LIQUID DISCHARGE APPARATUS AND DYEING APPARATUS

Abstract

 A liquid discharge apparatus (100) includes a head (310) configured to discharge a liquid from nozzles (311) onto a linear member (10) conveyed in a conveyance direction, the head (310) including a nozzle array (313) including the nozzles (311) arrayed along the conveyance direction, and a state check unit (700) downstream of the head (310) in the conveyance direction, the state check unit (700) configured to guide the linear member (10) to form a two-dimensional surface (730) with the linear member (10).

Description

BACKGROUND

Technical Field

[0001] Aspect of this disclosure relates to a liquid discharge apparatus and a dyeing apparatus.

Related Art

[0002] There is an apparatus that colors a linear member such as a thread by using a head that discharges a liquid.

[0003] As described in Japanese Patent Application Laid Open Publication No. 2006-299462, a colored pattern flat knitting machine includes a synthetic dyeing unit, a knitting unit, and a positive thread feeding unit. The synthetic dyeing unit dyes a knitting thread to a desired color. The knitting unit knits a colored pattern knitted fabric from a dyed knitting thread. The positive thread feeding unit feeds a knitting thread used for knitting.

[0004] The positive thread feeding unit is positively and rotationally driven. Further, one or more turns of the knitting thread are wound around each of a front roller and a rear roller. The positive thread feeding unit supplies the knitting thread while applying a constant tension between the front roller and the rea roller. The front roller is disposed upstream in a feeding direction of the knitting thread and the rear roller disposed downstream of the front roller in the feeding direction. The colored pattern flat knitting machine includes the synthetic dyeing unit between the front roller and the rear roller.

[0005] However, when a liquid of desired color is applied to the linear member using a head that discharge a liquid, whether the liquid of desired color has been applied to the linear member has to be checked.

SUMMARY

[0006] The present invention has been made in view of the above-described problem, and an object of the present invention is to easily check a state of a liquid applied on the linear member (liquid application state).

[0007] In an aspect of this disclosure, a novel liquid discharge apparatus includes a head configured to discharge a liquid from nozzles onto a linear member conveyed in a conveyance direction, the head including a nozzle array including the nozzles arrayed along the conveyance direction, and a state check unit downstream of the head in the conveyance direction, the state check unit configured to guide the linear member to form a two-dimensional surface with the linear member.

[0008] According to the present embodiment, it is possible to easily check the liquid application state of the linear member.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] A more complete appreciation of the disclosure and many of the attendant advantages and features thereof can be readily obtained and understood from the following detailed description with reference to the accompanying drawings, wherein:

FIG. 1 is a schematic side view of a liquid discharge apparatus according to a first embodiment of the present disclosure;

FIG. 2 is a schematic side view of a liquid application unit of the liquid discharge apparatus illustrated in FIG. 1;

FIG. 3 is a plan view of a head array of the liquid application unit as viewed from below;

FIG. 4 is a schematic perspective view of a part of the liquid application unit relating to a movement of a head of the liquid application unit according to the first embodiment;

FIG. 5 is a schematic perspective view of a state check unit according to the first embodiment;

FIG. 6 is a schematic perspective view of a winder of the state check unit;

FIG. 7 is a schematic side view of an example of the liquid application unit in a discharge state to illustrate the effect of the winder according to the first embodiment;

FIG. 8 is a schematic plan view of the liquid application unit illustrating a portion of the thread, wound around the winder, to which the liquid is applied by the liquid application unit;

FIG. 9 is a schematic plan view of the thread illustrating a dyed state of the thread when the liquid is applied to the thread in the same manner as in FIG. 7;

FIG. 10 is a block diagram illustrating a portion related to control of a state checking operation according to a second embodiment of the present disclosure;

FIG. 11 is a flowchart illustrating an example of a control of the state check operation in the second embodiment;

FIG. 12 is a flowchart illustrating an example of a control of the state check operation according to a third embodiment of the present disclosure;

FIG. 13 is a schematic side view of the winder illustrating the state check unit of the winder according to a fourth embodiment of the present disclosure;

FIG. 14 is a schematic side view of the state check unit according to a fifth embodiment of the present disclosure; and

FIG. 15 is a schematic side view of a dyeing apparatus according to an embodiment of the present disclosure.

