Flexible Roll Printing Synchronization Error Compensation
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Solution Overview
Problem
Current contact type electronic printing technologies face synchronization errors between the roll and substrate support due to deformation caused by printing pressure, leading to reduced printing precision, as existing solutions do not effectively compensate for these errors.
Innovation Solution
A printing apparatus and method that includes a rotating part with a flexible roll, a substrate support, a printing pressure mechanism, and a compensation unit with sensors to measure forces and control the rotating velocity and movement velocity of the roll and substrate support to compensate for synchronization errors, ensuring precise alignment and pattern transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a flexible roll is used for contact type printing, then the roll can conform to the substrate and perform printing, but the radius of the roll changes due to deformation from printing pressure, causing synchronization error between the roll and substrate support
Solution Approach 1:
The patent employs feedback control by measuring the actual position of the roll surface using sensors (such as capacitive or optical sensors) and comparing it with the expected position. The control unit adjusts the rotation speed of the roll based on the detected position deviation, thereby compensating for synchronization errors caused by roll deformation during printing pressure application.
Solution Approach 2:
The patent dynamically changes the rotation speed parameter of the roll based on detected synchronization errors. The control unit modifies rotational velocity in real-time to compensate for radius changes caused by deformation, maintaining accurate synchronization between the roll surface movement and substrate transport speed.
2Productivity
If the roll rotation speed is increased to improve productivity, then mass production can be achieved, but synchronization error increases due to deformation under higher printing pressure
Solution Approach 1:
The feedback control system continuously monitors roll surface position and adjusts rotation speed dynamically. This allows the system to operate at higher speeds for improved productivity while automatically compensating for increased deformation effects that occur under higher printing pressure conditions.
Solution Approach 2:
The patent transitions from static roll rotation speed control to dynamic adjustment. The rotation speed is no longer fixed but is continuously modified based on real-time deformation detection, enabling the system to adapt to varying operational conditions and maintain precision across different productivity levels.
3Manufacturing precision
If synchronization control is added to compensate for roll deformation, then printing precision is improved, but device complexity increases due to additional sensors and control units
Solution Approach 1:
While feedback control does increase device complexity by adding sensors and control units, it enables precise compensation for roll deformation. The added complexity is justified by the significant improvement in printing precision, particularly for fine pattern formation where synchronization accuracy is critical.
Solution Approach 2:
The patent replaces complex mechanical synchronization mechanisms with sensor-based detection and electronic control. Instead of using elaborate mechanical coupling systems to maintain synchronization, the invention uses electronic sensing of roll surface position and electronic adjustment of rotation speed, which can achieve higher precision with potentially simpler overall system architecture.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution actively compensates for synchronization errors by measuring tangential forces and performing feedback control, significantly improving printing precision by maintaining accurate synchronization between the roll and substrate, thereby enhancing the quality of pattern transfer in electronic printing.
Implementation Method 1
a sensor unit which is disposed on a lower portion of the substrate to measure forces which are applied between the roll and the substrate at a contact position between the roll and the substrate
Implementation Method 2
a printing pressure part formed to provide adhesion and printing pressure of the roll to the substrate by changing an interval between the rotating part and the support part
Implementation Method 3
a motor rotating the roll
Data Source
AI summary
A printing apparatus for measuring and compensating for a synchronization error is provided. The printing apparatus includes: a rotating part configured to include a roll of which the surface is made of a flexible material and a motor rotating the roll; a support part having a substrate disposed on an upper portion thereof to support the substrate and formed to relatively move in a direction parallel with a tangential direction of the rotating part and the roll; a printing pressure part formed to provide adhesion and printing pressure of the roll to the substrate by changing an interval between the rotating part and the support part; and a compensation unit configured to include a sensor unit which is disposed on a lower portion of the substrate to measure forces which are applied between the roll and the substrate at a contact position between the roll and the substrate and a control unit which performs a control to compensate for the synchronization error by using values of forces measured by the sensor unit.