharge device forming part of a treatment unit;

FIG. 4a is a schematic top view of a part of a discharge device according to an embodiment;

FIG. 4b is a schematic top view of a part of a discharge device according to an embodiment;

FIG. 5a is a schematic view of a part of a treatment unit according to an embodiment;

FIG. 5b is a schematic view of a part of a treatment unit according to an embodiment;

FIG. 5c is a schematic view of a part of a treatment unit according to an embodiment;

FIG. 5d is a schematic view of a part of a treatment unit according to an embodiment;

FIG. 5e is a schematic view of a part of a treatment unit according to an embodiment;

FIG. 5f is a schematic view of a part of a treatment unit according to an embodiment;

FIG. 6a is a schematic view of a system according to an embodiment, and

FIG. 6b is a schematic view of a system according to an embodiment.

DETAILED DESCRIPTION

An idea of the present invention is to provide a system and method for distributing a coating substance onto a thread in a controlled manner, for use in association with a thread consumption device. Starting in FIG. 1a a schematic view of system 10 for in-line treatment of thread is shown. The system 10 comprises a treatment unit 100 for dispensing one or more coating substances onto at least one thread. The system 10 further comprises at least one thread consuming device 15, which may e.g. be in the form of one or several embroidery machine(s), a weaving machine(s), a sewing machine(s), knitting machine(s), a tufting machine(s), a thread winding machine(s) etc. The system thereby forms a thread consuming unit, including the at least one thread consuming device 15 and the treatment unit 100. It should be noted that more than one thread can be used in the thread consuming device(s).
It should be noted that several aspects of a system are described within this specification, and they do not require the inclusion of the thread consuming device 15. As will be further understood from the following, for all embodiments the system for in-line treatment of thread requires a treatment unit 100, to be used with a thread consuming device 15.
Now turning to FIG. 1b the thread consuming device 15 is exemplified as an embroidery machine, here illustrated as a single-head embroidery machine, being equipped with a treatment unit 100. The embroidery machine 15 comprises a moveable stage 2 b carrying the fabric to be embroidered. During operation the moveable stage 2 b is controlled to rapidly change its position in the X and Y direction (i.e. in this case the horizontal plane, but it could also be in the vertical plane).
The treatment unit 100 allows the embroidery machine 15 to operate without the provision of uniquely pre-coloured threads, as is required for conventional embroidery machines. Instead, the treatment unit 100 provides in-line colouring of a thread 20 in accordance with predetermined colouring patterns, such that a coloured embroidery can be produced. The treatment unit thus replaces individual thread reels as is present in prior art systems.
As is shown in FIG. 1b the only connection between the treatment unit 100 and the embroidery machine 15 is the thread 20, as well as electrical connections (not shown). The treatment unit 100 is thus provided as a stand-alone unit having no mechanical connection with the moveable stage 2 b. In an optional embodiment, the stand-alone treatment unit 100 is mounted to the thread consuming device 15 via a suspension arrangement for reducing the transmission of vibrations to the treatment unit 100.
The system 10 described herein is capable of treating one or more threads 20 a-c with coating substances using only one treatment unit 100. If plurality of threads are used in the system 10, different coating substance may be dispensed onto the different threads 20 a-c at the same time. Additionally, or alternatively, the coating substance may be dispensed in different patterns for the different threads 20 a-c.
The various components of the treatment unit 100 configured to treat one or more threads are shown in FIG. 2. In the following the system will be described for the use of two threads, however it should be understood that the system could be adapted for a single thread or more than two threads.
The majority, or all, of the components described for the system 10 may be arranged inside a housing.
Each thread 20 a-b is arranged to pass through a respective thread reel 120 a-b. Immediately downstream the thread reels 120 a-b, thread feeders 130 a-b are arranged—one thread feeder 130 a-b for each thread 20 a-b. The thread feeder 130 may be configured to pull the thread forward through the treatment unit 100. The thread feeder 130 is not described further herein, but for a more general understanding each thread feeder 130 receives and forwards its respective thread 20 a-b. For this, the thread feeders 130 may be controlled by a control unit 190 described further below. After the threads 10 a-b have passed its respective thread feeder 130, each thread 20 a-b engages with a respective thread guiding device 140 a-b. Each thread guiding device 140 a-b, which may e.g. be in the form of one or more guiding rollers or other suitable means, is ensuring that its thread 20 a-b is aligned with one or more treatment nozzles forming part of at least one discharge device 150. Both the threads 20 a-b then pass through the common discharge device 150.
