Source: http://www.google.com/patents/US5035018?dq=5,884,272
Timestamp: 2017-02-27 17:16:11
Document Index: 570536247

Matched Legal Cases: ['art 106', 'art 106', 'art 106', 'art 106', 'art 106', 'art 106']

Patent US5035018 - Method of applying dye - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inPatentsAn automated dye pattern application system includes a support bed to support a mat or other dye receiving medium; perpendicular guide tracks supporting a carrier on which a dye spray head is mounted; stepper motors engaged between the tracks, the support bed, and the spray head carrier and forming an...http://www.google.com/patents/US5035018?utm_source=gb-gplus-sharePatent US5035018 - Method of applying dyeAdvanced Patent SearchTry the new Google Patents, with machine-classified Google Scholar results, and Japanese and South Korean patents.Publication numberUS5035018 APublication typeGrantApplication numberUS 07/581,479Publication dateJul 30, 1991Filing dateSep 12, 1990Priority dateSep 12, 1989Fee statusLapsedPublication number07581479, 581479, US 5035018 A, US 5035018A, US-A-5035018, US5035018 A, US5035018AInventorsRonald B. Robbins, John D. Sakowski, William R. WaldenOriginal AssigneeSakowski And Robbins CorporationExport CitationBiBTeX, EndNote, RefManPatent Citations (15), Non-Patent Citations (2), Referenced by (14), Classifications (5), Legal Events (6) External Links: USPTO, USPTO Assignment, EspacenetMethod of applying dye
US 5035018 AAbstract
1. A method of applying dye in a selected two dimensional pattern to a dye receiving medium, said method comprising the steps of:(a) positioning said dye receiving medium on stationary dye receiving medium support means; (b) providing a dye spray head including spray head motor means operable to cause relative movement along both an x-axis and a y-axis of said spray head relative to said support means; (c) providing dye valve means controlling communication of said dye from dye supply means to said head; (d) controlling said motor means to cause said relative movement between said head and said support means through a selected spray path in relation to said support means; and (e) controlling said valve means to supply said dye to said head to said spray said dye onto said medium at selected locations along said path to thereby apply said dye in said selected two dimensional pattern so as to form an image on said medium. 2. A method as set forth in claim 1 and including the steps of:(a) providing control means interfaced to said motor means and said valve means, said control means including memory means; (b) storing image data representing said selected pattern in said memory means; and (c) executing a dye application program by said control means to cause said motor means to cause said relative movement along said path and to cause said valve means to supply said dye to said head at said selected locations according to said image data. 3. A method of applying dye in a selected dye image pattern to a dye receiving medium, said method comprising the steps of:(a) positioning said dye receiving medium on dye receiving medium support means; (b) providing a dye spray head including spray head motor means operable to cause relative movement between said spray head and said support means; (c) providing dye valve means controlling communication of said dye from dye supply means to said head; (d) controlling said motor means to cause said relative movement between said head and said support means through a selected spray path in relation to said support means; (e) controlling said valve means to supply said dye to said head to said spray said dye onto said medium at selected locations along said path to thereby apply said dye in said selected pattern; (f) providing control means interfaced to said motor means and said valve means, said control means including memory means; (g) storing image data representing said selected pattern in said memory means; (h) executing a dye application program by said control means to cause said motor means to cause said relative movement along said path and to cause said valve means to supply said dye to said head at said selected locations according to said image data; (i) optically scanning an image in a two dimensional scanning pattern of image coordinates; (j) sensing a light intensity at each of said coordinates; (k) converting said light intensity to a numeric value representing same and; (l) storing said numeric value in an image array in said memory means in a sequence of said dye pattern data ordered according to said scanning pattern. 4. A method as set forth in claim 3 and including the steps of:(a) processing said dye pattern data and said scanning pattern to generate a sequence of spray segment commands, each command including a motor path instruction to activate said motor means to cause said relative movement through a selected segment of said spray path and a spray activity instruction, said spray activity instruction being a spray turn-on instruction or a spray turn-off instruction; (b) interfacing an intelligent controller circuit between said control means and said motor means and said valve means; and (c) communicating said sequence of spray segment commands to said controller circuit. 5. A method of applying dye in a selected dye image pattern to a dye receiving medium, said method comprising the steps of:(a) providing dye medium support means; (b) providing a dye spray head including spray head motor means operable to move said spray head relative to said support means; (c) providing dye valve means controlling communication of said dye from dye supply means to said head; (d) providing control means interfaced to said motor means and said valve means, said control means including memory means; (e) providing limit switch means at a reference position on said support means, said limit switch means being interfaced to said control means and communicating thereto a reference position signal upon said head being located at said reference position; (f) storing image data representing a dye image pattern to be applied to said medium in said memory means; (g) positioning said dye receiving medium on said support means; (h) controlling said motor means to move said spray head in a selected spray path relative to said reference position; and (i) controlling said valve means to supply said dye to said head according to said image data to reproduce said dye image pattern on said medium. 