[0010] The accompanying drawings are intended to depict embodiments of the present invention and should not be interpreted to limit the scope thereof. The accompanying drawings are not to be considered as drawn to scale unless explicitly noted. Also, identical or similar reference numerals designate identical or similar components throughout the several views.

DETAILED DESCRIPTION

[0011] In describing embodiments illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the disclosure of this specification is not intended to be limited to the specific terminology so selected and it is to be understood that each specific element includes all technical equivalents that have a similar function, operate in a similar manner, and achieve a similar result.

[0012] Referring now to the drawings, embodiments of the present disclosure are described below. As used herein, the singular forms "a", "an", and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise.

[0013] Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, embodiments of the present disclosure are described below. First, an example of a liquid discharge apparatus according to a first embodiment of the present disclosure is described with reference to FIGS. 1 to 3.

FIG. 1 is a schematic side view of the liquid discharge apparatus 100 according to the first embodiment of the present disclosure.

FIG. 2 is a schematic side view of a liquid application unit 300 of the liquid discharge apparatus illustrated in FIG. 1.

FIG. 3 is a plan view of a head array of the liquid application unit 300 as viewed from below.

[0014] The liquid discharge apparatus 100 is an in-line embroidery device. The liquid discharge apparatus 100 includes a supply unit 200, a liquid application unit 300, a fixing unit 400, a post-processing unit 500, and an embroidery unit 600.

[0015] The supply unit 200 includes a supply reel 210 and rollers 220 and 230. A thread 10 as a linear member is wound around the supply reel 210. The rollers 220 and 230 guide the thread 10 to the liquid application unit 300. The roller 230 includes an encoder 231 including an encoder wheel 231b and an encoder sensor 231a in the roller 230.

[0016] The liquid application unit 300 applies a liquid to the thread 10 to dye (color) the thread 10 in a desired color. The liquid application unit 300 includes multiple heads 310 (310a to 310d) that discharge liquid of a desired color and multiple maintenance units 320 (320a to 320d) that respectively perform maintenance of the multiple heads 310 (310a to 310d) as illustrated in FIG. 2. The heads 310a to 310d discharge, for example, cyan (C), magenta (M), yellow (Y), and black (K) color liquids.

[0017] As illustrated in FIG. 3, each of the heads 310 (310a to 310d) includes a nozzle surface 312 in which a nozzle array 313 is formed. The nozzle array 313 includes multiple nozzles 311, from which a liquid is discharged, are arranged in one line in a conveyance direction as indicated by arrow in FIG. 3. Each head 310 is disposed such that a direction of the nozzle array 313 (nozzle arrangement direction) is along the conveyance direction of the thread 10.

[0018] FIG. 3 illustrates the head 310 in the first embodiment including one nozzle array 313 on the nozzle surface 312 as an example. The head 310 may include multiple row of nozzles arrays 313 disposed on the nozzle surface 312 of the head 310. The head 310 may be configured to move in a direction orthogonal to the conveyance direction of the thread 10. Thus, the nozzle surface 312 of the head 310 may be capped by a cap 325 (see FIG. 4) of the maintenance unit 320 or may discharge a liquid from the nozzles 311 in different nozzle arrays 313 to apply liquid on the thread 10.

[0019] The liquid discharge apparatus 100 according to the first embodiment includes a state check unit 700 (state check region) having a path along which the threads 10 are arranged in a direction orthogonal to a radial direction.

[0020] The liquid discharge apparatus 100 according to the first embodiment may include a state check unit 700 having a path along which the thread 10 is bent multiple times in a radial direction or tangential direction orthogonal to the conveyance direction. The bent thread 10 is arrayed in the conveyance direction.

[0021] The state check unit 700 is disposed downstream of the liquid application unit 300 and upstream of a fixing unit 400 in the conveyance direction. The state check unit 700 is not particularly limited as long as the state check unit 700 is disposed downstream of the liquid application unit 300 in the conveyance direction.