The discharge device 150 is configured to discharge treatment substance, such as a colouring substance, onto the thread 20 as it passes the discharge device 150. For this the nozzles are arranged preferably in the longitudinal direction of the thread 20 as will be further explained in relation to FIGS. 3-5.
The discharge device 150, or parts of the discharge device 150 such as the print head(s) 151 a-d (as shown for example in FIG. 3), may be moveable by means of a drive unit (not shown). Having a drive unit will make it possible to arrange the discharge device 150, or parts of the discharge device 150, in different operating states in order to perform different tasks, such as for example a first state of dispensing a coating substance to a thread and a second state of performing a cleaning session, or other maintenance or idling.
Downstream the discharge device 150 the threads 20 a-b are separated onto a respective thread guiding device 160 a-b. The second thread guiding devices 160 a-b are cooperating with the respective first thread guiding devices 140 a-b such that the position of the respective threads 20 a-b are correct during its travel along the discharge device 150. The second thread guiding device 160 may e.g. be in the form of one or more guiding rollers, although it may also be designed to induce a rotation of the thread 20 along its longitudinal axis.
The system 10 may further comprise one common, or two separate, or any number of thread speed sensor(s) (not shown) configured to measure the speed of the threads 20 a-b passing through the system 10.
Moreover, one common, or two separate, light detection system(s) (not shown) may be arranged downstream the discharge device 150 along the travel direction of the threads 20 a-b. The light detection system(s) is arranged to illuminate the threads 20 a-b in order to receive light which is reflected from the threads 20 a-b when the threads 20 a-b are illuminated. The information gathered from the light detection signal may for example be used to determine the position of the threads in relation to the nozzles 152 a-f, the width of each thread and/or properties of each thread. This information can in turn for example be used to detect nozzle(s) that are in need of maintenance, that the position of the nozzle(s) needs to be altered and/or detect variations in the coating substance. Additionally, or alternatively, the light detection system(s) may be used to determine different properties of the threads that have been applied with one or several coating substances.
The threads 20 a-b are then fed forward to pass one or more fixation units 170 which are provided in order to fixate the treatment substance to the thread 20 a-b. The fixation unit may be common for both threads, or provided as two separate units having one for each thread 20 a-b. The fixation unit 170 preferably comprises heating means, such as a hot air supply or heated elements, or an UV light source such that the treatment substance, e.g. a colouring substance, is cured or fixated onto the thread 20. As is shown in FIG. 2 the fixation unit 170 may either be arranged horizontally, vertically, or at an angle between horizontally and vertically.
Before exiting the housing, the threads 20 a-b may pass a cleaning unit 180, such as an ultrasonic bath, where unwanted particles are removed from the threads 20 a-b. The cleaning unit may be common for both threads, or provided as two separate units having one for each thread 20 a-b. As the treatment substance is fixated onto the threads 20 a-b, the cleaning unit 180 will leave the treatment substance unaffected.
The treatment unit 100 may further comprise a lubrication unit (not shown). The lubrication unit may be common for both threads or provided as two separate units having one for each thread 20 a-b. Additional thread buffers and feeders (not shown) may also be included in the treatment unit 100, arranged at various positions in the thread path.
The threads 20 a-b preferably exits the treatment unit 100 through an aperture or similar, whereby the threads 20 a-b are forwarded to an associated thread consuming device, such as an embroidery machine 15 as is shown in FIGS. 1a -b.
A control unit 190 with associated electronics, such as power electronics, communication modules, memories, etc. is also provided. The control unit 190 is connected to the thread feeders 130 a-b, the discharge device 150, and the fixation unit 170 for allowing control of the operation of these components. Further, the control unit 190 is configured to controlling operation of the entire treatment unit 100 including the cleaning unit 180, the lubrication unit, a disruption of the threads 20 a-b, the thread speed at various position along the treatment unit 100, the thread buffers, etc. The control unit 190 may also be configured to receive control signals from one or more components of the treatment unit 100, e.g. control signals for triggering specific control, or other information relating to e.g. thread consumption by the embroidery machine 15.
