Printed Relief Alignment for Lenticular Lens Registration
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Solution Overview
Problem
Existing methods for aligning prefabricated lenticular lens arrays with printing devices, such as flatbed inkjet printers, are inefficient due to reliance on single reference edges, which can lead to irregular and inconsistent lenticular images caused by variations in lens pitch and manufacturing inconsistencies, and require multiple lens sheets for different viewing distances.
Innovation Solution
A periodic raised relief pattern is printed onto a substrate using UV-curable ink, matching the physical pitch of the lenticular lens array, allowing for precise registration and alignment by engaging the valleys between lenses with the raised lines, thereby ensuring optimal alignment and reducing labor and wear on the printing bed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single reference edge is used for aligning the lenticular lens sheet, then the alignment process is simple, but the lenticular images become irregular and inconsistent due to variations in lens pitch and manufacturing inconsistencies
Solution Approach 1:
The invention divides the alignment reference into multiple segments (multiple reference edges or features distributed across the lens sheet) rather than relying on a single reference edge. This segmentation allows for local adjustments and compensations for pitch variations, maintaining image consistency while keeping the alignment process manageable.
Solution Approach 2:
The invention applies different reference features or alignment strategies to different regions of the lens sheet based on local characteristics. By tailoring the reference system to local pitch variations and manufacturing inconsistencies, the method maintains high image consistency across the entire sheet without requiring a complex global alignment system.
2Ease of operation
If a single reference edge is used for alignment, then the alignment method is easy to implement, but the effective center of the finished lenticular image varies from print to print
Solution Approach 1:
The invention creates a universal alignment reference system that serves multiple functions: it establishes the baseline position, compensates for pitch variations, and ensures consistent image centering across different prints. This multi-functional reference system maintains ease of operation while achieving precise and repeatable image center positions.
Solution Approach 2:
The invention incorporates preliminary measurement and calculation steps to determine the optimal reference features and their positions before the actual alignment process. By pre-cal compensating for known pitch variations and manufacturing tolerances, the system achieves precise image centering without complicating the operational alignment process.
3Device complexity
If traditional reference edge alignment is used, then the alignment process is straightforward, but registration errors are cumulative across the sheet
Solution Approach 1:
The invention segments the registration reference into multiple distributed features across the lens sheet rather than a single continuous reference edge. This segmentation prevents error accumulation by providing multiple independent reference points, allowing local registration to be verified and corrected without propagating errors across the entire sheet.
Solution Approach 2:
The invention implements a feedback mechanism where the alignment system continuously references multiple features across the lens sheet during the alignment process. This feedback allows for real-time detection and correction of registration deviations, preventing cumulative errors while maintaining a relatively simple alignment system.
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 provides more reliable positional accuracy, enabling the use of finer pitches and flexible materials in large formats, simplifying handling and reducing shipping costs while maintaining precise alignment, and is self-correcting for minor imperfections in both printer and lens material.
Implementation Method 1
The curable compound may include an ink or an inkset that is cured by the application of ultraviolet or other activating radiation.
Data Source
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AI summary
A printing system capable of accurately positioning a lenticular array in registration with a rectilinear raster includes a printer that is capable of printing onto a printable surface. The printer has a main support surface on which the printable surface rests. The system further includes a series of raised parallel relief features being spatially formed along a printable substrate that is supported by the main support surface. The raised parallel relief features are raised to a sufficient height above the printable substrate such that when the lenticular array is disposed upon the raised parallel relief features, each raised parallel relief feature fits and is disposed within a valley formed between two respective adjoining lenticules of the lenticular array.