[0022] With reference to FIG. 1, the fixing unit 400 performs a fixing process (drying process) on the thread 10 to which the liquid discharged from the heads 310 of the liquid application unit 300 is applied. The fixing unit 400 includes, for example, a heater such as an infrared irradiator and a hot air sprayer to heat and dry the thread 10.

[0023] The post-processing unit 500 includes, for example, a cleaning device that cleans the thread 10, a tension adjustment device that adjusts a tension of the thread 10, a feed amount detector that detects an amount of movement of the thread 10, and a lubricant application device that lubricates a surface of the thread 10.

[0024] The embroidery unit 600 includes a needle 610 (embroidery needle) and a needle driver 620 (needle drive mechanism). The embroidery unit 600 vertically movably supports the needle 610. The needle driver 620 vertically moves the needle 610. The embroidery unit 600 sews the dyed thread 10 as an upper thread on the medium 20 (embroidery medium) such as cloth according to an embroidery pattern to perform an embroidery process.

[0025] The embroidery unit 600 includes a winding collector 630 that winds and collects the thread 10 serving as an upper thread to be sewn on the medium 20 after passing through a hole of the needle 610.

[0026] In the present embodiment, an example is described in which the liquid discharge apparatus 100 serves as an embroidery apparatus. The liquid discharge apparatus 100 according to the first embodiment is not limited to the embroidery apparatus.

[0027] The liquid discharge apparatus 100 may be applicable to, e.g., an apparatus using a linear object such as a thread, for example, an apparatus such as a loom, a sewing machine, or a printer to print image on a general sheet material.

[0028] Further, aspects of the present disclosure can be applied not only to apparatuses having a post-process, such as an embroidery machine, but also to dyeing apparatuses and the like that dye and the wind threads 10, etc. as described below.

[0029] Examples of "thread" include glass fiber thread, wool thread, cotton thread, synthetic thread, metal thread, mixed thread of wool, cotton, polymer, or metal, thread, filament, and linear member (continuous base materials) to which liquid can be applied. Example of the "thread" further includes braids and flat cords (flat braids).

[0030] Next, an example of a part relating to a movement of the head 310 is described with reference to FIG. 4.

[0031] FIG. 4 is a schematic perspective view of the part of the liquid application unit 300 relating to the movement of one head 310 according to the first embodiment.

[0032] The head 310 is mounted on a carriage 351. The carriage 351 is reciprocally movable in an X-direction indicated by arrow "X" in FIG. 4. Thus, the head 310 is movable between a home position at which the head 310 is capped with the cap 325 of an individual maintenance unit 320 and a discharge position (dyeing position) at which the head 310 discharges the liquid onto the thread 10.

[0033] The carriage 351 is reciprocally movably held by a main guide rod 352 and a sub-guide member 353.

[0034] The liquid application unit 300 includes a driver 360 to reciprocally moves the carriage 351. The driver 360 includes a motor 361 and a crank 362. The crank 362 is a drive force transmission member moved by the motor 361. The motor 361 includes a motor shaft 361a coupled to an arm 363.

[0035] A rear end of the crank 362 is rotatably attached to the arm 363 with a shaft 364. The arm 363 is coupled to the motor shaft 361a. A leading end of the crank 362 is rotatably coupled to the carriage 351 by a support shaft 365 on the carriage 351.

[0036] A tension coil spring 370, which is an elastic member, is disposed between the carriage 351 and a fixed portion.

[0037] With such a structure, the motor 361 reciprocally moves the carriage 351 along the main guide rod 352 and the sub-guide member 353 via the crank 362 as the driver 360 drives the motor 361.

[0038] The carriage 351 repeatedly moves and stops between the home position and the discharge position to maintain and recover the head 310. The head 310 faces the cap 325 and the cap 325 caps the head 310 at the home position. The head 310 discharges a liquid onto the thread 10 to dye the thread 10 as an application target at the discharge position.

[0039] The maintenance unit 320 includes the cap 325 and a wiper 326. The cap 325 caps the nozzle surface 312 of the head 310. The wiper 326 wipes the nozzle surface 312. When the liquid is not discharged from the head 310, the driver 360 moves the head 310 to the home position facing the cap 325. Then, the maintenance unit 320 caps the nozzle surface 312 with the cap 325. The driver 360 moves the head 310 to wipe the nozzle surface 312 of the head 310 with the wiper 326 when the head 310 performs a dummy discharge operation (discharges a dummy liquid), for example.

