Switching station, method and system

Abstract

A transfer station, method and system are provided, the transfer station comprising: a mechanism operable to support at least a portion of a web; a conversion device located above the mechanism, the conversion device being operable to traverse a conversion zone located below the conversion device to bring the cutting member into contact with the web to convert the web into one or more individual products; an image capture device located above the mechanism and adjacent to the conversion device but outside the conversion zone, the image capture device being positioned at a non-vertical imaging angle with respect to the surface plane of the web, the image capture device is operable to capture image information by imaging features located on the web when one or more features are positioned within the transition zone; and a control system operable to align the web within the transition zone based on the image information.

Description

[0001] This application is a divisional application of the invention patent application filed on November 30, 2017 (date of entry into the Chinese national phase: June 3, 2019), with the invention name being “Membrane Alignment in a Conversion Station” and application number being PCT / US2017 / 063858 (national application number: 2017800747967). Technical Field

[0002] The present disclosure relates to methods and systems for alignment and converting processes for producing film products from web materials. Background Art

[0003] The manufacturing process for making various types of films, such as transparent polyester films, involves making the films in continuous long sheets called webs. The web itself is typically a material with fixed dimensions in one direction (the "crossweb direction") and a predetermined or undetermined length in the orthogonal direction (the "downweb direction"); the web may have various features, such as printed indicia, applied to one or both surfaces of the film. In addition, one or more features, such as indicia, may be embedded within the film, where the features are visible through the surface of the film.

[0004] Generally speaking, a web is often converted into a plurality of individual products. For example, a web may include a series of designated areas of film, in some embodiments the designated areas having a width dimension and a length dimension, which are to be separated from the web using a converting process to provide individual products. Examples of individual products include a cover film for a display such as a computer monitor, or a cover sheet or cover layer for a display screen of a mobile device such as a cell phone. Summary of the invention

[0005] In general, the present disclosure describes a converting station and alignment process that is based on a printed mark or other imprint or feature that will remain on the individual product itself after it is converted, rather than a fiducial mark or another mark on a portion of the web that is outside the area designated to become the individual product. This approach provides the advantage that alignment is now based on the same entity (i.e., the imprint or other feature on the individual product to be converted) that was the object that drove the need for proper alignment prior to converting the product. As such, the techniques described herein can achieve higher alignment accuracy than a converting station based on fiducial marks on an unused portion of the web.

[0006] As one embodiment, the present disclosure relates to a conversion station, which includes: a mechanism that is operable to support at least a portion of a manufactured web; a conversion device that is located above the mechanism, the conversion device being operable to traverse a conversion zone located below the conversion device so that a cutting member contacts the web to convert the web into one or more individual products; an image capture device that is located above the mechanism and adjacent to the conversion device but outside the conversion zone, the image capture device being positioned at a non-perpendicular imaging angle relative to a surface plane of the web, the image capture device being operable to capture image information by imaging features located on the web when one or more features are positioned within the conversion zone; and a control system that is operable to align the web within the conversion zone based on the image information.

[0007] As another embodiment, the present disclosure relates to a method, comprising: aligning a web for conversion at a conversion station based on a feature of a manufactured web, the feature remaining in an area of ​​the web designated to become the individual products once the individual products are converted from the web, wherein the step of aligning the web comprises imaging the feature of the web using an image capture device located outside a conversion zone of the conversion station and at an imaging angle relative to the web, and positioning the web within the conversion station based on imaging information captured by imaging the feature on the web when the feature is positioned within the conversion zone, and actuating the conversion station to convert the individual products from the web.

[0008] In further embodiments, the present disclosure is directed to a system comprising: a mechanism operable to support at least a portion of a web being manufactured; a conversion station comprising a press and at least one die positioned above the mechanism and above the web and operable to traverse a conversion zone to bring the at least one die into contact with the web to cut a thickness dimension through the web; an image capture device positioned above the mechanism and adjacent to the conversion device but outside of the conversion zone, the image capture device operable to capture image information of a feature located on the secondary material when the feature is positioned within the conversion zone; and a control / A drive system coupled to the press and to the image capture device, the control / drive system operable to transport a web to introduce an area of ​​the web designated for conversion into individual products into a conversion station, receive imaging information from the image capture device, align the web based on the imaging information into a position beneath at least one die and in a position such that when the at least one die is actuated to traverse a conversion zone between the die and the web, the die cuts the web to provide individual products having dimensions between a feature located on the web and an edge of the converted individual product falling within a specified range. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The details of one or more embodiments of the present disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the present disclosure will be apparent from the description and drawings, and from the claims.

[0010] Figure 1 is a block diagram illustrating a global network environment in which a conversion control system controls conversion of web materials.

[0011] Figure 2 is a block diagram providing a top view of an embodiment production line for converting a web of material into individual components according to one or more embodiments described in the present disclosure.

[0012] Figure 3 is a diagram providing a side view of an embodiment of a converting station for converting web material into individual products according to one or more embodiments described in the present disclosure.

[0013] Figure 4 is a flow chart illustrating one or more embodiment methods according to various techniques described in this disclosure.

[0014] The drawings and descriptions provided herein illustrate and describe various embodiments of the inventive methods, devices, and systems of the present disclosure. However, the methods, devices, and systems of the present disclosure are not limited to the specific embodiments shown and described herein, and as will be appreciated by those of ordinary skill in the art, other embodiments and variations of the methods, devices, and systems of the present disclosure are contemplated within the scope of the present application. DETAILED DESCRIPTION

[0015] As described above, the web may include a plurality of areas designated as individual products, which are intended to be separated from the web to form individual products. In various embodiments, the separation of individual products from the web is referred to as a conversion process. In some embodiments, the conversion process includes aligning the web below a mechanical press including one or more dies, which is operable to drop onto the web once the web is correctly aligned below the one or more dies, thereby causing the one or more dies to contact the web and cut through the film layer of the web to form one or more desired individual products. The correct alignment of the web below one or more dies is extremely important. For example, some webs include printing on the surface of the film forming the web, wherein once the individual product is separated from the web (converted from the web), the printing needs to be correctly positioned relative to the edge of the individual product. If the web is not aligned below the die when the die drops onto the web, the printing on the resulting individual product will not be correctly aligned with the edge of the resulting individual product or may be incorrectly spaced apart from the edge, and may be made unsuitable for its intended use in the final product that the individual product is intended to be used for.

[0016] In conventional techniques for aligning the web correctly under the die before the conversion process is performed, once the individual products are converted from the web, a fiducial mark or some other type of mark is applied to the web in an area outside the area of ​​the web designated as part of the individual products. This allows the fiducial mark (or other type of mark) to be imaged without the imaging device being used to locate the mark, thereby creating an obstruction to the movement of the mechanical press and die when the actual conversion process is performed. For example, in preparation for converting this particular individual product, a point printed on the surface of the film in an area next to or near the area of ​​the web designated to become the individual product can be used as a basis for aligning the web under the die. Alignment of the web under the die is based on imaging the fiducial mark or other mark, and aligning the web based on the location of the fiducial mark or other mark. However, because the film itself has a certain degree of flexibility, stretching or other distortion of the film (or other reasons) may result in errors in the alignment of the fiducial mark relative to the area of ​​the individual product associated with the fiducial mark or other mark, especially because the mark used as the basis for alignment is located outside the area of ​​the web designated to become the individual product.