The control unit 190 may be implemented by any commercially available CPU (“Central Processing Unit”), DSP (“digital signal processor”) or any other electronic programmable logic device, or a combination of such processors or other electronic programmable logic device. The control unit 190 may be implemented using instructions that enable hardware functionality, for example, by using executable computer program instructions in a general-purpose or special-purpose processor that may be stored on a computer readable storage medium (disk, memory etc.) to be executed by such a processor. The storage medium is preferably in operative communication with the control unit 190.
In one embodiment, a user interface is also provided, preferably via a display arranged at the front end of the housing. The display allows a user to interact with the control unit 190 and is thus connected thereto, so that the control parameters of the thread feeder 130, the discharge device 150, the fixation unit 170, etc. may be set depending on process specifications. The display may also preferably be used for alerting the user of critical situations, whereby the display may be used for the control unit 190 to issue alarms or the like.
It should be noted that the components described above may not necessarily be included in the stand-alone treatment unit 100, but instead the components of the treatment unit 100 may be separated into several units, Preferably, the stand-alone unit includes at least the at least one discharge device 150. In one embodiment the components are not provided as a stand-alone unit but are integrated with the thread consuming device 15.
In FIG. 3 a discharge device 150 is shown, forming part of the treatment unit 100 as described above. The direction of movement of the thread(s) 20 a-b in use is indicated by the solid arrow in FIG. 3. As will soon be described in more detail, the discharge device 150 comprises a plurality of nozzles 152 a-f arranged at different longitudinal positions (for example spaced by a distance dl) along the thread 20 which passes by the treatment unit 100 during use.
Each nozzle 152 a-f is arranged to dispense a coating substance, such as ink, onto the thread 20 when the nozzle is activated. The coating substance is absorbed by the thread 20, e.g. at different circumferential positions of the thread 20 when the thread 20 twists about its longitudinal axis. The relative position of two adjacently dispensed droplets of coating substance may be selected such that the droplets will overlap.
The treatment unit 100 comprises one or more discharge devices 150. Each discharge device 150 is preferably formed as a series of ink-jet print heads 151 a-d, each print head 151 a-d having one or more nozzle arrays. Each nozzle array typically comprises hundreds or thousands of nozzles. For illustrative purpose only six nozzles 152 a-f are shown for one print head 151 a-d; it should however be realized that each nozzle array may be provided with hundreds or thousands of nozzles 152 each. As an example, each print head 151 a-d may be associated with a single colour; in the shown example, the discharge device 150 has four print heads 151 a-d, each print head 151 a-d being associated with a specific colour according to the CMYK standard. However, other colouring models may be used as well.
The exact configuration of the treatment unit 100 may vary. For example, the treatment unit 100 is provided with a single discharge device 150 having a plurality of print heads 151 a-d. Each print head 151 a-d is in turn provided with a plurality of nozzles 152 a-f.
In another embodiment the treatment unit 100 is provided with several discharge devices 150, arranged either in series or in parallel. Each discharge device 150 is then provided with a plurality of print heads 151 a-d. If serially arranged, the upstream discharge device 150 may have print heads 151 a-d being associated with one or more colours of a specific colour standard, while the downstream discharge device 150 has print heads 151 a-d being associated with other colours of the same colour standard. If arranged in parallel, each discharge device 150 may have print heads 151 a-d being associated with all colours of a specific colour standard, but with different threads 20. For such embodiment, two separate threads 20 can be treated simultaneously and in parallel. Combinations of parallel/serial configurations are of course also possible.
In a yet further embodiment, the discharge device 150 is only having a single print head 151 a-d; dynamic colouring of the thread 20 would then require several discharge devices 150 of the treatment unit 100.
Each nozzle 152 a-f may dispense a coating substance having a colour according to the CMYK colour model, where the primary colours are Cyan, Magenta, Yellow, and Black. It may thus be possible to dispense a wide variety of colours onto the thread by activating nozzles 152 a-f such that the total colouring substance of a specific length of the thread 20 will be a mix of the colouring substances dispensed by the nozzles 152 a-f. As explained earlier, this is preferably achieved by having several print heads 151 a-d arranged in series, whereby the nozzles 152 a-f of a specific print head 151 a-d are dedicated to a single colour.
