Laser Register Control via Ink Mark Alteration
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Solution Overview
Problem
Laser processes in reel-to-reel manufacturing lack effective register control due to their inability to produce marks on the base or carrier material, leading to accuracy issues and drifts that compromise the alignment with printing process stages, especially during long production runs.
Innovation Solution
Implementing a method where a laser plots a negative mark on a printed ink mark, which is easily detectable by computer vision or sensors, allowing for accurate alignment and monitoring between laser and printing process stages, even if the laser does not leave marks on the surface, by altering the reflection or penetration of the laser beam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If laser processing is used to avoid marks on the base material, then the quality of the finished product is improved, but the ability to perform register control is lost
Solution Approach 1:
The patent introduces an intermediary layer (conductive foil or adhesive layer) between the base material and the laser processing target. This intermediary layer absorbs the laser energy and creates detectable marks without affecting the base material quality. The intermediary layer serves as a mediator that enables register control while protecting the base material from direct laser impact.
Solution Approach 2:
The patent creates a copy of the registration marks on the intermediary layer rather than directly on the base material. The conductive foil or adhesive layer receives the laser processing and forms mark copies that can be detected for register control, while the original base material remains unmarked and high-quality.
2Productivity
If laser scanning is used for patterning, then processing speed is improved, but alignment drift occurs during long production runs
Solution Approach 1:
The patent implements a feedback mechanism where registration marks are continuously monitored using optical sensors or computer vision systems. The system detects the position of marks created on the intermediary layer and provides real-time feedback to adjust the laser scanner position, compensating for drift that occurs during long production runs while maintaining high processing speed.
Solution Approach 2:
The patent applies preliminary action by pre-processing the base material with an intermediary layer (conductive foil or adhesive) that is specifically prepared to receive laser marks. This preliminary preparation ensures that the laser can create detectable marks on the intermediary layer without affecting the base material, enabling continuous monitoring and correction of alignment throughout the production run.
3Measurement precision
If register marks are printed on the base material for laser alignment, then alignment monitoring is enabled, but the laser cannot produce corresponding marks
Solution Approach 1:
The patent introduces an intermediary layer (conductive foil or adhesive layer) between the base material and the laser processing target. This intermediary layer absorbs the laser energy and creates detectable marks without affecting the base material quality. The intermediary layer serves as a mediator that enables register control while protecting the base material from direct laser impact.
Solution Approach 2:
The patent creates a copy of the registration marks on the intermediary layer rather than directly on the base material. The conductive foil or adhesive layer receives the laser processing and forms mark copies that can be detected for register control, while the original base material remains unmarked and high-quality.
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 ensures precise and rapid alignment of laser and printing process stages, maintaining accuracy throughout long production runs and allowing for real-time correction of alignment errors, even when the laser beam's impact is not visible on the surface.
Implementation Method 1
by altering the reflection or penetration of the laser beam
Implementation Method 2
utilizing a colourless or white absorbent ink
Data Source
Figure 1~2
AI summary
A laser process alignment measuring method applicable to a reel-to-reel manufacturing process including a laser process stage, wherein before at least one laser process stage, on the base or carrier material of the web (2) are made marks, patterns or surfaces (4, 9) with printing ink, on which the laser beam used can make a mark (7, 10), for example, by removing or changing the printing ink, whereby at the laser process stage, another mark is plotted with the laser beam on the said mark printed with printing ink, and the position of the mark printed with printing ink (4, 9) and the mark plotted with the laser (7, 10) are read optically to measure the alignment of the printing ink stage and the laser process stage.