[0017] The present disclosure describes an embodiment conversion station and alignment process based on printed marks or other prints or features that are to remain on individual products after they are converted. As recognized herein, this approach provides the advantage that alignment is now based on the same entity (i.e., the print or other feature on the individual product to be converted), which is the object that drives the need for proper alignment prior to converting the product. In this way, the techniques described herein can achieve higher alignment accuracy than conversion stations based on fiducial marks on unused portions of auxiliary materials.

[0018] As described herein, when alignment is based on prints or other features that will remain on the individual products themselves, the system for obtaining an image of the prints or other features and thus providing information related to web alignment must remain unobstructed by the mechanical press and die during the actual conversion process. Specific implementations of the embodiments described herein provide for aligning the web beneath the mechanical press and die while providing alignment based on prints or other features within areas of the web that will remain part of the individual products after conversion and do not interfere with actuation of the mechanical press and die during the conversion process. In various embodiments, the web material includes printed features on a surface of the web, or on a web layer that is fabricated so that the print is visible from one or both surfaces of the web.

[0019] Figure 11 is a block diagram of a global network environment 2 for showing the conversion of web materials by a conversion control system 4. More specifically, web manufacturing plants 6A-6N represent manufacturing locations for web materials in the form of web rolls 10 that are produced and transported. Web manufacturing plants 6A-6N may be geographically distributed. The web materials manufactured may include any sheet material having a fixed size in one direction and a predetermined or undetermined length in an orthogonal direction. Embodiments of web materials include, but are not limited to, metal, paper, fabric, non-woven fabric, glass, polymer film, flexible circuit, or a combination thereof. Metals may include materials such as steel or aluminum. Fabrics generally include various textiles. Non-woven fabrics include materials such as paper, filter media, or insulating materials. Films include transparent and opaque polymer films, which include, for example, laminates and coated films. As used herein, the term "film" is widely applicable to any web material, including web materials comprising multiple layers of different materials forming a composite web material, materials having one or more coatings applied to the material or a coating positioned with the web material, or layers comprising a single layer of material forming a web material.

[0020] For a variety of applications, the web material of the web roll 10 may have an applied coating, which is typically applied to an exposed surface of a base web material. Examples of coatings include adhesives, optical density coatings, low adhesion back coatings, metallized coatings, photoactive coatings, conductive or non-conductive coatings, or combinations thereof. The coating may be applied to at least a portion of the web material or may completely cover the surface of the base web material. In addition, the web material may be patterned or unpatterned.

[0021] In some embodiments, the web roll 10 is transported to a conversion site 8A-8N, which may be co-located in a web manufacturing plant 6A-6N or geographically distributed in different regions or countries. The conversion site 8A-8N ("conversion site 8") converts each web roll 10 into one or more products. Specifically, each of the conversion sites 8 includes one or more production lines that physically cut the web of a given web roll 10 into many individual sheets, individual components, or many web rolls, referred to as products 12A-12N. As an embodiment, the conversion site 8A may convert a web roll 10 of a film into an individual product to be used as a cover sheet or cover layer for a mobile phone display or a computer monitor. Similarly, webs of other forms may be converted into products 12 of different shapes and sizes according to the intended application of customers 14A-14N. Each of the conversion sites 8 may be capable of receiving different types of web rolls 10, and each conversion site may produce different products 12 according to the location of the conversion site and the specific needs of customers 14.

[0022] When converting a patterned film into a separate part or a separate product, it is often desirable to cut the part in registration with features inherent to the final part itself. A simple example of a feature inherent to the final part that is to become a separate product is a black line or a series of black lines on an optical film. In various embodiments, it is desirable to cut the edge of the part to within the size of a black line measuring 100 μm that will remain on the final product. It is common in the art to use features external to the final part for registration, such as fiducial markers and imaging techniques described for registration based on fiducial markers. Embodiments of fiducial markers include images that can be printed or otherwise formed on or within a web material. In some embodiments, the fiducial marker can be a cross or "X" shape, or, for example, a dot, square, or rectangular (bar) shape that has a solid color printed on or embedded in the web material. The fiducial marker is used to determine the position of one or more features on the web relative to the fiducial marker and is generally not intended to be a feature of the final product to be converted from the web. The fiducial markers are usually placed at regular intervals over the entire length of the web to accurately locate and uniquely identify the physical location on the web. Generally, the fiducial mark is located on a portion of the web that will not ultimately become part of the final (salable) product to be converted from the web. However, as recognized herein, reliance on features external to the final product (such as, fiducial marks) can result in errors in overall alignment because the external fiducial marks are located at an increased distance from the features of interest on the product, such as, but not limited to, one or more black lines printed in areas of the web that are designated to become separate products. This increased uncertainty can be caused by the printing process, where the fiducial marks are not accurately registered to the features of interest for all components. It can also be caused by errors in the conversion press or laser conversion operation when translating the location of the fiducial mark to the location of the feature of interest within the component.

[0023] As recognized herein, it can therefore be beneficial to align a component directly to a feature of interest (such as, but not limited to, one or more black lines printed on the surface of a web in an area of ​​the web designated as a separate product) during the conversion process. Typically, an imaging camera is used to position the feature on the web for registration purposes. Since the feature is located in an area of ​​the auxiliary material designated as the separate component itself, the feature is also located in the active punch area (conversion zone) of the press used for the conversion process, so the image capture device positioned for imaging the feature is mechanically constrained. In other words, it is generally not practical to image a feature on the web in a portion of the web in the punch area at an angle perpendicular to the web. Therefore, for a standard imaging device, it is not possible to focus on the entire image of the feature contained in the web area designated as a separate product, and therefore it is generally impossible to accurately align the feature using standard techniques. Therefore, the common practice of using additional fiducial marks outside the punch area leads to subsequent accuracy limitations.

[0024] Implementations of the embodiments described herein provide a variety of methods that can be incorporated into systems used in a converting process to convert individual products from a web to overcome these problems. Implementations of a first embodiment use a precision telecentric Scheimpflug lens with an imaging camera to provide highly accurate focus and spatial resolution throughout a field of view including features located within areas of the web that are designated to become individual products due to the converting process. Implementations of a second embodiment use a linear array or line scan camera with precision motion control to achieve the same highly accurate imaging. In various embodiments, implementations of the first embodiment provide high levels of system throughput without explicit motion of the image capture device used to image features within areas of the web that are designated to become one or more individual products. Additionally, implementations of these embodiments may be applicable to other converting methods, such as lasers. These methods will be described with reference to Figure 2 and Figure 3 Further shown and described.

