3D Image Formation Using Balanced Photothermal Expansion
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Solution Overview
Problem
Existing methods for forming three-dimensional images using thermally expandable sheets often result in unintended bulge heights due to the influence of grayscale and density variations in both the print image on the surface and the light absorption pattern on the back, leading to inconsistent or excessive bulge heights in the final image.
Innovation Solution
A method and apparatus that form a first print image on one surface of a thermally expandable sheet and a mirror image with adjusted photothermal conversion material density on the other surface, allowing for controlled thermal expansion to achieve a predetermined bulge height by irradiating the sheet with light from the back, thereby balancing the thermal energy generated from both surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a light absorption pattern is formed on the back of the thermally expandable sheet to correspond to the color image on the surface, then the three-dimensional image can be formed with controlled bulge height, but the bulge height becomes inconsistent or excessive due to the combined influence of grayscale from both surfaces
Solution Approach 1:
The patent applies preliminary anti-action by forming a light absorption pattern on the back surface that is specifically designed to counterbalance the thermal effect of the color image on the front surface. The light absorption pattern's grayscale is calculated in advance to offset the varying thermal contributions from the color image, ensuring that the net thermal energy distribution produces uniform bulge height across all regions of the three-dimensional image.
Solution Approach 2:
The patent utilizes parameter changes by adjusting the grayscale values of the light absorption pattern on the back surface based on the color image parameters on the front surface. The system dynamically modifies the light absorption characteristics (grayscale parameters) to compensate for variations in the color image, thereby maintaining consistent bulge height despite differences in front surface image density.
2Manufacturing precision
If the density of the light absorption pattern is set to correspond to the color image pattern, then the thermal expansion can be controlled, but the combined thermal effect from both surfaces causes the three-dimensional image to exceed the intended bulge height
Solution Approach 1:
The patent implements feedback by using the color image information from the front surface as input to determine the appropriate light absorption pattern parameters for the back surface. The system calculates the required light absorption density based on the color image's grayscale distribution, creating a feedback loop where the front surface image characteristics directly influence the back surface pattern design to achieve the desired bulge height.
Solution Approach 2:
The patent applies preliminary action by pre-calculating and forming the light absorption pattern on the back surface before the thermal expansion process. The pattern is designed in advance with specific grayscale values that will produce the correct thermal balance when both surfaces are illuminated, eliminating the need for complex real-time adjustments during manufacturing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the formation of three-dimensional images with consistent and intended bulge heights, addressing the issue of inconsistent bulge heights caused by surface and back image density variations, resulting in a more controlled and precise three-dimensional image formation.
Implementation Method 1
a density of a photothermal conversion material contained in the second print image being set based on a density of a photothermal conversion material contained in the first print image; and forming a three-dimensional image of the first print image by selectively expanding the thermally expandable layer with thermal energy that is generated in the second print image when irradiating the thermally expandable sheet with light from the other surface
Implementation Method 2
selectively expanding the thermally expandable layer with thermal energy that is generated in the second print image when irradiating the thermally expandable sheet with light
Data Source
AI summary
An apparatus for forming a three-dimensional image, the apparatus including a cartridge that stores ink which a printing head discharges and which has a photothermal conversion property; a conveying unit that conveys a thermally expandable material so as to pass the thermally expandable material through a first position where the printing head faces and so as to form an image on the thermally expandable material with the ink discharged by the printing head; and a light irradiating unit that emits light toward a second position which is in a downstream side from the first position in a conveying path of the conveying unit, so as to perform photothermal conversion. The cartridge is disposed at a position which deviates from an extending line of an irradiation path of the light irradiation unit.