In another embodiment, each nozzle 152 a-f dispenses a coating substance having a colour comprising a mix of two or more primary colours of the CMYK colour model.
The control unit 190 is configured to control the activation of the nozzles 152 a-f such as the coating substance is emitted onto the thread 20 as it passes through the treatment unit 100, and especially pass the discharge device 150. By such configuration very precise colouring of the thread 20 is possible e.g. in order to provide advanced embroidery patterns, visually extremely sophisticated by means of the colouring provided by the treatment unit 100.
For a colouring operation the control unit 190 receives one or more input signals specifying the desired colour and/or colouring effect. The colour input preferably includes information regarding the exact colour, as well as the longitudinal start and stop positions of the thread 20 for that particular colour. The longitudinal start and stop position could be represented by specific time values if the thread speed is determined.
FIG. 4a-b illustrates a respective top view of a print head 151 a. The print head 151 a has a planar surface on which the nozzles 152 are arranged. As mentioned earlier, the total number of nozzles 152 of a single print head can be up to several thousands, provided on a print head 151 a in the size of a couple of centimeters. In the shown example, a far less number of nozzles 152 are shown. The nozzles 152 can be distributed in one or more nozzle arrays 153 a-b. In FIG. 4a , the nozzles 152 are distributed in two parallel arrays 153 a-b. The arrays 153 a-b are aligned with each other, such that nozzles 152 of one array 153 a-b are arranged adjacent a nozzle 152 of the other array 153 a-b.
FIG. 4b shows a similar example, however there is a longitudinal offset between the two arrays 153 a-b.
The system 10 described herein is capable of treating one or more threads 20 a-c with coating substances using only one treatment unit 100. If plurality of threads are used in the system 10, different coating substance may be dispensed onto the different threads 20 a-c at the same time. Additionally, or alternatively, the coating substance may be dispensed in different patterns for the different threads 20 a-c.
The dispensing coating substance onto a plurality of threads is preferably achieved by arranging the nozzles of the discharge device 150 into several dispensing zones 154 a-c that can be controlled independently. Some exemplified embodiments will now be described with reference to FIGS. 5a-f . In FIGS. 5a-f , the print head 151 a is arranged to dispense coating substance onto at least two threads 20 a-b and in FIG. 5d , a situation having three threads 20 a-c is shown.
It should be noted that the following also is applicable for a higher number of threads such as four, five, etc. In a preferred embodiment, the threads 20 a-c are parallel with each other. Moreover, all threads 20 a-c used in the system may be of the same thickness or be of different thickness. Additionally, all threads 20 a-c used in the system may be of the same type, or being of a different types having different properties.
FIG. 5a shows a print head 151 a having two nozzle arrays 153 a-b. In this embodiment, the nozzle arrays 153 a-b are arranged in parallel with each other. The nozzles 152 a-f of the nozzle arrays 153 a-b are arranged in two dispensing zones 154 a-b. The dispensing zones 154 a-b are separated in a direction that is perpendicular to the longitudinal direction of the threads 20 a-b. In this embodiment, the nozzles of the first nozzle array 153 a are distributed in the first dispensing zone 154 a and the nozzles of the second nozzle array 153 b are distributed in the second dispensing zone 154 b. In the illustrative example, all nozzles 152 a-f of each nozzle array are part of the same dispensing zone 153 a-b. However, as is illustrated in FIGS. 5b-c , not all nozzles 152 a-f of the same array 153 a-b must be of the same dispensing zone 154 a-b. In this example, the first dispensing zone 154 a is configured to dispense coating substance onto the first thread 20 a and the second dispensing zone 154 b is configured to dispense coating substance onto the second thread 20 b.
In FIG. 5a , the print head 151 a is arranged in the direction of the length of the threads 20 a-b. The nozzle arrays 153 a-b are aligned with the direction of the length of the threads 20 a-b.
It should be noted that the print head 151 a shown in FIG. 5a also could be defined as having ten nozzle arrays comprising two nozzles each. With this definition, the nozzle arrays are perpendicular with the length of the thread 20 a,b. This situation is illustrated in FIG. 5 f.
FIG. 5b shows a print head 151 a having one single nozzle array 153 a. The nozzles 152 a-f of the nozzle arrays 153 a-b are arranged in three dispensing zones 154 a-c. In this embodiment, the nozzles that are covering, i.e. is able to dispense coating onto, the first thread 20 a are distributed in the first dispensing zone 154 a and the nozzles that are covering the second thread 20 b are distributed in the second dispensing zone 154 b. Here, an intermediate dispensing zone 154 c is arranged for nozzle(s) that are not covering any of the threads 20 a-b.