[0025] Figure 22 is a block diagram showing a top view of an illustrative production line 200 for converting a web into individual parts according to one or more embodiment techniques described in the present disclosure. As shown, the production line 200 includes a support mechanism 240 that supports a web 250. In various embodiments, the mechanism is a bottom plate or some other type of planar surface that is operable to physically support at least a portion of the web 250. In various embodiments, the web 250 can be any sheet material having a fixed width dimension 251 in one direction and a predetermined or undetermined length in an orthogonal direction in various embodiments. In various embodiments, the length dimension is many, many times greater than the width dimension. As an illustrative embodiment, the web can have a width dimension in the range of 32 inches, wherein the length dimension of the web can be 1000 meters. As another illustrative embodiment, a "sheet" of web material can have a width dimension in the range of 32 inches, wherein the length of the sheet of web material can have a length dimension in the range of 48 inches. However, these are merely provided examples, and it should be understood that these sizes can vary significantly. In implementations of the embodiments as described herein, the web 250 is operable to be transported along the production line 200 to move portions of the web 250 into and out of various locations along the production line 200, as further described below. In implementations of the embodiments as described herein, the web 250 includes sheets of material, each sheet having a fixed width dimension and a fixed longitudinal dimension, the sheets including one or more regions designated for conversion into individual products, and operable to be fed into, positioned in, and removed from a conversion station on an individual sheet-by-sheet basis. Implementations of the embodiments as described herein may be applicable to aligning and converting the web 250 while the web 250 is being transported through the production line 200 as a continuous length of web material or, in various implementations, while being provided to the production line 200 as individual sheets.

[0026] like Figure 2 As shown, the web 250 is operable to be transported on the mechanism 240 in a direction along the length dimension of the web (as represented by arrow 252). As shown, the width dimension 251 of the web 250 is sufficient to allow the placement of two individual products (in one embodiment, individual products 201A, 202A) adjacent to each other along the width dimension of the web 250. It should be understood that the number of individual products that can be arranged in the width dimension 251 of the web 250 can vary from one individual product to a plurality of individual products. The number of products that can be arranged in the width dimension 251 of the web 250 is not limited to a specific number of individual products, and can vary based on the size and shape of the individual products and the width dimension 251.

[0027] The production line 200 is operable to position the web 250 along the mechanism 240 at different locations. As shown, the position 205A represents a first position at which the web 250 includes products 201A and 202A occupying web areas adjacent to each other and having substantially identical end locations 204A, 204B, respectively, relative to the length dimension of the web 250. That is, the area of ​​the web 250 at the position 205A includes a designated area for the individual product 201A, surrounded by a dashed line 211, and representing the area of ​​the web 250 to be converted into the individual product. As shown, the web 205 at the position 205A includes a second designated area for the individual product 202A, surrounded by a dashed line 212, and representing the area of ​​the web 250 to be converted into another individual product. When web 250 is cut through the thickness dimension of the web material along the contours formed by dashed lines 211 and 212, conversion of individual products 201A and 202A may occur to form individual products cut from web 250. In various embodiments, location 205A may include one or more fiducial marks 216 located outside of a designated area for the individual products but located in an area on web 250 adjacent to the individual products. As shown, individual product 201A includes printed features 213, which are shown as a series of line segments within dashed line 211 and near edge 204; and individual product 202A includes printed features 215, which are shown as a series of line segments within dashed line 212 and located near edge 204B. In various embodiments, dimension 206 between printed features 213 and edge 204A is a critical dimension, and if the product ultimately converted from web 250 to form individual product 201A does not include dimension 206 within the specified range, individual product 201A will be considered defective and unusable for its intended use. In various embodiments, the dimension 206 between the printed feature 215 and the edge 204B is a critical dimension, and if the product ultimately converted from the web 250 to form the individual product 202A does not include the dimension 206 within the specified range, the individual product 202A will be considered defective and unusable for its intended use.

[0028] Position 205B shows a second position along production line 200 including press 220 and dies 221 and 222. In various embodiments, position 205B of the web processing system is referred to as a conversion station because position 205B is the location along production line 200 where actual conversion of individual products from web 250 can operate to occur. As shown, at position 205B, web 250 includes individual products 201B and 202B positioned adjacent to each other in a similar manner as described with respect to individual products 201A and 202A. Individual product 201B is positioned under press 220 and die 221 so that the cutting pattern provided by die 221 is aligned above and matches the contour shape of dashed line 211, so that when die 221 is lowered onto web 250 and contacts web 250, die 221 cuts through the thickness dimension of web 250 to form individual product 201B having a shape matching dashed line 211. Similarly, the individual product 202B is positioned under the press 220 and the die 222 so that the cutting pattern provided by the die 222 is aligned above the dotted line 212 and matches the contour shape of the dotted line 212, so that when the die 222 is lowered onto the web 250 and contacts the web 250, the die 222 cuts through the thickness dimension of the web 250 to form an individual product 202B having a shape matching the dotted line 212.

[0029] In various embodiments, location 205B includes an image capture device 260 that generates image data for feature 215 and / or feature 213 of product 202B and product 201B of web 250 when feature 215 and feature 213 are positioned within an operating region of press 220, as described herein. In various embodiments, imaging capture device 260 includes a device, such as, but not limited to, a camera, operable to capture image information, represented by arrow 261, related to printing or markings on web 250 located within a region designated as individual product 202B. In various embodiments, image capture device 260 is operable to provide image information 261 as an output to drive / control system 210 and / or to press 220 to allow individual products 201B and 202B to be properly positioned beneath press 220 for a converting process, as further described below. In various embodiments, image capture device 260 is positioned above mechanism 240 and above web 250, and is also horizontally adjacent to press 220, but outside of the vertical operating area (conversion zone) of press 220. In various embodiments, the operating area of ​​press 220 includes the area through which press 220 and dies 221 and 222 travel as press 220 moves from its original position above web 250 to a position in which dies 221 and 222 contact web 250. The location of image capture device 260 is not limited to being positioned above mechanism 240 and above web 250. Figure 220B, and in various embodiments may be located on the side of press 220 above fiducial mark 225, adjacent individual product 202B. In various embodiments, image capture device 260 is located on the outward side of press 220, where web 250 is operable to move away from position 205B in the direction indicated by arrow 252. In various embodiments, determinations regarding the placement of image capture device 260 are based on the location of the print within the individual product to be used for image capture and determining the proper position of the web material relative to press 220. For example, as Figure 2 As shown, individual product 202B includes a print 215 near an edge of an area designated as individual product 202B that trails a leading edge relative to the direction of travel of web 250 through production line 200. In this example, image capture device 260 is positioned adjacent press 220 at an inboard side of location 205B so that when individual product 202B is in position within location 205B for conversion, print 215 is relatively close to the side of press 220 where image processing device 260 is positioned. However, for different print patterns or features for different individual products, the position of image capture device 260 may be set to other positions relative to press 220, and as shown in FIG. Figure 2 The position of image capture device 260 shown is merely illustrative of one such position.