[0040] The maintenance unit 320 includes a dummy discharge receptacle 321 having an opening on a top of the discharge receptacle 321 as illustrated in FIG. 4. The head 310 discharges the dummy liquid into the opening in the dummy discharge receptacle 321. The dummy liquid is a liquid not discharged onto the thread 10 and does not contribute to a dyeing process of the thread 10.

[0041] A state check unit 700 according to the first embodiment of the present disclosure is described with reference to FIGS. 5 and 6.

[0042] FIG. 5 is a schematic perspective view of the state check unit 700.

[0043] FIG. 6 is a schematic perspective view of a winder 710.

[0044] The winder 710 around which the thread 10 is wound is disposed in the state check unit 700. The winder 710 is a device to form a path. The winder 710 forms a path in which the thread 10 is arranged such that the liquid droplets discharged from an identical nozzle 311 of the nozzle array 313 of the head 310 are linearly arranged in the conveyance direction orthogonal to ra radial direction (width direction) of the thread 10.

[0045] Thus, a liquid discharge apparatus 100 includes the head 310 including nozzles 311 from which a liquid is discharged onto the thread 10 (linear member) conveyed in a conveyance direction, and the state check unit 700 downstream of the head 310 in the conveyance direction.

[0046] The thread 10 is bent multiple times in a direction different from the conveyance direction to form a two-dimensional surface 730 in the state check unit 700, wherein the nozzles 311 are arrayed along the conveyance direction in the head 310. The direction different from the conveyance direction includes the radial direction (width direction) of the thread 10 and a tangential direction (winding direction) of the thread 10.

[0047] The winder 710 is a roller-shaped member around which the thread 10 is to be wound without overlap to form the two-dimensional surface 730. The thread 10 is wound around the winder 710 a plurality of times (here, four times) in the first embodiment in FIG. 5. A part of a surface of the winder 710 around which the thread 10 has been wound forms the two-dimensional surface 730.

[0048] Thus, the state check unit 700 is configured to guide the thread 10 (linear member) to form the two-dimensional surface 730 with the thread 10 (linear member).

[0049] A circumferential length of one turn of the thread 10 in a state wound around the winder 710 is equal to a length of the nozzle array 313 of the head 310 in the winder 710. The circumferential length of one turn of the thread 10 does not have to be equal to the length of the nozzle array 313 in the winder 710. For example, a region onto which the liquid is not applied may be interposed between regions to which the liquid is applied by all the nozzles 311 in the nozzle array 313.

[0050] Thus, a part of the thread 10 (linear member) wound around a circumferential surface of the winder 710 one turn has a length equal to a length of the nozzle array 313.

[0051] Thus, the winder 710 can arrange a region of the thread 10 onto which the liquid is applied while making the circumferential length of one turn of the thread 10 to be longer than the length of the nozzle array 313.

[0052] Thus, the winder 710 is a path former in the state check unit 700. The winder 710 (path former) configured to form a path that forms the two-dimensional surface 730 by the thread 10. The multiple portions of the thread 10 which the liquid is discharged from an identical nozzle 311 of the nozzles 311 of the head 310 for multiple times are linearly arranged in the conveyance direction in the two-dimensional surface 730 of the state check unit 700.

[0053] Thus, in the two-dimensional surface 730, multiple portions of the thread 10 (linear member) onto which the liquid has been discharged from an identical nozzle 311 of the nozzles 311 are linearly arranged in the conveyance direction.

[0054] The winder 710 includes grooves 710a that guide the thread 10 in a coil shape around the winder 710.

[0055] The state check unit 700 includes a reader 720 such as a CCD sensor to read the thread 10 wound around the winder 710. Thus, the reader 720 in the state check unit 700 reads the thread 10 in the two-dimensional surface 730.

[0056] Next, an effect of the winder 710 according to the first embodiment is illustrated with reference to FIGS. 7 and 8.

[0057] FIG. 7 is a schematic side view of an example of the liquid application unit 300 in a discharge state to illustrate the effect of the winder 710 according to the first embodiment.

