Image Registration on Edible Substrates via Trigger Pulse Synchronization
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Solution Overview
Problem
Existing methods for printing images on edible substrates, such as dough sheets, face limitations in variety and sanitation issues due to equipment constraints and mechanical linkage requirements, leading to inconsistent image registration and reduced flexibility in image variety.
Innovation Solution
A method involving a trigger pulse signal to synchronize the printing of images with the cutting of edible substrates using an image disposal device like an ink jet printer, allowing for flexible image variety without equipment changes and ensuring proper registration through signal processing and sensor integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a rotary printer roll is mechanically linked to the cutter roll, then image registration is achieved, but the variety of printable images is limited by the printer roll surface area
Solution Approach 1:
The patent replaces the mechanical linkage between printer and cutter with a sensor-based detection and control system. A sensor detects the position of the cutter roll, and this information is used by a controller to precisely control the printing mechanism's timing and position, achieving accurate image registration without mechanical coupling. This substitution enables greater flexibility in image selection and printing options.
2Ease of manufacture
If the printer roll contacts the dough sheet, then image printing is achieved, but sanitation issues arise
Solution Approach 1:
The patent introduces an intermediary non-contact printing mechanism, specifically an inkjet printing system, that deposits ink onto the dough sheet without physical contact from the printing mechanism. This intermediary approach maintains sanitation by preventing direct contact between the printer and the edible substrate while still achieving effective image printing.
3Adaptability or versatility
If the printer roll surface area is increased to accommodate more images, then image variety increases, but equipment complexity and production time for roll changes increase
Solution Approach 1:
The patent implements a dynamic image selection system where the controller can select from a library of stored images and dynamically adjust which image is printed based on detected cutter position and timing signals. This dynamic approach allows unlimited image variety without requiring physical changes to the printing mechanism, eliminating the need for roll changes and associated production downtime.
4Manufacturing precision
If mechanical linkage between printer and cutter is used, then image registration is maintained, but the system lacks flexibility for different printing scenarios
Solution Approach 1:
The patent implements a feedback control system where a sensor continuously monitors the position and speed of the cutter roll, and this information is fed back to the controller. The controller uses this feedback to adjust the printing timing and position in real-time, maintaining accurate image registration while adapting to varying printing conditions and requirements.
Data Source
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AI summary
A method of making edible substrates that have an image registered on them in a consistent manner. The method comprises the steps of providing an edible substrate sheet (90) , and an image source (160) , wherein the image source has at least one image. Further, a trigger pulse signal (154) is provided, which relays the frequency of a process element (72) that is communicated to an image disposal device (100) . The image disposal device (100) uses the trigger pulse signal (154) to determine when to dispose an image from the image source (160). Then an image is disposed on the edible substrate sheet (90) with the image disposal device (100) to form an image-disposed edible substrate sheet. And then a portion of the edible substrate sheet that comprises an image is separated into an individual piece (95).