Printer Substrate De-skewing and Electronic Lateral Registration
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Solution Overview
Problem
High-speed printing systems face challenges in accurately registering substrates without causing wrinkles, tears, or buckles due to intense forces required for de-skewing and lateral registration, especially with lightweight media.
Innovation Solution
A printer system that decouples mechanical de-skewing from electronic lateral image registration, using a mechanical de-skewing device to correct substrate skew and an electronic system to adjust image data for inkjets, eliminating the need for substrate repositioning and reducing mechanical forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical devices are used to both de-skew and laterally register substrates, then registration accuracy is improved, but substrate damage (wrinkles, tears, buckles) increases due to intensified forces
Solution Approach 1:
The patent divides the registration function into two separate systems: a mechanical de-skewing device that only corrects skew, and an electronic lateral registration system that adjusts image data without physically moving the substrate. This segmentation eliminates the need for mechanical lateral registration forces that cause substrate damage.
Solution Approach 2:
The patent replaces the mechanical lateral registration system with an electronic image registration system. Instead of using rollers to physically reposition the substrate laterally, the system uses sensors to detect substrate position and electronically adjusts the image data sent to printheads, thereby eliminating mechanical forces that wrinkle and tear lightweight substrates.
2Productivity
If substrate processing speeds are increased, then productivity is improved, but the time available for de-skewing and lateral registration decreases, requiring intensified forces
Solution Approach 1:
By separating de-skewing from lateral registration, the system can process substrates at high speeds while applying minimal force. The mechanical de-skewing device operates independently at lower speeds on the substrate feed end, while the electronic lateral registration system operates simultaneously at high speeds by adjusting image data, thus maintaining productivity without requiring intensified forces.
Solution Approach 2:
The electronic lateral registration system replaces mechanical lateral adjustment mechanisms, allowing high-speed substrate processing without the need for high-force mechanical intervention. The system detects substrate position electronically and compensates through image data adjustment rather than physical substrate manipulation.
3Device complexity
If mechanical devices are used for both de-skewing and lateral registration, then device complexity is reduced, but substrate damage increases due to intensified forces
Solution Approach 1:
The patent segments the registration system into a simple mechanical de-skewing component and an electronic lateral registration component. This segmentation allows each component to be optimized for its specific function with minimal complexity, while the overall system avoids substrate damage by eliminating the need for high-force mechanical lateral registration.
4Manufacturing precision
If forces are intensified to correct skew and lateral registration within decreasing time, then registration accuracy is maintained, but substrate damage (wrinkles, tears, buckles) occurs
Solution Approach 1:
The electronic lateral registration system replaces mechanical forces with electronic image adjustment. The system maintains registration accuracy by detecting substrate position with sensors and electronically shifting image data to compensate for lateral position variations, thereby preserving substrate integrity while achieving precise registration.
Data Source
AI summary
A printer uses a mechanical device to correct skew in substrates and uses an electronic lateral registration system to shift ink images to be placed on the de-skewed substrates to remove the need for mechanical components that laterally register de-skewed substrates. The removal of the mechanical lateral registration components enable the substrates to be printed more quickly than printers that use mechanical devices to both de-skew substrates and laterally register de-skewed substrates in a print zone.