Flexible Packaging Print Layout Reduces Paper Waste
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Solution Overview
Problem
Existing data processing methods for creating print layouts result in significant paper waste when repeatedly printed, complicating post-processes like cutting, especially in mass-producing flexible packaging.
Innovation Solution
A data processing method that arranges basic pattern images without gaps in the main scanning direction, allowing continuous and repeated recording on a long strip-shaped base material, thereby reducing paper waste and simplifying post-processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional print layout methods are used to print multiple objects on one page, then printing efficiency is improved, but paper waste occurs repeatedly and post-processes become complicated
Solution Approach 1:
The patent applies continuity by arranging multiple basic pattern images (first and second patterns) side-by-side in the main scanning direction without gaps, creating a continuous printable sequence. This allows the printing apparatus to print continuously across the entire width of the base material, eliminating the need to stop and reposition between separate print layouts, thereby reducing paper waste while maintaining high printing efficiency
Solution Approach 2:
The patent transitions from conventional single-column print layout to a multi-column arrangement by utilizing the main scanning direction (horizontal dimension) more effectively. By arranging multiple basic patterns side-by-side across the width of the base material and repeating them in the sub-scanning direction (vertical dimension), the system maximizes material utilization and eliminates waste spaces that occur with traditional sequential printing methods
2Productivity
If conventional print layout methods are used, then printing efficiency is improved, but post-processes such as cutting become complicated and irregular
Solution Approach 1:
The patent segments the printable content into standardized basic pattern images that can be independently arranged and repeated. Each basic pattern is a self-contained unit that can be positioned at regular intervals in both main and sub-scanning directions, creating a modular structure that simplifies subsequent cutting and processing operations by providing clear, predictable boundaries
Solution Approach 2:
The patent changes the spatial parameters of the print layout by arranging multiple basic patterns side-by-side in the main scanning direction with specific spacing relationships. This creates a regular, repeating pattern structure where the position and dimensions of each pattern are precisely controlled, enabling standardized post-processing operations with simplified timing and positioning requirements
3Productivity
If print layouts are repeatedly printed, then production volume is increased, but paper waste occurs every time and manufacturing costs increase
Solution Approach 1:
The patent performs preliminary arrangement of multiple basic pattern images side-by-side in the main scanning direction before the actual printing process begins. This pre-planned configuration ensures that the entire width of the base material is utilized efficiently from the start, eliminating waste spaces that would otherwise occur with conventional sequential printing methods, thereby reducing material loss while maintaining high production volume
Solution Approach 2:
The patent merges multiple basic pattern images into a single continuous print sequence by arranging them side-by-side in the main scanning direction. This consolidation allows the printing apparatus to process multiple patterns in one continuous operation rather than printing them separately, thereby maximizing material utilization and reducing waste while achieving high production volumes
Data Source
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AI summary
A data processing method for repeatedly recording a first basic pattern image and a second basic pattern image on a base material includes the following a) and b). In the a), the first basic pattern image (D1) and the second basic pattern image (D2) are stored. In the b), a pixel value to be recorded is calculated for each recording layout coordinate set indicating a position on the base material. Further, in the b), a pixel value of a first basic pattern coordinate set indicative of a position on the first basic pattern image (D1) and a pixel value of a second basic pattern coordinate set indicative of a position on the second basic pattern image (D2) are each assigned to a corresponding one of the recording layout coordinate sets so as to cause the first basic pattern image (D1) and the second basic pattern image (D2) to be arranged side by side in an X-axis direction and to cause the first basic pattern image (D1) and the second basic pattern image (D2) to be each arranged continuously and repeatedly in a Y-axis direction orthogonal to the X-axis direction.