Flexible Substrate Periodic Pattern for Digital Printing Position Control
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Solution Overview
Problem
Digital printing systems face challenges in accurately controlling and monitoring the operation of flexible intermediate transfer members (ITMs) due to limitations in marker placement and registration, leading to image distortions and increased manufacturing costs.
Innovation Solution
A digital printing system incorporating a flexible substrate with a periodic pattern, an optical assembly, and a processor that illuminates and detects light from the substrate to derive signals indicative of the pattern, allowing for precise control and monitoring of the printing process, including ink droplet placement and tension adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If position markers are placed on the flexible substrate to monitor position, then position control capability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The flexible substrate itself serves as the measurement tool through its periodic pattern, eliminating the need for external position markers. The substrate's inherent structure provides the reference pattern that the optical sensor detects to determine position, allowing the system to self-monitor without additional components.
Solution Approach 2:
The position monitoring function is extracted from separate physical markers and integrated into the periodic pattern structure of the flexible substrate itself. This removes the need for distinct position markers while maintaining the measurement capability through the substrate's own geometric features.
2Measurement precision
If position markers are used for monitoring, then position tracking is improved, but manufacturing cost increases
Solution Approach 1:
The flexible substrate provides its own position reference through the periodic pattern, eliminating the need for separate position markers that would increase manufacturing cost. The pattern is inherently part of the substrate structure, reducing overall system cost.
Solution Approach 2:
The periodic pattern serves multiple functions: it provides mechanical flexibility as part of the substrate structure and simultaneously serves as the position reference for optical detection. This multi-functionality eliminates the need for separate position markers, reducing manufacturing cost.
3Productivity
If the flexible substrate moves during printing, then printing speed is improved, but image quality deteriorates due to distortions and registration errors
Solution Approach 1:
The optical sensor continuously detects the periodic pattern on the moving flexible substrate, providing real-time position feedback to the control system. This feedback allows the system to compensate for movement variations and maintain accurate ink droplet placement, preserving image quality during high-speed printing.
Solution Approach 2:
The periodic pattern is pre-established on the flexible substrate before printing begins. This pre-configured reference pattern enables the optical sensor to continuously track position during movement, allowing the control system to proactively adjust ink droplet placement to maintain registration accuracy despite substrate motion.
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
This approach improves image quality by reducing distortions and registration errors, eliminates the need for position markers, and enhances system reliability by closely tracking the ITM's condition and movement.
Implementation Method 1
The optical assembly is configured to illuminate the flexible substrate with light, to detect the light from the flexible substrate, and to derive from the detected light a signal indicative of the periodic pattern
Data Source
AI summary
A digital printing system (10) includes a flexible substrate (44), an optical assembly (200, 301) and a processor (20). The flexible substrate (44) has a periodic pattern, and is configured to be moved and to receive ink droplets in a printing process that forms an image thereon. The optical assembly (200, 301) is configured to illuminate the flexible substrate (44) with light (215, 315), to detect the light (215, 315) from the flexible substrate (44), and to derive from the detected light (215, 315) a signal indicative of the periodic pattern. The processor (20) is configured to receive the signal and to monitor or control the digital printing system (10) based on the periodic pattern as indicated by the signal.