[0030] Further, various embodiments of location 205B are not limited to including a single image capture device, and in some embodiments may include multiple image capture devices. Figure 2 205B and the die 221 are shown in dashed boxes adjacent to the individual product 201B and the die 221 in FIG. In a manner similar to that described above with respect to the image capture device 260, the image capture device 260' when included at position 205B can be positioned above the mechanism 240 and above the web 250 and adjacent to the press 220, but outside the operating area of ​​the press 220. In various embodiments, the image capture device 260' includes a device (such as, but not limited to, a camera) operable to capture image information related to the print or other features on the web 250 located in the area designated as the individual product 201B, as indicated by arrow 263. In various embodiments, the image capture device 260' is operable to provide the image information 263 as an output to the drive / control system 210 and to 220 to allow the individual products 201B and 202B, or (in some embodiments, only the individual product 201B) to be properly positioned below the press 220 for the converting process. Further, in embodiments where only one image processing device 260 is included at location 205B, the specific individual product or products imaged by the image capture device are not limited to, for example, Figure 2In the illustrated embodiment, image capture device 260 may be positioned to capture image information based on print 213 , based on print 215 , or based on both print 213 and print 215 .

[0031] The production line 200 is not limited to having a specific number of individual products adjacent to each other along the width dimension 251 of the web 250 that will be at the position 205B at a given time, and is not limited to having a specific number of image capture devices located at the position 205B relative to the number of individual products adjacent to each other along the width dimension 251 of the web 250 that are at the position 205B at the same time. In some embodiments, only a single image capture device 260 is included at the position 205B. In other embodiments, multiple image capture devices are included at the position 205B. In some embodiments, the number of image capture devices located at the position 205B is equal to the number of individual products that are positioned adjacent to each other along the width dimension 251 of the web 250 at the position 205B, wherein each image capture device is positioned to capture image information related to print or other features on an individual of the individual products at the position 205B. In various embodiments, the total number of image capture devices at the position 205B is less than the total number of individual products that are adjacent to each other along the width dimension 251 of the web 250 at the position 205B.

[0032] It should be understood that the arrangement of individual products on web 250 that may be positioned for conversion at location 205B is not limited to individual products being adjacent to one another, and may, for example, be in other geometric arrangements, such as, but not limited to, a linear arrangement relative to the longitudinal axis of web 250. The placement of one or more image capture devices may be made at different locations at location 205B based on the particular arrangement of individual products being converted from web 250 at a given time.

[0033] As shown, position 205C illustrates a third position along production line 200 at which point web 250 includes illustrative individual products 201C and 202C. Individual product 201C illustrates an individual product that has been converted (i.e., cut through the thickness dimension of web 250) to the shape shown as shell 231. Individual product 201C includes print 213 that now resides at a distance 206 from trailing edge 204A, as determined by control of the positioning of individual product 201C under press 220 when individual product 201C was previously positioned at position 205B and converted by operation of press 220 and die 221. Similarly, individual product 202C illustrates an individual product that has been converted (i.e., cut through the thickness dimension of web 250) to the shape shown as shell 232. Individual product 202C includes print 215 that now resides at a distance 206 from trailing edge 204B, the distance 206 being determined by control of the positioning of individual product 201C under press 220 when individual product 201C was previously positioned at position 205B and transferred by operation of press 220 and die 222. Figure 2 As shown, individual products 201C and 202C are separated from web 250, but still reside in their respective cut-out regions of web 250. Thus, each time web 250 moves along mechanism 240, individual products 201C and 202C are transported along these locations. It should be understood that now that individual products 201C and 202C have been converted, they should be operable to be removed from web 250 at location 205C or some other location downstream of location 205C by such devices operable to separate individual products 201C and 202C for further processing, including, in some embodiments, inspection and packaging for shipment to a customer. In various embodiments, location 205C includes a fiducial mark 235 located on web 250 adjacent to one of individual products 201C, 202C.

[0034] In operation, the control / drive system 210 is operable to transport the web 250 along the mechanism 240 in the direction indicated by arrow 252. In various embodiments, the mechanism 240 includes side rails 241A, 241B operable to provide a set of edges that rise above the mechanism 240 at intervals substantially equal to the width dimension 251 of the web 250 to provide lateral positioning of the web 250 under the press 220 at a position 205B relative to the width dimension 251 of the web 250. In various embodiments, the production line 200 includes one or more sensors 203 coupled to the control / drive system 210, wherein the control / drive system 210 is operable to provide lateral positioning control of the web 250 along the width dimension 251 relative to the press 220 at the position 205B. In addition, the control / drive system 210 is operable to precisely transport the web 250 along its longitudinal axis as indicated by arrow 252 so as to position the individual products 201B and 202B beneath the press 220 and the dies 221 and 222 so that when the press 220 is operated to convert the individual products 201B and 202B, the dimension 206 between the prints 213 and 215, respectively, on these individual products has a dimension 206 from the trailing edge 204A, 204B, respectively, that is within an acceptable tolerance of the final product into which the individual products 201B and 202B are intended to be incorporated.

[0035] In various embodiments, correctly aligning one or more individual products for conversion at a conversion station is not limited to a specific alignment process or a specific positioning mechanism. In various embodiments, the web is transported to the conversion station in a direction (such as, the direction shown by arrow 252) and advances in the transport direction until the correct alignment of one or more individual products under the conversion station is achieved. In various embodiments, one or more different speeds are used to transport the web to the appropriate position for correct alignment at the conversion station. For example, a first faster speed can be used to transport the web to the conversion station to a position where the correct alignment position for converting one or more individual products is lacking, wherein one or more slower speeds are then used for the final correct alignment of one or more individual products for conversion. In various embodiments utilizing such multi-speed alignment techniques, image scanning of one or more individual products as described herein can be incorporated into the process of transporting the web at one or more slower speeds to allow the web to be transported to the desired and correct alignment position at the conversion station.

[0036] In various embodiments, the web is transported and positioned at an initial position under the conversion station, and final correct alignment of the one or more individual products at the conversion station is provided by moving the press and / or the die located at the conversion station to properly position and align the one or more dies with the one or more individual products to be converted. In various embodiments, the control / drive system 210 includes one or more positioning mechanisms ( Figure 2 2 and 3. The press 220 and / or individual dies 221 and 222 are operative to allow the control / drive system 210 to adjust the position of the press 220 and / or individual dies 221 and 222 to provide proper alignment of the dies for converting one or more individual products positioned at the conversion station. In various embodiments, the positioning of the press 220 and / or individual dies 221 and 222 is based on imaging one or more features located within an area designated to become one or more individual products after the one or more individual products have been transported to an initial position under the conversion station.

[0037] In various embodiments, instead of having a web 250 with a width dimension and a length that is many times the width dimension or with an indeterminate length dimension, the web 250 may include individual sheets having a width dimension and a predetermined length dimension such that the web includes a series of individual sheets, each of which has an area that is designated to become one or more individual products once the one or more individual products are converted from the web. In various embodiments, the sheets may be fed into the converting station one at a time and positioned, for example, using a stopper, pusher, or other positioning mechanism (in Figure 2 The webs may be positioned (not shown) as will be appreciated by those skilled in the art. In various embodiments, the individual sheets may be mechanically held in position at the conversion station, such as by a clamping mechanism or, for example, by a vacuum applied to the web. In various embodiments, once the sheet is initially positioned at the conversion station, final alignment of the sheet for conversion may be achieved by moving the sheet, moving the press and / or die at the conversion station, or a combination of moving the sheet and moving the press / die. After the sheet conversion is complete, the sheet with the now converted one or more individual products may be removed from the conversion station, and the process of positioning another (unconverted) sheet at the conversion station is then repeated.

