Color Patch Positioning for Substrate Height Variability
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Solution Overview
Problem
Color analysis in printing systems is affected by substrate-height variability, leading to inconsistent color measurements due to factors like substrate deformation and sensor-to-substrate distance sensitivity, particularly in methods using hand-held spectrophotometers and non-contact color sensors.
Innovation Solution
The solution involves strategically selecting the dimension and location of color patches to be printed such that at least a portion of each patch is positioned on support projections within the color measurement zone, allowing for consistent color calibration by operating a color sensor at a nominal sensor-to-substrate distance, thereby reducing substrate-height variability and improving measurement accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a non-contact color sensor is used to measure color patches, then the measurement process is non-destructive and faster, but substrate-height variability reduces measurement accuracy
Solution Approach 1:
The patent introduces support projections as an intermediary structure between the substrate and the color sensor. These projections create localized reference planes that ensure consistent sensor-to-substrate distance, thereby maintaining measurement accuracy while preserving the benefits of non-contact measurement.
Solution Approach 2:
The substrate is pre-positioned on support projections before measurement occurs. This preliminary positioning ensures that the substrate surface is at the correct height relative to the color sensor, eliminating the need for real-time height adjustment during measurement and maintaining both speed and accuracy.
2Measurement precision
If a hand-held spectrophotometer with contact wheel is used, then sensor-to-substrate distance is controlled, but the measurement process is slower and more complex
Solution Approach 1:
The patent replaces the mechanical contact wheel system with a non-contact optical sensor positioned over support projections. This substitution eliminates the mechanical complexity and speed limitations of contact-based systems while maintaining distance control through the geometric design of the projections rather than mechanical feedback.
3Measurement precision
If color patches are measured at multiple locations to compensate for substrate deformation, then measurement accuracy improves, but ink consumption and measurement time increase
Solution Approach 1:
The patent creates localized measurement zones on the support projections where substrate height is controlled and consistent. By concentrating measurements on these locally optimized areas rather than attempting multiple measurements across the entire substrate, the system achieves accurate color data with minimal ink consumption and measurement time.
4Adaptability or versatility
If the color sensor operates at varying distances from the substrate, then it can accommodate different media thicknesses, but color analysis accuracy decreases
Solution Approach 1:
The support projections create equipotential surfaces (reference planes) at a specific height that the color sensor is optimized for. By positioning the substrate on these projections, the system ensures that the sensor operates at the nominal distance regardless of the overall substrate thickness, maintaining measurement accuracy while accommodating media thickness variations.
Data Source
AI summary
Techniques related to printing are described herein. According to an example, color patches are to be printed on a substrate. The substrate can be positioned on a substrate support for operation of a color sensor in a color measurement zone. Dimension and location in the substrate of the color patches are selected such that, for each color patch, at least a portion of the color patch can be positioned on a support projection in the color measurement zone. In some examples, color analysis techniques are described.