[0058] FIG. 8 is a schematic plan view of the liquid application unit 300 illustrating a portion of the thread 10, wound around the winder 710, to which the liquid is applied by the liquid application unit 300.

[0059] When the liquid discharge apparatus 100 performs a nozzle check operation to detect a discharge state of the nozzles 311 of the head 310, for example, the liquid discharge apparatus 100 performs a liquid application operation to discharge liquid 315 from all the nozzles 311 of the nozzle array 313 of the head 310 to apply the liquid 315 to the thread 10 as illustrated in FIG. 7.

[0060] When there is a nozzle 311 having a discharge failure as illustrated in FIGS. 3 and 7, an undyed region 111b in the thread 10 to which a liquid is not applied is generated together with a dyed region 111a in the thread 10 to which a liquid is applied in a liquid application region 111 in the thread 10. A length of the liquid application region 111 in the thread 10 corresponds to a length of the nozzle array 313. The discharge failure means non-discharge, bent discharge, or the like.

[0061] This nozzle check operation is performed the number of times of winding around the winder 710 (here, four times as illustrated in FIG. 8).

[0062] At this time, a circumferential length of the winder 710 in a circumferential direction of the winder 710 is substantially the same as the length of the nozzle array 313. Therefore, the thread 10 is wound around the winder 710 side by side such that the droplets discharged from an identical (same) nozzle 311 are arranged linearly in the conveyance direction as illustrated in FIG. 8.

[0063] The undyed region 111b (white portion in FIG. 8) appears in the thread 101 wound around the winder 710 such that the undyed regions 111b linearly aligned in one line in an arrangement direction (conveyance direction) of the thread 10 whereas the thread 10 is wound around the winder 710 in a direction orthogonal to the conveyance direction if there is the undyed region 111b in the thread 10 when the thread 10 is wound around the winder 710 as illustrated in FIG. 8.

[0064] Thus, the liquid discharge apparatus 100 can increase an area of a check unit in the thread 10 to be checked when the liquid discharge apparatus 100 check a discharge failure of a nozzle 311, a dyeing failure, or the like by a visual checking or by detection by a reading device. Thus, the liquid discharge apparatus 100 can easily check an application state of liquid 315 on the thread 10.

[0065] A liquid discharge apparatus according to a comparative example is described below with reference to FIG. 9.

[0066] FIG. 9 is a schematic plan view of the thread 10 illustrating a dyed state of the thread 10 when the liquid 315 is applied to the thread 10 in the same manner as in FIG. 7.

[0067] The liquid discharge apparatus in the comparative example does not include the state check unit 700 and the winder 710. Thus, the thread 10 is linearly conveyed as it is in the conveyance direction of the thread 10 without wound around the winder 710. Therefore, the undyed regions 111b appear at intervals (dispersed manner) of the nozzle array 313 in the thread 10 as illustrated in FIG. 9 when the undyed regions 111b are generated in the thread 10.

[0068] In this way, the undyed regions 111b appear in a dispersed manner in the thread 10 in the comparative example, unlike the first embodiment of the present disclosure. Thus, the liquid discharge apparatus in the comparative example cannot easily check the dyed state (application state) of the liquid on the thread 10.

[0069] The liquid discharge apparatus 100 according to a second embodiment of the present disclosure is described with reference to FIG. 10.

[0070] FIG. 10 is a block diagram illustrating a portion related to control of the state checking operation in the second embodiment.

[0071] The liquid discharge apparatus 100 includes a main controller 801 to control the head 310 to discharge liquid 315 from all the nozzles 311 in the nozzle array 313 of the head 310 via a head drive controller 802 in the nozzle check operation. The main controller 801 controls the head 310 to perform a dummy discharge operation from the nozzles 311, the discharged liquid of which does not contribute to an image formation, in a recovery operation of the nozzle 311 having the discharge failure of the head 310.

[0072] When the main controller 801 performs the nozzle check operation, the main controller 801 drives a winding collector 630 to wind and collect the thread 10 via a winding-collector drive controller 803 to discharge the liquid from all nozzles 311 in the head 310 for a plurality of times. Thus, the main controller 801 drives a winding collector 630 to convey the thread 10 for each length of the nozzle array 313 to update a liquid application position at which the head 310 discharge the liquid from the nozzles 311 onto the thread 10. The main controller 801 may not include the winding collector 630, and the main controller 801 may drive the needle 610 to feed the thread 10 to update the liquid application position.