In FIG. 5b , the print head 151 a, and thus its nozzle array 153 a, is arranged such that it is tilted compared to the length of the threads 20 a-b. The nozzle array 153 a is thus arranged at an angle in relation to the length of the parallel threads 20 a-b. The angle is either larger or smaller than 0 degrees. The nozzle array is inclined relative to the direction of the thread in order to be able to simultaneously treat more than one thread using a single nozzle array. The higher angle that is between the nozzle array and the threads, the more threads will be possible to colour with one nozzle array. The trade-off with a higher angle is that fewer nozzles per nozzle array can be utilised to colour each thread 20 a-b.
The length of the nozzle array may preferably be at least as long as the distance it takes for the thread 20 to rotate one 180° revolution around itself, and more preferably at least as long as the distance it takes for the thread 20 to rotate a 360° revolution around itself. For this, means may be provided to induce a rotation of the thread as it passes the treatment unit.
FIG. 5c illustrates a print head 151 a similar to that of FIG. 5a , with the difference that the print head 151 a, and thus its parallel nozzle arrays 153 a-b, are arranged with an angle compared to the parallel threads 20 a-b and that not all nozzles 152 a-f of the same array 153 a-b are part of the same dispensing zones 154 a-b. Having both nozzle arrays inclined relative to the direction of the thread allows nozzles of both the nozzle arrays to dispense coating onto both threads 20 a-b. The higher angle that is between the nozzle arrays and the threads, the more threads will be possible to colour with each nozzle array. The trade-off with a higher angle is that fewer nozzles per nozzle array can be utilised to colour each thread 20 a-b.
FIG. 5d illustrates a print head 151 a similar to that of FIG. 5a , with the difference that the print head comprises three parallel nozzle arrays 153 a-c and three dispensing zones 154 a-c. Moreover, in FIG. 5d the print head 151 a is arranged to dispense coating substance onto at least three parallel threads 20 a-c.
FIG. 5e illustrates a print head 151 a similar to that of FIG. 5a , with the difference that the nozzles are distributed in six different dispensing zones 154 a-f. Each nozzle array 153 a, 153 b comprises different sections of nozzles comprising different coating substance, such as different colour, as illustrated by the patterned filled nozzles in FIG. 5e . Each section of nozzles having different coating substances are seen as one dispensing zone 154 a-f. Each nozzle array 153 a, 153 b may thus comprise different colours, with different colours for each dispensing zone 154 a-f. Although FIG. 5e illustrates a print head 151 comprising two identical nozzle arrays, it should be noted that the nozzle arrays does not need to be identical with each other.
FIG. 5f illustrates a print head 151 a similar to that of FIG. 5a having two dispensing zones 154 a-b each covering one thread 20 a-b. Here, the threads 20 a-b are shown having different thickness. Depending on the thickness, or width, of the thread 20 a-b different number of nozzles will cover the thread 20 a-b. It should be noted that the size of the nozzles of FIGS. 3-5 are made large in relation to the thickness and/or width of the thread 20 a, 20 b only for illustrative purposes.
In addition to the components described with reference to FIG. 2, the system 10 may comprise one or more encoders (not shown). In one embodiment the number of threads 20 a-b in the system 10 and the number of encoders is the same, hence one encoder is provided for each thread 20 a-b. The individual encoders are arranged to trigger dispensing signals to the individual nozzles of a dispensing zone. In yet one embodiment, one single encoder is provided for all threads 20 a-b. The one encoder is thus configured to trigger dispensing signals to the individual nozzles of a dispensing zone and/or to trigger to all dispensing zones.
The encoder may comprise or being in communication with a wheel such as a pulley or a guiding roller. The encoder may for example be a rotary encoder or a shaft encoder.
The control unit 190 is configured to control activation and deactivation of each dispensing zone 154 a-c of nozzles 152 a-f independently. For this, the control unit 190 may be configured to transmit trigger signals to the nozzles 152 a-f being arranged in a specific dispensing zone 154 a-c. Additionally, or alternatively, if the nozzles arranged in one nozzle array 153 a-c are distributed into one single dispensing zone 154 a-c, the control unit 190 may be configured to transmit trigger signals to the individual nozzle array 153 a-c in order to activate or deactivate the nozzles of that array, and thus that dispensing zone.
The control unit 190 may further be configured to control the activation and deactivation of the nozzles 152 a-f individually in each dispensing zone 154 a-b by transmitting trigger signals to the nozzles 152 a-f being arranged in the specific dispensing zone 154 a-c.
