Image Processing Apparatus for Resin Roughness Shape Correction
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Solution Overview
Problem
Image forming apparatuses struggle to faithfully reproduce roughness shapes due to surface tension and wetting spreading characteristics of curable resin materials, resulting in loss of sharpness or elevation differences during the printing process.
Innovation Solution
An image processing apparatus that corrects roughness shape data by adjusting frequency and amplitude to ensure the texture is maintained within the output capabilities of the image forming system, using methods like frequency correction, amplitude correction, and sharpening processing to enhance the reproducibility of desired textures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the image forming apparatus outputs resin printing material based on roughness shape data specifying a sharp roughness shape, then the intended sharp roughness shape should be reproduced, but the shape changes before the resin printing material solidifies due to surface tension and wetting spreading characteristics, resulting in loss of sharpness
Solution Approach 1:
The patent applies preliminary action by performing sharpening processing on the roughness shape data before output to the image forming apparatus. The correction unit sharpens the roughness shape data in advance to compensate for the expected blurring effect that will occur when the resin material spreads during printing. This pre-compensation ensures that the final reproduced shape achieves the desired sharpness despite the material's wetting characteristics.
Solution Approach 2:
The patent utilizes parameter changes by adjusting the frequency and amplitude parameters of the roughness shape data through correction processing. The correction unit modifies these parameters to account for the resin material's surface tension and wetting spreading characteristics, transforming the input parameters into corrected parameters that will produce the desired output shape after material deposition and solidification.
2Manufacturing precision
If the image forming apparatus outputs resin printing material based on roughness shape data specifying a shape with large elevation difference, then the intended large elevation difference should be reproduced, but the resin printing material spreads from convex portions to concave portions, resulting in loss of elevation difference
Solution Approach 1:
The patent applies preliminary action by performing amplitude correction on the roughness shape data before output. The correction unit calculates corrected amplitude values that compensate for the expected material spreading from convex to concave portions. By adjusting the amplitude parameters in advance, the system ensures that the final reproduced elevation differences match the intended design despite the resin material's flow characteristics during solidification.
3Manufacturing precision
If the roughness shape data is corrected to account for material characteristics, then the texture reproduction accuracy improves, but additional processing steps are required
Solution Approach 1:
The patent applies universality by designing a correction unit that handles multiple types of corrections (frequency correction, amplitude correction, and sharpening processing) through a unified processing framework. This multi-functional approach consolidates various correction operations into a single integrated unit, reducing overall system complexity while maintaining comprehensive correction capabilities for different roughness shape characteristics.
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 enables the image forming apparatus to produce outputs with maintained texture and enhanced reproducibility of roughness shapes, even when the original data exceeds the system's limitations, by adjusting the roughness shape data to fit within the system's output range.
Implementation Method 1
the curable resin printing material has the surface tension and wetting spreading characteristics
Implementation Method 2
the curable resin printing material has the surface tension and wetting spreading characteristics
Data Source
Figure 1A~1D
Figure 2
Figure 3
AI summary
An image processing apparatus that supplies roughness shape data to an image forming apparatus that forms a roughness shape based on a roughness shape of an object to be reproduced, the image processing apparatus comprising: an input reception unit (602, S702) configured to receive an input of information representing the roughness shape of the object to be reproduced; an acquisition unit (603, S703) configured to acquire output characteristics relating to a roughness shape that the image forming apparatus can output; and a generation unit (606, S707 to S714) configured to generate the roughness shape data that is supplied to the image forming apparatus based on the information representing the roughness shape of the object to be reproduced and the output characteristics.