[0073] The main controller 801 receives a start instruction to start the nozzle check operation from an operation part 820. The nozzle check operation is started not only in response to the start instruction from the user but also at a predetermined timing.

[0074] The main controller 801 controls a reader 720 to read a state of the thread 10 on the winder 710. Further, the main controller 801 inputs read information that is obtained by image processing a read output of the reader 720 by an image processor 804.

[0075] The main controller 801 determines whether a recovery operation (maintenance operation) of the head 310 has to be performed according to the read information input to the main controller 801. When the main controller 801 determines that the recovery operation has to be performed, the main controller 801 executes the recovery operation and displays information such as the occurrence of the discharge failure on the display 830 to notify the user of the occurrence of the discharge failure.

[0076] Next, an example of a control of the state check operation (nozzle check operation) in the second embodiment is described below with reference to a flowchart illustrated in FIG. 11.

[0077] The main controller 801 starts a process as illustrated in FIG. 11 when the main controller 801 receives the start instruction to start the nozzle check operation from the operation part 820. The main controller 801 may start a process as illustrated in FIG. 11 at a predetermined timing. The predetermined timing includes, for example, a cumulative number of discharge of the liquid from the nozzles 311 of the head 310 reaching to a predetermined amount, a cumulative discharge amount of the liquid from the nozzles 311 of the head 310 reaching to a predetermined amount, or elapsed time of a standby state reaching to a predetermined time.

[0078] When the main controller 801 starts the nozzle check operation, the main controller 801 applies liquid according to a nozzle check pattern to the thread 10 (step S1).
Hereinafter, the step S1 is also simply referred to as "S1". The nozzle check pattern is a pattern in which liquid is discharged from all the nozzles 311 of the nozzle array 313 of the head 310 and applied to the thread 10.

[0079] Then, the main controller 801 drives and controls, for example, the winding collector 630 to convey the thread 10 by a predetermined amount (S2). The predetermined amount corresponds to the length of the nozzle array 313.

[0080] Next, the main controller 801 determines whether the head 310 has discharged the liquid according to the nozzle check pattern for a predetermined number of times (S3). When the head 310 has not discharged the liquid according to the nozzle check pattern for a predetermined number of times (S3, NO), the main controller 801 returns the nozzle check operation to step S1.

[0081] When the head 310 discharges the liquid according to the nozzle check pattern for a predetermined number of times (S3, YES), the main controller 801 conveys the thread 10 until a portion of the thread 10 applied with (corresponding to) the nozzle check pattern has been wound around the winder 710 (S4).

[0082] Then, the main controller 801 controls the reader 720 to read the state of the thread 10 wound around the winder 710. Then, the main controller 801 captures read information obtained by performing image processing on the read result by the image processor 804 (S5).

[0083] Then, the main controller 801 checks whether there is the nozzle 311 having a discharge failure based on captured read information and determines whether there is an abnormal discharge (S6).

[0084] At this time, if there is an abnormal discharge (S6, YES), the main controller 801 performs a dummy discharge operation as a recovery operation. The dummy discharge operation performs a dummy discharge in which the main controller 801 controls the head 310 to discharge a liquid from nozzles 311 in which a discharge failure has occurred (S7). Then, the main controller 801 returns the process to step S1 to apply the liquid according to the nozzle check pattern on the thread 10.

[0085] If there is no abnormal discharge (S6, NO), the main controller 801 ends this state check operation (nozzle check operation).

[0086] The recovery operation may be performed by, for example, the main controller 801 notifying the user of the discharge failure through the display 830. Then, the main controller 801 performs the recovery operation after an instruction of the recovery operation is input from the operation part 820.

[0087] The above describes the liquid discharge apparatus according to the second embodiment that reads a state of the thread 10 in the state check unit 700 by the reader 720 to check the state of the nozzles 311 (discharge state) of the head 310, as an example. However, the state check operation (nozzle check operation) of the liquid discharge apparatus 100 according to the second embodiment is not limited to the embodiments as described above.

