Printer Thermal Head Segmentation for Textured Finish
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Solution Overview
Problem
Existing thermal transfer printing methods struggle to consistently produce a glossy textured finish similar to silver halide photographs, often resulting in unprinted spots or degradation of print quality due to surface roughness issues and the need for large embossing devices.
Innovation Solution
A printer apparatus with a thermal head that linearly arranges heating elements and control means to selectively apply different thermal energies, dividing heating elements into groups to form a reproducible uneven pattern on the image protecting layer, achieving a textured finish.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If embossing is performed using an embossing roll on a polyolefin resin layer, then a textured finish is achieved, but surface roughness increases causing unprinted spots and degradation in print quality
Solution Approach 1:
The heating elements are divided into multiple groups along the conveyance direction, with each group independently controllable. This segmentation allows selective application of thermal energy to specific regions, enabling formation of uneven patterns while maintaining overall print quality by avoiding excessive surface roughness in critical areas.
Solution Approach 2:
Different amounts of thermal energy are applied to different heating element groups based on their positions. This local quality approach creates regions with different surface characteristics - some areas develop textured finishes while others maintain smooth surfaces for optimal printing, thus resolving the contradiction between textured finish and print quality.
2Shape
If an embossing roll with surface irregularities is used to emboss under heating conditions, then a matte pattern is formed, but the device becomes large and difficult to accommodate in the printer
Solution Approach 1:
The mechanical embossing roll is replaced with a thermal field approach using multiple independently controllable heating elements. Instead of using mechanical surface irregularities to create the matte pattern, the invention uses selective thermal energy application to form uneven patterns on the image protecting layer, thereby eliminating the need for a large mechanical embossing device.
Solution Approach 2:
The invention changes the approach from mechanical embossing to thermal processing by varying the amount of thermal energy applied to different heating element groups. This parameter change allows formation of uneven patterns and matte effects through controlled thermal effects on the polyolefin resin layer, avoiding the need for complex mechanical embossing equipment.
3Shape
If thermal energy is continuously varied during image protecting layer formation, then regions of different gloss levels can be arranged, but the heating process becomes complex
Solution Approach 1:
The heating system is segmented into multiple independent heating element groups, each capable of receiving different thermal energy inputs. This segmentation simplifies the control approach by allowing independent adjustment of each group's thermal energy application, making it easier to create regions of different gloss levels without requiring complex continuous variation of heating parameters across the entire surface.
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
The solution effectively forms a glossy textured finish on printed materials with improved reproducibility and print quality, comparable to silver halide photographs, by applying consistent thermal energy to adjacent heating element groups, enhancing the visual effect and surface texture.
Implementation Method 1
an image protecting layer by thermal transfer
Implementation Method 2
selectively applying different amounts of thermal energy to heating elements
Implementation Method 3
applying the same amount of thermal energy to heating elements included in the same heating element group
Implementation Method 4
forming an uneven pattern on the image protecting layer
Data Source
AI summary
A printer apparatus including a printing-medium conveying unit conveying a printing medium, a sheet conveying unit conveying a thermal transfer sheet having an image protecting layer to be thermally transferred onto an image formed on the printing medium, a thermal head with heating elements linearly arranged in a direction orthogonal to a conveyance direction of the printing medium, and a control unit driving and controlling the thermal head. For selectively applying different amounts of thermal energy to the heating elements to form an uneven pattern on the image protecting layer thermally transferred onto the image on the printing medium, the control unit randomly divides a row of the heating elements into heating element groups each including at least two adjacent heating elements, applies the same amount of thermal energy to heating elements in the same heating element group, and applies different amounts of thermal energy to adjacent heating element groups.