Decorative Substrate Inkjet Printing Error Correction
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Solution Overview
Problem
Decorative panels with uniform base colors, such as wood, stone, or cement décor, are prone to printing defects like banding and missing nozzles due to variations in printing performance, which existing digital inkjet printing methods struggle to fully correct, often requiring repeated software interventions and temporary solutions.
Innovation Solution
A method that involves printing a master image on a substrate, evaluating defects, and performing error correction by adding intentional defects to the image, which are designed to be imperceptible and work in conjunction with software to permanently disguise other printing errors, improving the quality and consistency of the decorative substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If digital inkjet printing is used to print decorative substrates with uniform base colors, then flexibility and variation of decor are improved, but printing defects like banding and missing nozzles become more visible
Solution Approach 1:
The patent applies the principle of converting harm into benefit by intentionally adding defects (noise) to the master image that will disguise the actual printing defects. The intentional defects serve as a visual mask that makes the harmful printing variations (banding, missing nozzles) less perceptible, thereby converting the harmful effect of visible printing defects into a beneficial camouflage effect.
Solution Approach 2:
The patent modifies the master image parameters by adding intentional defects with specific characteristics (size, distribution, visual properties) to change the overall appearance of the printed decor. This parameter modification allows the intentional defects to effectively mask the printing variations while maintaining the desired decor flexibility and variation.
2Manufacturing precision
If software correction is applied to remove printing defects, then temporary defect removal is achieved, but repeated interventions are required during production batches
Solution Approach 1:
The patent applies preliminary action by pre-processing the master image to add intentional defects before printing. This preliminary modification ensures that when the image is printed, the intentional defects are already present to mask any printing variations, eliminating the need for repeated software corrections during production batches and reducing production time.
Solution Approach 2:
The approach converts the harmful effect of printing defects into a beneficial permanent solution by adding intentional defects that serve as a lasting mask. Unlike temporary software corrections that require repeated interventions, the intentional defects embedded in the master image provide continuous camouflage throughout the production batch, eliminating time loss from repeated corrections.
3Manufacturing precision
If intentional defects are added to the master image, then printing defects are permanently disguised, but the complexity of the image processing increases
Solution Approach 1:
The patent simplifies the overall system by applying the blessing in disguise principle. Instead of requiring complex real-time defect detection and correction systems, the solution embeds intentional defects in the master image that passively mask printing variations. This converts the complexity of active defect management into a simple passive camouflage approach, reducing image processing complexity while maintaining printing quality.
Data Source
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AI summary
A method for manufacturing a decorative substrate (30) for decorative panels that comprises the steps of: a) providing a master image; b) printing said master image on a first printable substrate (6) using an inkjet printer (4), thereby obtaining a first decorative substrate (8); c) evaluating a printing defect in the first decorative substrate (8); d) performing an error correction operation on said master image on the basis of said evaluation; e) printing the corrected master image on a second printable substrate (28) to obtain a second decorative substrate (30), wherein the method has the characteristic that said error correction operation at least involves adding an intentional defect to the corrected master image.