Digital Image Subdivision for Substrate Shrinkage Compensation
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Solution Overview
Problem
Ink jet printing faces challenges with substrate shrinkage due to ink drying, leading to distortion and register errors, as existing methods require high computational effort and can compromise image quality.
Innovation Solution
A method that pre-distorts digital image data by subdividing it into blocks and shifting them to create single-pixel gaps, which are then filled with neighboring pixel data, compensating for substrate shrinkage without visible artifacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If automated fan-out control is used to compensate for substrate shrinkage, then manufacturing precision is improved, but computing time and computational effort increase significantly
Solution Approach 1:
The patent divides the substrate into multiple zones and applies different compensation parameters to each zone. Instead of calculating the entire substrate transformation in one complex computation, the method segments the problem into smaller, more manageable calculations for individual zones, reducing overall computational effort while maintaining precision.
Solution Approach 2:
The patent pre-calculates and stores compensation parameters for different substrate zones before the actual printing process. By performing these calculations in advance and storing them for reuse, the method eliminates the need for complex real-time computations during printing, significantly reducing computing time while maintaining manufacturing precision.
2Manufacturing precision
If manual or automated fan-out control is applied to compensate for substrate expansion, then manufacturing precision is improved, but the screened image quality deteriorates due to manipulation of screened data
Solution Approach 1:
The patent applies the compensation transformation to the un-screened image data before the screening process. By pre-distorting the image in the continuous tone domain and then applying screening, the method avoids the need to manipulate already-screened data, thereby maintaining image quality and avoiding mottled prints while still achieving the required register accuracy.
Solution Approach 2:
Instead of applying compensation after screening (which would require manipulating screened data), the patent inverts the process order by applying the compensation transformation before screening. This reversal allows the compensation to be applied to the original image data, preserving screening integrity and image quality while achieving the desired register accuracy.
3Productivity
If the substrate is heated quickly to remove moisture during drying, then productivity is improved, but the substrate undergoes non-linear shrinkage causing distortion
Solution Approach 1:
The patent pre-calculates and applies compensation parameters that account for the expected non-linear shrinkage that will occur during rapid drying. By pre-distorting the image data according to these parameters before printing, the method compensates for the anticipated distortion, ensuring that the final dried substrate maintains correct geometric accuracy despite the rapid drying process.
Solution Approach 2:
The patent applies a pre-distortion to the image data that is the opposite of the expected shrinkage distortion. By enlarging and distorting the image data in advance according to calculated compensation parameters, the method creates an anti-action that counterbalances the subsequent non-linear shrinkage during rapid drying, maintaining geometric accuracy in the final product.
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 method efficiently compensates for substrate shrinkage, ensuring precise geometric dimensions in printed images without the need for re-screening or high computational effort, maintaining image quality.
Implementation Method 1
the introduction of fluids into the printing substrate by the application of ink causes the printing substrate to widen
Implementation Method 2
the water that is introduced needs to be removed as quickly as possible from the printing substrate by drying the ink
Implementation Method 3
That drying of the ink is achieved by heating the printing substrate in a dedicated drying component
Implementation Method 4
This loss of moisture in the printing substrate causes the printing substrate to shrink in a non-linear way
Data Source
AI summary
A method for compensating substrate shrinkage during printing on a printing machine includes generating multiple image parts of a digitally available image to be produced, factoring in information on substrate shrinkage by subdividing the image using a computer, subdividing generated image parts into data blocks using the computer, saving actual positions of blocks in the digital image using the computer, calculating target positions of all blocks in the digital image using the computer by shifting the blocks away from one another by one pixel creating single-pixel-wide gaps between blocks in the digital image, copying and rearranging blocks in the digital image according to calculated target positions using the computer, calculating positions of single-pixel-wide gaps using the computer, filling gaps with digital image data of neighboring pixels using the computer to create a compensated digital image. The compensated digital image is printed on the printing machine.