[0038] In various embodiments, when the conversion process of the individual products at position 205B is complete and the press 220 raises the dies 221 and 222 back to a position above the web 250, the control / drive system 210 begins to transport the web 250 along the mechanism 240 in the direction indicated by the arrow 252. As the web 250 is transported, the converted product previously positioned at position 205B is transported outwardly from position 205B toward position 205C. The next individual product or products at position 205A are also transported inwardly toward position 205B for positioning under the press 220. When the individual product or products are introduced into position under the press 220, in various embodiments, the image capture device 260 captures image data related to the print 215 on the individual product 202B. The image capture device 260 provides image information 261, represented by arrow 209, to the control / drive system 210, which is operable to use the image information to ultimately determine the position of the individual product 202B within the location 205B and aligned with the die 212. In various embodiments, once the individual product 202B is properly aligned under the die 222 based on the image information 261 provided by the image capture device 260, the control / drive system 210 is operable to actuate the press 220 and traverse the conversion zone to bring the die 222 into contact with the web 250 to cut the web 250 to form the individual products 202B converted from the web 250. In various embodiments, the operation of the press 220 is also operating the die 221 simultaneously with the die 222, and thus the operation of the press 220 also causes the individual products 201B to be cut from the web 250 to form the individual products 201B converted from the web 250. Once the press 220 has converted both individual products 201B and 202B, the press 220 and dies 221, 222 can be raised above the web 250 to allow the web 250 to be transported again to move the now converted individual products 201B, 202B outward from position 205B and, in various embodiments, reintroduce another pair of individual products previously positioned at position 205A. The converted individual products leaving position 205B can be transported along with the web 205 and, at some point, removed from the web 250 as individual products for further processing.

[0039] By using image information from the image capture device 260 to control the positioning of the web 250 within the position 205B and relative to the press 220 and the dies 221, 222, the production line 200 can be operated to perform registration and alignment of the individual products 201B, 202B based on features (such as, prints 215) on the web 250 located in an area designated to become part of the actual individual products after conversion from the web, while utilizing an image capture device positioned adjacent to the press 220 and the dies 221, 222 but still outside the conversion zone of the press 220.

[0040] In various embodiments including both the image capture device 260 and a second image capture device (such as, image capture device 260'), the production line 200 may be operable to independently align the individual product 201B for conversion from the individual product 202B. For example, the press 220 may be operable to independently lower the die 221 and the die 222 so that when the die 221 is lowered onto the web 250, only the individual product 201B is converted, and the die 222 may be lowered onto the web 250 at a different time so that only the individual product 202B is converted at this time. In this embodiment example, the web 250 may be transported to the position 205B until one of the image capture devices 260, 260' provides imaging information indicating that the individual product imaged by the image capture device is properly aligned under the corresponding die for converting the individual product. At this time, the corresponding die can be actuated to convert the properly aligned individual product, while the second die remains in the original position or in the raised position. After converting the correctly aligned individual products, the die performing the conversion is raised back above the web 250. The production line 200 can then continue to transport the web 250 until the image capture device imaging the individual products that have not yet been converted provides imaging information indicating that the individual products that have not yet been converted are now correctly aligned under the corresponding die for converting the individual products. At this point, the corresponding die can be actuated to convert the correctly aligned individual products, while the first die remains in the original position or raised position. Once the corresponding (second) die is raised above the web 250 again, the production line 200 can transport the two converted individual products outward from position 205B. By using these techniques, variations between prints or other features relative to individual products adjacent to each other (such as, print variations) can be compensated by using separate image capture and separate conversions to maintain the desired dimensions of the converted individual products.

[0041] The above description of the conversion station at position 205B has been described in terms of a mechanical press and a die. However, alternative devices for cutting the web at the conversion station are contemplated. For example, instead of using a mechanical press and one or more dies, the production line 200 may include other devices such as, but not limited to, a laser device (in Figure 3 The web 250 is shown as 220 in the figure, which is operable to provide a laser for cutting the web at position 205B so as to convert the web 250 into individual products. As mentioned in the present disclosure, the term "cutting member" can be any device operable to convert one or more individual products from the web 250 and any energy form generated by these devices, such as but not limited to a mechanical press and die, or a laser device and a laser (laser beam) generated by the laser device.

[0042] As described above, production line 200 is capable of providing individual products having dimensions for printing or other features relative to the edges of the individual products, with the printing or other features maintaining high precision with respect to these dimensions. Figure 3 Further implementations and techniques of the embodiments described above may achieve dimensions such as Figure 2 The tolerance of the dimensions 206 shown in FIG. 2 is within the range of ±10 μm.

[0043] In various embodiments, production line 200 includes one or more production lines including Figure 1 However, the embodiments of production line 200 are not limited to any particular production line or any particular conversion location, and may be used in any production line operable to convert individual products from webs based on the specific implementations and techniques of the embodiments described herein and any and all equivalents thereof.

[0044] Figure 3 is a diagram that provides a cross-web view of an embodiment converting station 300 for converting a web 250 into individual products according to one or more embodiments described in the present disclosure. In various embodiments, the converting station 300 is the converting station shown as position 205B in the production line 200, but the embodiments of the converting station 300 are not limited to any particular production line. Figure 3 shown, and is shown for Figure 2 The same or similar components at position 205B in FIG. 1 correspond to components at conversion station 300 in FIG. Figure 3 The same reference numerals are retained in the Figure 3 As shown, the conversion station 300 includes a mechanism 240 for supporting the web 250. The conversion station 300 is operable to transport the web 250 in at least the direction indicated by arrow 252 to position the web 250 below the press 220 and the dies 221, 222. Other directional movements of the web 250 are contemplated in positioning the web 250 relative to the press 220 and the dies 221, 222. For example, the lateral positioning of the web 250 for the production line 200 as described above can be incorporated into the positioning of the web 250 in the conversion station 300. As shown in FIG. Figure 3 As shown, web 250 includes one or more individual products, which are designated by the area enclosed by dashed lines 211, 212. In various embodiments, image capture device 260 is positioned adjacent to press 220 and dies 221, 222, but in a position such that the entire image capture device is outside of a transition zone of press 220 and dies 221, 222, indicated by arrow 244. In various embodiments, transition zone 244 is when one or more of press 200 and dies 221, 222 are moved from the press 220 to the die 221, 222. Figure 3 The home position shown is the area that the press 220 and dies 221 , 222 traverse as they move to a position where one or more of the dies 221 , 222 contact the web 250 so that one or more of the dies 221 , 222 cuts through the dimensional thickness of the web 250 .

