Dual-Reader Image Forming Correction on Embossed Paper
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Solution Overview
Problem
Conventional image forming apparatuses struggle to accurately reproduce code images and patch images on embossed paper due to surface unevenness, leading to reading abnormalities and reduced accuracy in automatic adjustments.
Innovation Solution
The apparatus employs a dual-sheet reading system with a first and second sheet reader to acquire unevenness information, generate base image data, and correct the image forming position using correction values derived from reading the formed base images.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a base image is formed on embossed paper to reduce surface unevenness, then image quality of code images is improved, but position accuracy of the base image shifts relative to the embossed pattern
Solution Approach 1:
The patent applies preliminary action by forming a base image on the embossed paper before forming the code image. This base image compensates for surface unevenness in advance, ensuring that subsequent code images are formed on a more uniform surface, thereby improving image quality while maintaining position accuracy through the preliminary correction of surface defects.
Solution Approach 2:
The base image acts as an intermediary layer between the embossed paper surface and the code image. This intermediate layer compensates for the unevenness of the embossed paper, providing a more uniform surface for code image formation without directly altering the embossed pattern itself, thus resolving the contradiction between improving image quality and maintaining position accuracy.
2Measurement precision
If a registration mark image is formed on embossed paper for alignment correction, then position alignment is improved, but reading accuracy of the registration mark deteriorates due to surface unevenness
Solution Approach 1:
The patent forms a base image on the embossed paper before forming the registration mark image. This preliminary base image compensates for surface unevenness, creating a more uniform reading surface for the registration mark. As a result, both alignment accuracy and reading accuracy are improved, as the registration mark is formed on a corrected surface that reduces reading errors.
Solution Approach 2:
The patent changes the surface parameters of the embossed paper by forming a base image that modifies the physical characteristics of the surface. This parameter change creates a more uniform surface topology, allowing registration marks to be read accurately while maintaining their alignment function, thus resolving the contradiction between alignment accuracy and reading reliability.
3Loss of substance
If code images are formed directly on embossed paper without base image correction, then toner consumption is reduced, but image reproduction accuracy deteriorates due to surface unevenness
Solution Approach 1:
The patent applies partial action by forming a base image only in specific areas where code images will be formed, rather than covering the entire sheet. This selective approach compensates for surface unevenness in the critical code image areas while minimizing unnecessary toner consumption in other regions, thus balancing image reproduction accuracy with toner efficiency.
Data Source
AI summary
Disclosed is an image forming apparatus including: a conveyer; an image former; a first sheet reader on an upstream side; a hardware processor that causes the first sheet reader to read the sheet, generates image data of a base image based on unevenness information of the sheet surface, and controls to form the base image on the sheet; and a second sheet reader on a downstream side. The hardware processor causes the first sheet reader to read a correction sheet, generates image data of a correction base image based on unevenness information of the correction sheet surface, controls to form the correction base image on the correction sheet, causes the second sheet reader to read the correction sheet having the correction base image thereon, obtains a correction value from the read image, and corrects the image forming position in the image former based on the correction value.