The control unit 190 may further be configured to activate the nozzles of one dispensing zone 154 a-c individually using a predetermined offset from receiving the trigger signal. The offset may for example be a specific time, length and or a combination of both.
In one embodiment, the first thread 20 a-b is arranged with a trigger for activation of the nozzles 152 a-f being distributed in the first dispensing zone 154 a and the second thread 20 b is arranged with a trigger for activation of the nozzles 152 a-f being distributed in the second dispensing zone 154 b.
Each thread 20 a-b may have its own trigger for activation of the nozzles of its dispensing zone, i.e. the nozzles that are arranged in a dispensing zone covering the thread 20 a-b. In one embodiment, all dispensing zones are arranged with a common trigger.
The control unit 190 may further be configured to alter the size of the dispensing zones 154 a-c. Moreover, the control unit 190 may be configured to alter which nozzles that are to be distributed in the dispensing zones 154 a-c. These alternations may be based on for example the thickness of the threads, the density of the threads, the number of threads to be treated, the properties of the coating substance, calibration results and/or based on the number of active nozzles.
The control unit 190 may further be configured to alter the angle of the print head(s) 151 a, or its nozzle arrays 153 a-c, in relation to the treads 20 a-c to be treated. The control unit 190 may be configured to alter the angle based on the thickness of the threads, the density of the threads, the number of threads to be treated, the properties of the coating substance and/or based on the number of active nozzles.
In the above, reference is made to one or more threads 20 a-c. In one embodiment, all threads arranged through the system 10 are in need of in-line treatment. In yet one embodiment, when several threads are used, it is sufficient if one of the threads are in need of in-line treatment (such as a thread that is not pre-coloured). The system 10 is thus configured to handle both uniquely pre-threated threads and threads that are in need of in-line treatment at the same time. For example, an embroidery machine could combine an in-line treated thread with a pre-threated thread to create a specific pattern on a substrate. Such a pre-treated thread could for example be a metallic, thick, thin, neon-coloured thread.
The control unit 190 may thus be configured to determine if the thread shall be treated or not when passing through the discharge device 150. However, it should be noted that not all threads need to pass though the treatment unit 100. This is for example the case when a thread does not need to be treated with a coating substance.
Although the present invention has been mainly described with reference to a system comprising one treatment unit 100 and one thread consuming device 15, it should be understood by a person skilled in the art that the inventive features could be applied to other systems as well. FIGS. 6a-b illustrates two examples of such alternative systems.
In FIG. 6a , the system 10 comprises a first and a second treatment unit 100 a, 100 b as well as a first and a second thread consuming device 15 a-b. Each treatment unit 100 a, 100 b is controlling and performing the operations on each thread consuming device 15 a-b. It should be noted that the first and second treatment unit 100 a, although being separated may share one or more components. In one embodiment, the control unit 190 is arranged as a separate unit from the first and second treatment unit 100 a, 100 b and one control unit 190 is thus configured to control the operation of both treatment units 100 a, 100 b and correspondingly the operation of both thread consuming devices 15 a-b.
In FIG. 6b , the system 10 comprises one treatment unit 100 a and a first and a second thread consuming device 15 a-b. In this embodiment, one treatment unit 100 a is configured to control and perform the operation of the two thread consuming devices 15 a-b.
It should be noted that although only two treatment units and two thread consuming devices are shown in FIG. 6a , and only one treatment unit and two thread consuming devices are shown in FIG. 6b , it should be understood that any reasonable number of treatment units and/or thread consuming devices could be present in the system 10.
Although the present invention has been described above with reference to specific embodiments, it is not intended to be limited to the specific form set forth herein. Rather, the invention is limited only by the accompanying claims.
In the claims, the term “comprises/comprising” does not exclude the presence of other elements or steps. Additionally, although individual features may be included in different claims, these may possibly advantageously be combined, and the inclusion in different claims does not imply that a combination of features is not feasible and/or advantageous. In addition, singular references do not exclude a plurality. The terms “a”, “an”, “first”, “second” etc do not preclude a plurality. Reference signs in the claims are provided merely as a clarifying example and shall not be construed as limiting the scope of the claims in any way.