[0045] In accordance with the techniques described herein, the image capture device 260 is positioned at an imaging angle 271 relative to the surface plane 270 of the web 250. When imaging in this manner, the image capture device 260 is not at right angles (perpendicular) to the web, and therefore, for most imaging systems, it is not possible to maintain focus across the entire field of view. For example, for conventional imaging systems that typically image at an angle such as imaging angle 271, in some instances only the center of the image is in focus while the top and bottom are blurred. In specific implementations of the various embodiments described herein, to overcome this problem, the image capture device 260 is operable to provide Scheimpflug imaging as well as telecentric imaging using a single lens. This allows both focus and spatial resolution to be controlled to a desired precision while imaging the printed features 213, 215 at the imaging angle 271 relative to the web 250 throughout the entire field of view being captured. Scheimpflug imaging is performed relative to the lens 262 and relative to the image obtained by Figure 3 The image sensing array is configured at an oblique position of the image plane represented by plane 270 in FIG. Figure 3 265). Using Scheimpflug imaging, image capture device 260 can be operated to provide a focused image over the entire field being imaged as represented by the area between dashed lines 267 and 269. Using this technique, image capture device 260 can be operated to capture high resolution image information over the entire field being imaged without having to physically move image capture device 260 during the image capture process.

[0046] The image capture device 260 is not limited to any particular type of image capture device. In various embodiments, the image capture device 260 is a camera including a lens 262 and a sensing array 265 within the image capture device 260, the sensing array being operable to tilt to an imaging angle relative to the lens 262. In various embodiments, the lens 262 is a telecentric lens. The telecentric lens is operable to provide an orthographic projection, which provides the same magnification for objects at all distances from the lens. In various embodiments, the image sensing array 265 is adjusted to a particular angle to compensate for an angled position for allowing the image capture device 260 to be located outside of the conversion zone 244 and the image printing features 213, 215, which are located within an area designated to be within one or more individual products when the one or more individual products are aligned for conversion under the press 220. In various embodiments, Scheimpflug imaging provides for calculation of the amount of tilt provided to the image sensing array 265 to achieve focus across the field of view based on the focal length of the lens 262, the value of the angle 271, the distance between the lens 262 and a point along the line of sight from the lens 262 to the surface plane 270 of the web 250 being imaged.

[0047] like Figure 3 As shown, the first vector 267 has a distance from the lens 262 of the image capture device 260 that is less than the distance of the second vector 269 from the web 250 to the lens 262. When imaged using a conventional image capture device, this difference in distance between the web 250 and the lens 262 from one side of the lens 262 (vector 267) to the other side of the lens 262 (vector 269) may cause distortion in the image received at the image capture array 265. By tilting the image array 265 at a certain angle based on the Scheimpflug imaging technique, the image capture device 260 can be operated to provide accurate image data over the entire field of the image being captured, and the imaging information can be output as output data to the control / drive system 210 to properly position one or more individual products designed by the dashed lines 211, 222 relative to the press 220 and the dies 221, 222 for conversion.

[0048] In various embodiments, the image capture device 260 is operable to capture images associated with one or both of the printed features 213, 215. In various embodiments, the printed features 213 and 215 are on a surface or visible at a surface of the web 250 and are located on a surface that is designed as one or more separate products (such as, Figure 2 The printing in one or more areas of the individual products 201B, 202B) shown. Figure 3As shown, printed features 213, 215 are located a distance 206 from the trailing edge designated by dashed lines 211, 213, respectively. Image capture device 260 is positioned above web 250, adjacent press 220 and dies 221, 222, but outside of transition zone 224, and mounted at imaging angle 271.

[0049] In various embodiments, the image capture device 260 is operable to provide an output of image information to the control / drive system 210 via a communication channel represented by connection 209 so that the control / drive system 210 is operable to transport the web 250 to properly position the individual products under the press 220 and one or more of the dies 221, 222. Once the web 250 is properly positioned under the press 220, the press 220 is actuated and traverses the conversion zone 244, where one or more of the dies 221, 222 contact the web 250 and cut the web 250 to form one or more individual products having the appropriate dimensions 206 between the printed features 213, 215 and the edges of the converted one or more individual products. The imaging information and output data provided by the image capture device 260 are not limited to any specific type of information and are not limited to any particular data format. The image information and data may include any type of information or data operable to be provided by the image capture device 260, which may be received by the control / drive system 210 and used by the control / drive system 210 to align the web 250 relative to the press 220 and dies 221, 222 for conversion through the press 220, thereby resulting in the proper size 206 after the conversion process is completed.

[0050] In various embodiments, the image capture device 260 is a line scan camera, and the image capture device 260 is mounted in a manner having an imaging angle 271 similar to that described above, but in a manner that allows the line scan camera to move in a pattern that allows the line scan camera to capture images of the printed features 213 and 215. In various embodiments, the line scan camera is operable to focus in one direction, and physically move in a second direction to form a two-dimensional image of the printed features 213, 215 that is used as a basis for positioning the web 250 under the press 220 for the converting process.

[0051] By using printed features printed on web 250 that are also located in areas designated to become individual products as image information for aligning the press and die for the converting process, the converting station is able to provide individual products having dimensions for the print or other features relative to the edges of the individual products (such as, but not limited to, dimension 206) that maintain a high degree of precision with respect to those dimensions.

[0052] In various embodiments, the conversion station 300 is Figure 2 The conversion station provided at position 205B in the production line 200 may include any one or more of the features, functions, and capabilities described above with respect to the production line 200. However, the embodiments of the conversion station 300 are not limited to any particular production line or to any particular conversion location, and may be used as a conversion station in any production line or process operation operable to convert individual products from a web based on the specific implementations and techniques of the embodiments described herein and any and all equivalents thereof.

[0053] Figure 4 4 is a flow chart illustrating one or more embodiments of a method 400 according to various techniques described in this disclosure. Although discussed with respect to production line 200, the techniques may be implemented at least in part by Figure 3 . In various embodiments, the production line 200 aligns the web for conversion at the conversion station based on features of the web that will remain within the region of the web designated to become individual products once the individual products are converted from the web (block 402). In various embodiments, the production line 200 aligns the web by imaging the features of the web using an image capture device, the image capture device being located outside of a conversion zone of the conversion station and at an imaging angle relative to the web. In various embodiments, the production line 200 then positions the web within the conversion station based on imaging information captured by imaging the features on the web when the features are positioned within the conversion zone. In various embodiments, the image capture device is positioned above the web and adjacent to the conversion station at an imaging angle relative to the web, wherein a line of sight from the image capture device to the features on the web being imaged forms an angle of less than 90 degrees relative to the surface of the web. In various embodiments, the image capture device allows adjustment of a tilt angle of an image sensing array included within the image capture device, the image sensing array being operable to be positioned at a tilt angle relative to a lens of the image capture device. In various embodiments, adjusting the tilt angle of the image sensing array includes setting the tilt angle to compensate for the angle of the image capture device relative to the surface of the web, such that when set to the tilt angle, each portion of the feature on the web being imaged is in focus across the field of view of the image capture device. In various embodiments, production line 200 uses a line scan camera to image features of the web.

[0054] In various embodiments, the production line 200 aligns the web for conversion at the conversion station based on the web features by imaging the print on the surface of the web, and then positions the web within the conversion station based on the imaging information captured by imaging the print on the surface web. In various embodiments, the production line 200 converts individual products from the web so that the dimensions between the features included in the individual products and the edges of the individual products have a tolerance of ±10 μm. In various embodiments, the production line actuates the conversion station to convert the individual products from the web (box 404). In various embodiments, the step of actuating the conversion station to convert the individual products from the web includes lowering a press and one or more dies to contact the one or more dies with the web to cut a thickness dimension through the web.

