Image Layer Separation for White Toner Control
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Solution Overview
Problem
Existing printing systems struggle to adequately modify and control the white layer in CMYW toner systems, leading to issues like overapplication of white toner, distortion of images, and bleeding of toner onto non-white areas.
Innovation Solution
A method to split an image into a white layer and a color layer, allowing for independent customization and adjustment of the white layer, which can then be printed in two passes using an electronic application that processes the image file to generate the white and color layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If standard printing systems print with white toner in a single pass, then printing efficiency is maintained, but white toner is overapplied causing image distortion and bleeding onto non-white toners
Solution Approach 1:
The patent segments the printing process into two separate passes: a first pass printing the color layer (CMYK) and a second pass printing the white layer. This segmentation allows independent optimization of each layer, preventing white toner overapplication and bleeding while maintaining overall printing efficiency through automated processing.
2Reliability
If white toner is applied generously to ensure coverage, then coverage completeness is improved, but the image appears distorted and t-shirts feel stiff with undesired sheen
Solution Approach 1:
The patent applies preliminary action by printing the color layer first in the first pass, establishing a foundation that guides subsequent white toner application. The white layer is then printed in the second pass with precise control, ensuring coverage only where needed without overapplication, thus maintaining image quality and preventing distortion.
3Productivity
If the white layer and color layer are printed together in a single pass, then printing time is reduced, but the white toner bleeds onto the non-white toners
Solution Approach 1:
The patent segments the printing process into two distinct passes with separate color layers, allowing precise control over toner application. The first pass deposits CMYK colors while the second pass applies white toner independently, preventing bleeding between layers while maintaining efficient automated processing.
4Adaptability or versatility
If standard printing software is used without layer separation, then system complexity is minimized, but users cannot customize the white layer independently of the color layer
Solution Approach 1:
The patent segments the image data into separate color layer and white layer components, enabling independent customization of each layer through software controls. This segmentation provides users with versatile adjustment options for white toner parameters while maintaining manageable software complexity through automated processing workflows.
Data Source
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AI summary
A method of splitting an image into a white layer and a color layer, comprising: providing an electronic application; receiving and loading, by the electronic application, an image file; the image file comprises a cyan color plane, a magenta color plane, a yellow color plane, a black color plane, and a white color plane; splitting the image file to create a white layer and a color layer; erasing the black color plane; generating a CMY color plane; outputting the CMY color plane to a first storage location, to generate the color layer; copying, in the electronic application, the white color plane into the black color plane; erasing the cyan color plane, the magenta color plane, and the yellow color plane to generate a white to black color plane; and outputting the white to black color plane to a second storage location, to generate the white layer.