[0088] For example, the main controller 801 may detect a state of the thread 10 such as a dyeing density or a color (using a color sensor) of the thread 10 to which the liquid is applied by using the read result of the reader 720. Then, the main controller 801 may control adjustment of the discharge amount for each color, for example, and correction of a density and a color tone of the thread according to the detection result.

[0089] Next, the liquid discharge apparatus 100 according to a third embodiment of the present disclosure is described with reference to FIG. 12.

[0090] FIG. 12 is a flowchart illustrating a control of the state check operation in the third embodiment.

[0091] A portion related to a control of the state check operation in the third embodiment is the same as a portion related to a control of the state check operation as described in the second embodiment. However, the liquid discharge apparatus in the third embodiment does not use the reader 720 in the nozzle check operation.

[0092] In steps S11 to S14, the main controller 801 performs the same processing as in the steps S1 to S4 of the second embodiment (see FIG. 11). Thus, a portion of the thread 10 to which the nozzle check patterns for times are formed is wound around the winder 710.

[0093] Thus, the user visually checks (confirms) whether there is a nozzle omission (discharge failure) as described above. The nozzle omission is occurred when the nozzle 311 is clogged by hardened ink or foreign material so that the ink may not be discharged from the clogged nozzle 311. At this time, when the user determines that there is a discharge failure and a recovery operation has to be performed, the user instructs the main controller 801 to perform the recovery operation from the operation part 820.

[0094] The main controller 801 determines whether there is an instruction input of a recovery operation from the operation part 820 (S15). At this time, if there is the instruction input of the recovery operation, the main controller 801 performs the dummy discharge operation as the recovery operation similarly to the step S6 (see FIG. 11) in the second embodiment (S16). Then, the main controller 801 returns the process to step S11 to apply the liquid according to the nozzle check pattern on the thread 10 after the step S16.

[0095] Conversely, if there is no instruction input of the recovery operation from the operation part 820 (S15, NO), the main controller 801 ends the state check operation (nozzle check operation). The main controller 801 can determined an absence of the instruction input of the recovery operation in any way so that a state of the absence of the instruction input may include a state when the instruction for recovery operation is input, when another instruction is input, or when the instruction for recovery operation is not input for a predetermined time.

[0096] In the above manner, the liquid discharge apparatus 100 can improve visibility of the undyed region 111b in the thread 10 that is a region corresponding to the discharge failure also when the user visually checks the discharge failure since the undyed region 111b is linearly aligned in one line in the thread 10 wound around the winder 710.

[0097] Next, the liquid discharge apparatus 100 according to a fourth embodiment of the present disclosure is described with reference to FIG. 13.

[0098] FIG. 13 is a schematic side view of the winder 710 illustrating the state check unit of the winder 710 in the fourth embodiment.

[0099] The liquid discharge apparatus 100 in the fourth embodiment includes the winder 710 around which the thread 10 is spirally wound. The winder 710 in the fourth embodiment has a shape in which an outer diameter of the winder 710 is varied stepwise in the conveyance direction.

[0100] In such a configuration as illustrated in FIG. 13, the thread 10 is wound around the winder 710 side by side so that positions of the liquid discharged from the same (identical) nozzle 311 on the thread 10 are linearly arranged while being obliquely shifted in the winding direction orthogonal to the conveyance direction when the thread 10 is wound around the winder 710.

[0101] Thus, the liquid discharge apparatus 100 according to the third embodiment can obtain the same effect of easily detecting the discharge failure as the effect of the liquid discharge apparatus 100 according to each of the above described embodiment.

[0102] Next, the liquid discharge apparatus 100 according to a fifth embodiment of the present disclosure is described with reference to FIG. 14.

[0103] FIG. 14 is a schematic side view of the state check unit according to the fifth embodiment.

[0104] The liquid discharge apparatus 100 according to the fifth embodiment includes multiple guides 740 to guide the thread 10. The multiple guides 740 guides the thread 10 while folding back the thread 10 for a plurality of times (two times in FIG. 14). At this time, the multiple guides 740 form a path along which the thread 10 is folded back side by side such that positions of the liquid discharged from the same (identical) nozzle 311 of the head 310 on the thread 10 are linearly arranged in one line in the conveyance direction.