[0055] The technology of the present disclosure can be implemented in various computing devices, image capture devices and various combinations thereof. Any of the described units, modules or components can be implemented together or separately as discrete but interoperable logic devices. Depicting different feature parts as modules, devices or units is intended to highlight different functional aspects, and does not necessarily imply that such modules, devices or units must be implemented by separate hardware or software components. On the contrary, the functions associated with one or more modules, devices or units can be performed by separate hardware or software components, or integrated in common or separate hardware or software components. The technology described in the present disclosure can be implemented at least in part with hardware, software, firmware or any combination thereof. For example, various aspects of the technology can be implemented in one or more microprocessors, digital signal processors ("DSP"), application specific integrated circuits ("ASIC"), field programmable gate arrays ("FPGA"), or any other equivalent integrated or discrete logic circuit systems, and any combination of such components, embodied in a programmer, such image capture devices 260, 261, control / drive system 210, a system or device for actuating or providing a cutting member (such as a computer-controlled hydraulic or pneumatic device or laser) or other devices. The terms "processor," "processing circuitry," "controller," or "control module" may generally refer to any of the aforementioned logic circuits, alone or in combination with other logic circuitry, or any other equivalent circuitry, and alone or in combination with other digital or analog circuitry.

[0056] For aspects implemented in software, at least some of the functionality attributable to the systems and devices described in the present disclosure may be embodied as instructions on a tangible computer-readable storage medium such as a random access memory ("RAM"), a read-only memory ("ROM"), a non-volatile random access memory ("NVRAM"), an electrically erasable programmable read-only memory ("EEPROM"), flash memory, magnetic media, optical media, and the like. Computer-readable storage media may be referred to as non-transitory. A server, client computing device, or any other computing device may also include a more portable type of removable memory to enable simple data transfer or offline data analysis. Instructions may be executed to support one or more aspects of the functionality described in the present disclosure. In some examples, a computer-readable storage medium includes a non-transitory medium. The term "non-transitory" may indicate that the storage medium is not specifically embodied in a carrier or propagating signal. In some examples, a non-transitory storage medium may store data that may change over time (e.g., in RAM or cache).

[0057] The following exemplary embodiments describe one or more aspects of the present disclosure.

[0058] Embodiment 1. A conversion station, comprising: a mechanism operable to support at least a portion of a manufactured web; a conversion device located above the mechanism, the conversion device operable to traverse a conversion zone located below the conversion device so that a cutting member contacts the web to convert the web into one or more individual products; an image capture device located above the mechanism and adjacent to the conversion device but outside the conversion zone, the image capture device being positioned at a non-perpendicular imaging angle relative to a surface plane of the web, the image capture device operable to capture image information by imaging features located on the web when one or more features are positioned within the conversion zone; and a control system operable to align the web within the conversion zone based on the image information.

[0059] Embodiment 2. A conversion station according to embodiment 1, wherein the image capture device includes a tiltable image sensing array that is tilted at an adjustable tilt angle to provide Scheimpflug imaging over the entire field of view of the image capture device.

[0060] Embodiment 3. A conversion station according to embodiment 2, wherein the image capture device includes a telecentric lens.

[0061] Embodiment 4. A conversion station according to any one of Embodiments 1 or 2, wherein the image capture device includes a telecentric lens.

[0062] Embodiment 5. A conversion station according to any one of embodiments 1-4, wherein the image capture device is a line scan camera.

[0063] Embodiment 6. The converting station of any of Embodiments 1-5, wherein one or more features are located in areas of the web designated as individual products to be converted from the web.

[0064] Embodiment 7. A conversion station according to any of Embodiments 1-6, wherein the individual products include a cover sheet or cover layer for covering a display of a mobile device, and wherein the feature portion includes a series of black lines printed on the surface of the web, which can be used to prevent light emissions generated within the mobile device from being visible when the display is viewed from outside the mobile device.

[0065] Embodiment 8. A conversion station according to any of Embodiments 1-7, wherein the cutting member includes one or more mechanical dies.

[0066] Embodiment 9. A conversion station according to any of Embodiments 1-8, wherein the cutting means comprises a laser beam.

[0067] Embodiment 10. The converting station of any of Embodiments 1-9, wherein the converting station is operable to convert individual products from the web material such that the tolerance of dimensions between features included within the individual products and edges of the individual products is ±10 μm.

[0068] Embodiment 11. A method comprising aligning a web for conversion at a conversion station based on features of a manufactured web, wherein once individual products are converted from the web, the features will remain in areas of the web designated to become the individual products, wherein the step of aligning the web includes imaging the features of the web using an image capture device located outside a conversion zone of the conversion station and at an imaging angle relative to the web, and positioning the web within the conversion station based on imaging information captured by imaging the features on the web when the features are positioned within the conversion zone; and actuating the conversion station to convert individual products from the web.

[0069] Embodiment 12. The method according to embodiment 11 also includes: positioning an image capture device above the web at the imaging angle to the web and adjacent to a conversion station, wherein a line of sight from the image capture device to a feature being imaged on the web forms an angle of less than 90 degrees relative to the surface of the web.

[0070] Embodiment 13. A method according to any one of embodiments 11 and 12, wherein the step of imaging a feature portion of the web comprises: adjusting a tilt angle of an image sensing array included in an image capture device, the image sensing array being operable to be positioned at a tilt angle relative to a lens of the image capture device, wherein the step of adjusting the tilt angle of the image sensing array comprises setting the tilt angle to compensate for the angle of the image capture device relative to the surface of the web, and wherein when set to the tilt angle, each portion of the feature portion being imaged on the web is focused over the entire field of view of the image capture device.

[0071] Embodiment 14. A method according to any one of embodiments 11-13, wherein the lens includes a telecentric lens.

[0072] Embodiment 15. The method of any of Embodiments 11-14, wherein the step of imaging the features of the web using an image capture device comprises imaging the features using a line scan camera.

[0073] Embodiment 16. The method of any of Embodiments 11-15, wherein the converting station is operable to convert the individual products from the web material such that the tolerance of dimensions between features included within the individual products and edges of the individual products is ±10 μm.

[0074] Embodiment 17. A method according to any one of Embodiments 11-16, wherein the step of aligning the web for conversion at a conversion station based on a feature portion of the web includes: imaging the printing on the surface of the web, and positioning the web within the conversion station based on the imaging information captured by imaging the printing on the surface web.

[0075] Embodiment 18. The method of any one of Embodiments 11-17, wherein the step of actuating a conversion station to convert individual products from the web comprises lowering a press and one or more dies to bring the one or more dies into contact with the web to cut a thickness dimension through the web.

[0076] Embodiment 19. A system comprising: a mechanism operable to support at least a portion of a web being manufactured; a conversion station comprising a press and at least one die positioned above the mechanism and above the web and operable to traverse a conversion zone to bring the at least one die into contact with the web to cut a thickness dimension through the web; an image capture device positioned above the mechanism and adjacent the conversion device but outside the conversion zone, the image capture device operable to capture image information of a feature located on the web when the feature is positioned within the conversion zone; and a control / drive system A control / drive system is provided that is coupled to a press and an image capture device, the control / drive system being operable to transport a web to introduce an area of ​​the web that is to be designated for conversion into individual products into a conversion station, receive imaging information from the image capture device, align the web into a position below at least one die based on the imaging information and in a position such that when the at least one die is actuated to traverse a conversion zone between the die and the web, the die cuts the web to provide individual products having dimensions between features located on the web and edges of the converted individual products that fall within a specified range.