6. A method as set forth in claim 5 and including the steps of:(a) optically scanning an image in a two dimensional scanning pattern of image coordinates; (b) sensing a light intensity at each of said coordinates; (c) converting said light intensity to a numeric value representing same and; (d) storing said numeric value in an image array in said memory means in a sequence of said dye pattern data ordered according to said scanning pattern. 7. A method as set forth in claim 6 and including the steps of:(a) processing said dye pattern data and said scanning pattern to generate a sequence of spray segment commands, each command including a motor path instruction to activate said motor means to cause movement of said head through a selected segment of said spray path and a spray activity instruction, said spray activity instruction being a spray turn-on instruction or a spray turn-off instruction; (b) interfacing an intelligent controller circuit between said control means and said motor means and said valve means; and (c) communicating said sequence of spray segment commands to said controller circuit. 8. A method as set forth in claim 7 and including the steps of:(a) optically scanning said image in said scanning pattern which progresses in image lines from a left image margin toward a right image margin, said image lines being scanned from a top image margin to a bottom image margin; and (b) processing said dye pattern data and said scanning pattern in such a manner as to generate said sequence of spray segment commands which cause said spray head to be moved along a spray path which progresses in spray lines extending between a lower medium margin and a top medium margin, said spray lines being scanned by said spray head from a first medium side margin to an opposite second medium side margin. 9. A method as set forth in claim 7 and including the steps of:(a) optically scanning said image in said scanning pattern which progresses in image lines from a left image margin toward a right image margin and retraces to said left margin, said image lines being scanned from a top image margin to a bottom image margin; and (b) processing said dye pattern data and said scanning pattern in such a manner as to generate said sequence of spray segment commands which cause said spray head to be moved along a spray path which progresses in spray lines extending between a lower medium margin and a top medium margin, said spray lines being scanned by said spray head from a first medium side margin to an opposite second medium side margin, said spray head being moved in opposite directions between said top and bottom medium margins in contiguous spray lines. 10. A method of applying dye in a selected dye image pattern to a dye receiving medium, said method comprising the steps of:(a) positioning said dye receiving medium on dye receiving medium support means; (b) providing a dye spray head including spray head motor means operable to cause relative movement between said spray head and said support means; (c) providing dye valve means controlling communication of said dye from dye supply means to said head; (d) controlling said motor means to cause said relative movement between said head and said support means through a selected spray path in relation to said support means; (e) controlling said valve means to supply said dye to said head to said spray said dye onto said medium at selected locations along said path to thereby apply said dye in said selected pattern; (f) providing control means interfaced to said motor means and said valve means, said control means including memory means; (g) storing image data representing said selected pattern in said memory means; (h) executing a dye application program by said control means to cause said motor means to cause said relative movement along said path and to cause said valve means to supply said dye to said head at said selected locations according to said image data; (i) providing limit switch means at a reference position along said path, said limit switch means being interfaced to said control means and generating a reference position signal upon said relative movement positioning said head at said reference position; (j) communicating said reference position signal to said control means; and (k) referencing, by said control means, said relative movement along said path to said reference position. Description
This is a divisional application of parent application Ser. No. 07/406,367, filed Sept. 12, 1989, and now U.S. Pat. No. 4,979,380, having a title of AUTOMATED DYE PATTERN APPLICATION SYSTEM.
FIG. 13 is a block diagram showing a computer control system of the dye plotter apparatus in conjunction with various devices that interface with the computer.
The reference numeral 1 generally designates an automated dye pattern application system embodying the present invention. The system 1 includes a dye medium support structure 2, a dye plotter apparatus 3, a dye supply mechanism 4, and a dye plotting controller or computer 5. The support structure 2 includes a support bed 6 on which a dye receiving medium 7, such as a mat, is positioned. The dye plotter apparatus 3 generally includes a dye spray head 8 (FIGS. 2 and 3) mounted on a spray head carrier 9, guide members 10 and 11, and motors 12 and 13 operable to move the spray head 8 along a selected scan path over the mat 7. The dye supply mechanism 4 supplies a dye to the spray head 8 and causes it to be sprayed onto the mat 7. The computer 5 stores data representing an image or design to be reproduced on the mat 7 and executes a program which controls the motors 12 and 13 to scan the mat 7 along the scan path and controls the dye suply mechanism 4 to communicate dye to the spray head 8 at locations determined by the image data stored in the computer 5.
Referring to FIG. 13, the dye supply mechanism 4 includes an air compressor 90 communicating through a master air valve 91 with a set of air pressure regulators 92. The compressor 90 may include a compressed air reservoir tank (not shown), according to the configuration of the compressor 90. The regulators 92 may be individual regulators or a single input/multiple output manifold type of arrangement. The spray drive conduit 83 and spray valve control conduit 84 are connected to outputs of the regulators 92. A dye volume compressed air conduit 93 is connected to one or more dye supply containers 94 which contain different color dyes. The dye volume conduit 93 pressurizes the containers 94 to positively urge dye in the dye conduits 82 into the mixing chamber 77 of the spray head 8. In the illustrated system 1, the regulators 92 provide compressed air at pressures of 4 to 6 pounds per square inch (psi) to the dye containers 94, 7 to 8 psi to the spray drive conduit 83, and 25 to 30 psi to the spray valve control conduit 84.