[0105] The multiple guides 740 as the path former guides the thread 10 while bending the thread 10 multiple times to form the two-dimensional surface 730.

[0106] Thus, the liquid discharge apparatus 100 according to the fifth embodiment can obtain the same effect of easily detecting the discharge failure as the effect of the liquid discharge apparatus 100 according to each of the above described embodiment.

[0107] Next, a dyeing apparatus 1000 according to an embodiment of the present disclosure is described with reference to FIG. 15.

[0108] FIG. 15 is a schematic side view of the dyeing apparatus 1000.

[0109] This dyeing apparatus 1000 includes a winding unit 1200 to wind the thread 10 after the thread 10 is dyed instead of the embroidery unit 600 in the liquid discharge apparatus 100.

[0110] The dyeing apparatus 1000 supplies the thread 10 from a supply reel 210 of the supply unit 200, discharges and applies a liquid of a desired color from the liquid application unit 300 onto the thread 10 to dye the thread 10 into a target color, and winds the dyed thread 10 with a winding reel 1220 of the winding unit 1200.

[0111] The liquid discharge apparatus 100 according to the present embodiment is not limited to the embroidery unit 600 or the dyeing apparatus 1000.

[0112] The above-described embodiments are illustrative and do not limit the present invention. Thus, numerous additional modifications and variations are possible in light of the above teachings. For example, elements and/or features of different illustrative embodiments may be combined with each other and/or substituted for each other within the scope of the present invention. Any one of the above-described operations may be performed in various other ways, for example, in an order different from the one described above.

[0113] Each of the functions of the described embodiments such as the main controller 801 may be implemented by one or more processing circuits or circuitry. Processing circuitry includes a programmed processor, as a processor includes circuitry. A processing circuit also includes devices such as an application specific integrated circuit (ASIC), a digital signal processor (DSP), a field programmable gate array (FPGA), and conventional circuit components arranged to perform the recited functions.

Claims

1. A liquid discharge apparatus (100) comprising:

a head (310) configured to discharge a liquid from nozzles (311) onto a linear member (10) conveyed in a conveyance direction, the head (310) including a nozzle array (313) including the nozzles (311) arrayed along the conveyance direction; and

a state check unit (700) downstream of the head (310) in the conveyance direction, the state check unit (700) configured to guide the linear member (10) to form a two-dimensional surface (730) with the linear member (10).

2. The liquid discharge apparatus (100) according to claim 1,

wherein the state check unit (700) includes a path former (710, 740) forming a path that guides the linear member (10) to form the two-dimensional surface (730),

wherein, in the two-dimensional surface (730), multiple portions of the linear member (10) onto which the liquid has been discharged from an identical nozzle (311) of the nozzles (311) are linearly arranged in the conveyance direction.

3. The liquid discharge apparatus (100) according to claim 2,
wherein the path former (710) includes a winder (710) around which the linear member (10) is to be wound without overlap to form the two-dimensional surface (730).

4. The liquid discharge apparatus (100) according to claim 3,
wherein a part of the linear member (10) wound around a circumferential surface of the winder (710) one turn has a length equal to a length of the nozzle array (313).

5. The liquid discharge apparatus (100) according to claim 3,
wherein an outer diameter of the winder (710) is varied stepwise in the conveyance direction.

6. The liquid discharge apparatus (500) according to any one of claims 3 to 5, wherein the winder (710) includes grooves (710a) that guide the linear member (10) to wind around the winder (710).

7. The liquid discharge apparatus (500) according to claim 2,
wherein the path former (710, 740) includes multiple guides (740) configured to bend the linear member (10) multiple times to form the two-dimensional surface (730).

8. A liquid discharge apparatus (100) according to any one of claims 1 to 7, wherein the state check unit (701) further includes a reader (720) configured to read the linear member (10) in the two-dimensional surface.

9. A dyeing apparatus (1000) comprising:

the liquid discharge apparatus according to claim 1,

wherein the head (310) discharges the liquid from the nozzles (311) to dye the linear member (10).

Drawing