[0077] Embodiment 20. A system according to embodiment 19, wherein the image capture device includes a tiltable image sensing array, which is tilted at an adjustable tilt angle to provide Scheimpflug imaging over the entire field of view of the image capture device.

[0078] Embodiment 21. A system according to any of embodiments 19 or 20, wherein the image capture device includes a line scan camera.

[0079] Embodiment 22. The system of any one of Embodiments 19-21, wherein the feature comprises a print on the surface of the web.

[0080] Embodiment 23. A system according to any of embodiments 19-22, wherein the lens includes a telecentric lens.

[0081] Various aspects of the disclosure have been described. These and other aspects are within the scope of the following claims.

Claims

1. A conversion station, comprising: a mechanism that supports at least a portion of a manufactured web, the web being a continuous long sheet of film having a fixed dimension in one direction and a predetermined or undetermined length in an orthogonal direction orthogonal to the one direction; a conversion device located above the mechanism, the conversion device being operable to traverse a conversion zone located below the conversion device to bring a cutting member into contact with the web to convert the web into one or more individual products; an image capture device located above the mechanism and adjacent the transition device but outside the transition zone, the image capture device being positioned at a non-perpendicular imaging angle relative to a surface plane of the web, the image capture device being operable to capture image information by imaging one or more features located on the web when the features are positioned within the transition zone; and a control system operable to align the web within the conversion zone based on the image information, wherein a dimension of the individual product between the feature on the web and an edge of the converted individual product falls within a specified range, and wherein the converting station is operable to convert individual products from the web material such that the tolerance of the dimensions between the features included in the individual products and the edges of the individual products is ±10 μm, Therein, the features correspond one-to-one with the individual products during conversion, such that during conversion of one individual product from the web, the conversion is performed based on the features to remain in the area of ​​the one individual product.

2. The conversion station of claim 1, wherein the image capture device comprises a tiltable image sensing array, the image sensing array tilted at an adjustable tilt angle to provide Scheimpflug imaging over the entire field of view of the image capture device.

3. The conversion station of claim 2, wherein the image capture device comprises a telecentric lens.

4. The conversion station of claim 1 wherein the image capture device comprises a telecentric lens.

5. The conversion station of claim 1 wherein the image capture device is a line scan camera.

6. The converting station of claim 1 wherein the one or more features are located in areas of the web that are designated as individual products to be converted from the web.

7. A conversion station according to claim 6, wherein the individual products include a cover sheet or cover layer for covering a display of a mobile device, and wherein the feature portion includes a series of black lines printed on the surface of the web, the series of black lines being able to prevent light emissions generated within the mobile device from being visible when the display is viewed from outside the mobile device.

8. The conversion station of claim 1 wherein the cutting member comprises one or more mechanical dies.

9. The conversion station of claim 1 wherein the cutting member comprises a laser beam.

10. A method comprising: aligning a manufactured web for conversion at a converting station based on features of the web that will remain in the area of ​​the web designated to become the individual products once they are converted from the web, the web being a continuous length of film having a fixed dimension in one direction and a predetermined or undetermined length in an orthogonal direction orthogonal to the one direction, wherein the step of aligning the web includes imaging the feature of the web using an image capture device located outside a conversion zone of the conversion station and at an imaging angle relative to the web, and positioning the web within the conversion station based on imaging information captured by imaging the feature on the web while the feature is positioned within the conversion zone; as well as actuating the conversion station to convert the individual products from the web, wherein the features correspond one-to-one to the individual products during conversion, so that during conversion of one individual product from the web, the conversion is performed based on the features to remain in the area of ​​the one individual product, wherein a dimension of the individual product between the feature on the web and an edge of the converted individual product falls within a specified range, and Wherein the converting station is operable to convert the individual products from the web material such that a tolerance of a dimension between the features included in the individual products and an edge of the individual products is ±10 μm.

11. The method according to claim 10, further comprising: The image capture device is positioned above the web at the imaging angle to the web and adjacent the converting station, wherein a line of sight from the image capture device to the feature on the web being imaged forms an angle of less than 90 degrees relative to a surface of the web.

12. The method of claim 10, wherein imaging the features of the web comprises: adjusting a tilt angle of an image sensing array included within the image capture device, the image sensing array being operable to be positioned at a tilt angle relative to a lens of the image capture device, wherein the step of adjusting the tilt angle of the image sensing array comprises setting the tilt angle to compensate for the angle of the image capture device relative to the surface of the web, and wherein when set to the tilt angle, each portion of the feature on the web being imaged is in focus across a field of view of the image capture device. The method of claim 12 , wherein the lens comprises a telecentric lens.

14. The method of claim 10, wherein imaging the features of the web using an image capture device comprises imaging the features using a line scan camera.

15. The method of claim 10, wherein aligning the web for conversion at the conversion station based on the features of the web comprises: imaging the print on the surface of the web, and The web is positioned within the converting station based on imaging information captured by imaging the print on the surface web.

16. The method of claim 10, wherein actuating the converting station to convert the individual products from the web comprises lowering a press and one or more dies to contact the one or more dies with the web to cut a thickness dimension through the web.

17. A system comprising: a mechanism operable to support at least a portion of a manufactured web, the web being a continuous long sheet of film having a fixed dimension in one direction and a predetermined or undetermined length in an orthogonal direction orthogonal to the one direction; a converting station including a press and at least one die positioned above the mechanism and above the web and operable to traverse a converting zone to bring the at least one die into contact with the web to cut a thickness dimension through the web; an image capture device located above the mechanism and adjacent the transition device but outside the transition zone, the image capture device operable to capture image information of a feature located on the web when the feature is positioned within the transition zone; and a control / drive system coupled to the press and the image capture device, the control / drive system operable to transport the web to introduce an area of ​​the web that is to be designated for conversion into individual products into the converting station, receive imaging information from the image capture device, align the web into a position below the at least one die based on the imaging information and in a position such that when the at least one die is actuated to traverse a conversion zone between the die and the web, the die cuts the web to provide individual products having dimensions between the features located on the web and an edge of the converted individual products falling within a specified range, wherein the converting station is operable to convert individual products from the web such that the tolerance for dimensions between the features included in the individual products and the edges of the individual products is ±10 μm, Therein, the features correspond one-to-one with the individual products during conversion, such that during conversion of one individual product from the web, the conversion is performed based on the features to remain in the area of ​​the one individual product.

18. The system of claim 17, wherein the image capture device comprises a tiltable image sensing array, the image sensing array tilted at an adjustable tilt angle to provide Scheimpflug imaging over the entire field of view of the image capture device.

19. The system of claim 17, wherein the image capture device comprises a line scan camera.

20. The system of claim 17, wherein the features comprise printing on a surface of the web.

21. The system of claim 17, wherein the image capture device comprises a telecentric lens.

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