Claims

1-17. (canceled)

18. A system for in-line treatment of one or more threads for use with a thread consuming device, comprising:

a treatment unit having a plurality of nozzles being distributed in at least a first and a second dispensing zone, the dispensing zones being separated in a direction being substantially perpendicular to the longitudinal direction of the at least one thread, said thread being in motion in use, each nozzle being configured to dispense one or more coating substances at least onto the at least one thread when activated; and

a control unit being configured to control activation of each dispensing zone of nozzles independently.

19. The system according to claim 18, wherein the plurality of nozzles are arranged in one or more nozzle arrays.

20. The system according to claim 19, wherein the plurality of nozzles are arranged in one nozzle array and wherein the nozzle array is arranged at an angle in relation to the direction of the at least one thread.

21. The system according to claim 19, wherein the plurality of nozzles are arranged in at least two nozzle arrays.

22. The system according to claim 21, wherein the at least two nozzle arrays are parallel to each other.

23. The system according to claim 19, wherein the nozzle arrays are arranged at an angle in relation to the direction of the at least one thread.

24. The system according to claim 21, wherein at least a part of the nozzles of the first nozzle array are distributed in the first dispensing zone and at least a part of the nozzles of the second nozzle array are distributed in the second dispensing zone.

25. The system according to claim 24, wherein all of the nozzles of the first nozzle array are distributed in the first dispensing zone and all of the nozzles of the second nozzle array are distributed in the second dispensing zone.

26. The system according to claim 18, wherein the system is arranged for in-line treatment of at least a first thread and a second thread, and wherein the control unit is configured to control activation of the nozzles of each dispensing zone independently such that the first thread can be treated by the first dispensing zone, while the second thread can be simultaneously treated by the second dispensing zone.

27. The system according to claim 26, wherein control unit is configured to control activation of each dispensing zone by transmitting trigger signals to the nozzles being arranged in the specific dispensing zone.

28. The system according to claim 27, wherein the control unit is further configured to activate the nozzles of one dispensing zone individually.

29. The system according to claim 28, wherein the control unit is further configured to activate the nozzles of one dispensing zone individually with a predetermined offset from receiving the trigger signal.

30. The system according to claim 26, wherein the first thread and a second thread are different from each other.

31. The system according to claim 18, wherein the nozzles are inkjet nozzles.

32. The system according to claim 18, further comprising a thread consuming device.

33. The system according to claim 32, wherein the thread consuming device is an embroidery machine, a sewing machine, a knitting machine, a weaving machine, a tufting machine, a thread winding machine, and or any combination thereof.

34. A method for in-line treatment of at least one thread, comprising:

providing a treatment unit having a plurality of nozzles being distributed in at least a first and a second dispensing zone, the dispensing zones being separated in a direction being perpendicular to the longitudinal direction of the at least one thread, said thread being in motion in use, each nozzle being configured to dispense one or more coating substances at least onto the at least one thread when activated; and

providing a control unit being configured to control activation of each dispensing zone of nozzles independently.