Printed Substrate Color References for Gravure Ink Matching
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Solution Overview
Problem
Existing printing technologies face challenges in seamlessly transitioning from low-volume digital printing to high-volume analog printing due to the need for complex setup and lack of efficient color matching, particularly in gravure printing.
Innovation Solution
A printed substrate with digitally printed color reference areas and patches allows for easy conversion to analog printing by providing color data without requiring original digital data, enabling precise ink formulation for gravure printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If digital printing is used for low-volume production, then flexibility and setup time are improved, but printing speed and productivity are reduced
Solution Approach 1:
The patent changes the volume parameter threshold at which printing mode switches from digital to analog. By identifying the crossover point where analog printing becomes more efficient, the system optimizes productivity without sacrificing flexibility for low-volume orders. This parameter-based decision rule allows seamless transition between printing technologies.
2Productivity
If analog gravure printing is used for high-volume production, then printing speed and productivity are improved, but setup time and device complexity increase
Solution Approach 1:
The patent performs preliminary color measurement and ink formulation calculations before the actual printing process. By pre-determining the exact ink composition needed based on measured color values from digital proofs, the system eliminates time-consuming color matching and adjustment during setup, allowing analog printing to start immediately at full speed.
Solution Approach 2:
The patent introduces color measurement devices and formulation software as intermediaries between digital proofing and analog printing. These intermediaries automatically translate digital color data into precise ink formulations, eliminating the need for manual color matching and reducing setup complexity while maintaining high printing speed.
3Measurement precision
If color matching is performed manually for analog printing conversion, then measurement precision may be improved, but time consumption and operational complexity increase
Solution Approach 1:
The patent replaces manual color matching operations with automated optical measurement and computational formulation systems. Spectrophotometers and color management software automatically measure color values and calculate ink formulations, eliminating manual intervention while maintaining or improving precision. This substitution dramatically reduces time consumption without sacrificing accuracy.
Solution Approach 2:
The patent creates a digital color model that copies and stores the exact color characteristics from the digital proof. This color model serves as a reference that can be rapidly reproduced in analog printing without repeated manual measurement and adjustment, significantly reducing formulation time while maintaining consistent color accuracy across production batches.
Data Source
AI summary
A method for formulating an ink for a gravure printing press may involve digitally printing of a decor and a patch onto a substrate. The patch may include at least one color reference area. The color reference area may include at least one digital ink. The patch may be located on a part of the substrate that is substantially free of the décor. A color of the at least one color reference area may be measured. A tone of an ink for gravure printing may be adjusted to match the color of the at least one color reference area.