Multi-Channel Imaging Head Calibration for Banding Reduction
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Solution Overview
Problem
Multi-channel imaging systems face challenges in reducing swath-to-swath and inter-swath banding, particularly when imaging regular patterns like color filters, due to variations in imaging characteristics among channels, which affect the quality and uniformity of the final product.
Innovation Solution
A method and apparatus for calibrating multi-channel imaging heads by analyzing optical properties of imaged features and adjusting individual channels to equalize optical properties within and between swaths, using a scanner and image data processor to provide correction instructions for power adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multi-channel imaging systems are used to reduce imaging time, then productivity is improved, but banding artifacts increase due to channel-to-channel variations
Solution Approach 1:
The system performs preliminary measurement of channel characteristics by imaging a test pattern with known optical properties before actual production imaging. Individual channel power, beam size, and focus are characterized in advance. Correction instructions are then calculated and applied to each channel based on these preliminary measurements, enabling the system to maintain high productivity while compensating for channel variations that would otherwise cause banding artifacts.
Solution Approach 2:
The system establishes a feedback loop where the actual optical properties of imaged features are measured and compared against desired uniformity. Correction instructions are generated based on the difference between actual and desired characteristics, and these corrections are applied to subsequent imaging. This continuous feedback mechanism allows the system to maintain manufacturing precision while using multi-channel parallel imaging for high productivity.
2Productivity
If channel power is increased to improve imaging speed, then productivity is improved, but banding artifacts worsen due to amplified channel variations
Solution Approach 1:
The system individually adjusts the power parameter of each imaging channel based on measured channel characteristics. Instead of using uniform high power across all channels, the system modifies power levels for specific channels that exhibit variations, thereby maintaining high imaging speed while compensating for channel-to-channel differences to prevent banding artifacts.
Solution Approach 2:
The system applies different power settings to different channels based on their individual characteristics. Each channel receives customized power adjustment rather than uniform treatment, allowing optimal imaging speed for each channel while compensating for local variations that would cause banding. This local quality approach enables high productivity without sacrificing uniformity.
3Manufacturing precision
If individual channel calibration is performed to reduce banding, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The calibration system is designed to be universally applicable to all channels in the imaging array. A single test pattern imaging process characterizes all channels simultaneously, and the same correction methodology is applied across the board. This universal approach reduces complexity compared to individualized calibration procedures, while still achieving the manufacturing precision required to minimize banding artifacts.
Solution Approach 2:
The system uses a test pattern with known optical properties as a copy or representation of the actual production pattern. By measuring channel characteristics using this standardized test pattern, the system simplifies the calibration process. The test pattern acts as a surrogate that captures channel variations without requiring complex real-time adjustments during actual production, thereby reducing overall system complexity while maintaining precision.
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 effectively minimizes banding artifacts, ensuring uniformity and quality of the imaged patterns, particularly in color filters, by optimizing channel power distribution and reducing visual beating, thereby enhancing the overall image quality.
Implementation Method 1
The dye donor element is image-wise heated to selectively transfer a dye from the donor element to the receiving element. Image-wise heating is typically done by means of a laser beam.
Implementation Method 2
Dye transfer processes are a particular type of thermal transfer process. Other thermal transfer processes include: laser-induced melt transfer, laser-induced ablation transfer, and laser-induced mass transfer.
Data Source
AI summary
A multi-channel imaging head is calibrated in accordance with a pre-determined regular pattern to minimize swath-to-swath and inter-swath variations during the imaging of the regular pattern. The imaging parameters of the imaging head are optimized in accordance with the pre-determined regular pattern.