The pressure of the spray drive air combined with the geometry of the orifice 76 causes the liquid dye to be atomized and controls the pattern of spray therefrom. In general, the spray plume diverges in proportion to its distance from the orifice 76. Various types and colors of dyes have different viscosities. The viscosity of the dye also affects the pattern of spray. It is generally desirable to maintain a consistent spray pattern from dye to dye to achieve a consistent sprayed pixel size. The system 1 is provided with a spray pattern control 95 which, in the illustrated dye supply mechanism 4, consists of a throttle to control the regulator 92 associated with the spray drive conduit 83. It is foreseen that the spray head 8 could be mounted on the spray head carrier 9 by means of a motor (not shown) which could be controlled by the computer 5 to raise and lower the spray head 8 along a z-axis in relation to the sprayed medium 7 to compensate for varying dye viscosities. Such an arrangement could also be used to advantage in spraying dyes or like materials with a consistent spray pattern on a medium having a relief or depth pattern. It is also foreseen that it might be desirable to use the system 1 to reproduce images of different pixel resolutions or pixel size. The manual spray pattern control 95, particularly if well calibrated, or a spray head 8 movable along a z-axis, would be useful for such a capability.
The spray drive conduit 83, spray valve control conduit 84, and dye conduit or conduits 82, and possibly electrical cables, are bundled together as a flexible umbilical piping group or umbilical 98. desirable for the umbilical 98 to be routed to the spray head carrier 9 in such a manner as to avoid dragging it over the mat 7 during movement of the spray head 8, which may smear already sprayed areas, and to avoid possible damage to the lines of the umbilical 98. In the illustrated system 1, the umbilical 98 is routed through a hinged umbilical arm 99. The arm 99 includes a first arm section 100 which is pivotally connected to the mobile track 10 near the top edge 23 of the bed 6 at a shoulder joint 101. A second arm section 102 is pivotally connected to the first section 100 by an elbow joint 103 and to the spray head carrier 9 by a wrist joint 104. The sections 100 and 102 are tubular in construction, and the umbilical 98 is routed therethrough and supported thereby. At the elbow joint 103 and wrist joint 104, the umbilical 98 is provided with sufficient slack to avoid interference with pivoting of these joints.
Components of the dye supply mechanism 4 in the illustrated system 1 are mounted on a mobile service cart 106, although the cart 106 may also be stationary. Additionally, the dye continers 94 are mounted on the cart 106. A compressed air equipment housing 107 is mounted on the cart 106 and has the compressor 90, regulators 92, and master air valve 91 mounted therein. The umbilical 98 extends between the housing 107 and the umbilical arm 99 with sufficient slack provided to prevent strain to the umbilical 98. If the cart 106 is mobile, it is preferred that means such as lockable casters 108 be provided thereon to allow the position of the cart 106 to be fixed once it has been properly positioned in relation to the dye medium support structure 2.
Such hand scanners operate in conjunction with software drivers to digitize a pictorial image across which the scanner is drawn and generate an image data file representing the image. The format of the image data file depends, to some extend, on the particular scanner 117 used, the software drivers, and whether or not the scanner has the capability of recognizing colors or gray levels in the scanned image. There are a number of standard formats for digitized images. Once the image data file has been generated, it may be stored in a mass storage device 115 for subsequent use. The image data file can be edited, added to, colored, or the like using a "paint" software, such as PaintShow+ (Logitech, Inc.), PC Paintbrush (ZSoft Corp.), or the like.
A beam of a conventional CRT is swept horizontally from left to right, retraced back to the left margin and down one line, and the process repeated for the number of lines of the display. The data content of the image data file is ordered in such a manner as to be, in effect, horizontally or x-axis oriented so that the video display circuitry can simply sequentially read the data representing the pixels to be displayed directly. While it would be possible for the spray head 9 of the dye plotter apparatus 3 to be scanned in the same manner as a CRT beam is, this not the most efficient use of the dye plotter apparatus 3, because of physical differences between it and a cathode ray tube.
It is foreseen that the spray head carrier 9 could be provided with multiple dye spray heads 8 of various colors and connected by respective dye conduits 82 to dye containers 94. Valving (not shown) would be provided, as in the regulator manifold 92, for controlling which dye would be sprayed at a given time. Such valving could be controlled automatically by the computer 5 according to the color represented by a color component plotter command file. It would be necessary to space such multiple spray heads 8 an integral number of motor steps from one another and for indexing calibrations in relation to the starting position 29 to be made for each spray head 8 in use. Such multiple heads 8 would speed up the image reproduction process by eliminating much of the dye conduit interchaning and purging of the spray head 8 thereafter.
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