Automated Foil Transfer System with Negative Toner Image
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Solution Overview
Problem
Existing foil transferring methods face challenges in accurately transferring desired foil images due to thermal fusion issues with toner images, requiring manual alignment, and lack of automation, leading to reduced productivity and quality.
Innovation Solution
An image forming system that automates the foil transfer process by forming a negative toner image on one base material and a positive toner image on another, using a control system to manage the transfer of foil images, ensuring precise alignment and avoiding unwanted edge transfers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If thermal transfer printing is used to transfer foil images, then foil images can be transferred to toner images, but unwanted foil images are also transferred to other toner images due to thermal fusion
Solution Approach 1:
The patent applies local quality by creating different surface properties in different regions of the base material. The desired toner image area has properties that promote foil transfer (higher surface energy), while other toner image areas have properties that resist foil transfer. This is achieved through selective application of a surface treatment layer or using toner formulations with different surface energy characteristics, allowing the thermal transfer process to selectively transfer foil images only to the desired location.
Solution Approach 2:
The patent implements preliminary anti-action by pre-treating the base material or toner images to prevent unwanted foil transfer before the thermal transfer process. This involves applying a release layer or surface treatment to areas where foil transfer should not occur, creating a protective barrier that prevents the foil image from adhering to unintended toner images during the heating process.
2Manufacturing precision
If manual alignment is used for foil transfer, then alignment can be performed, but productivity is reduced and alignment accuracy is difficult to maintain
Solution Approach 1:
The patent applies self-service by enabling the system to automatically align and transfer foil images without manual intervention. The alignment process is automated through coordinated movement of the base material and foil sheet by conveying mechanisms, with positioning controlled by the system's control unit. This eliminates the need for manual alignment operations while maintaining high precision through automated positioning systems.
Solution Approach 2:
The patent replaces manual mechanical alignment operations with an automated mechanical conveying and positioning system. Instead of manual handling and alignment, the system uses automated rollers, conveyors, and positioning mechanisms to precisely align the foil sheet with the desired toner image area, significantly improving both productivity and alignment consistency.
3Productivity
If successive automated steps are used for foil printing, then productivity improves, but the complexity of the system increases
Solution Approach 1:
The patent applies merging by combining multiple foil transfer operations into a single integrated processing step. Instead of separate manual operations for alignment, transfer, and positioning, the system integrates these functions into one automated process where the base material and foil sheet are simultaneously conveyed, aligned, and transferred in a coordinated manner, reducing overall system complexity while maintaining high productivity.
Solution Approach 2:
The patent implements universality by designing a multi-functional automated system that can handle various foil transfer scenarios using the same core mechanism. The conveying and positioning system serves multiple purposes: aligning the foil sheet, positioning it relative to the base material, and facilitating the transfer process. This multi-functionality reduces the need for separate dedicated mechanisms for each operation, thereby managing system complexity.
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 system enables high-accuracy, automated foil transfer with improved productivity by ensuring only the desired foil image is transferred, even when toner images are thermally fused, and handles varying paper sizes with flexible feeding trays.
Implementation Method 1
a heating unit that heats the foil sheet and the base material
Implementation Method 2
a pressing unit that presses the foil sheet and the base material
Data Source
AI summary
An image forming apparatus transfers a negative toner image on a waste sheet of paper having larger size than that of a printing sheet of paper and transfers all the toner images on the printing sheet of paper. A first thermal transferring portion transfers an unnecessary foil of a foil sheet on the negative toner image of the waste sheet of paper image. A second thermal transferring portion transfers a foil remained on the foil sheet on the positive toner image of the printing sheet of paper. The positive toner image is formed using transparent toner. Any gradation processing is performed on an edge of the positive toner image.