Roll-to-roll Image Formation Device Misregistration Correction

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Solution Overview

Problem

Conventional electrophotographic color printers with a roll-to-roll configuration cannot correct mechanical errors in real-time due to the inability to drive the transport belt during standby, leading to potential color tone deviations and misregistration issues during post-printing processes like laminate coating and label cutting.

Innovation Solution

An image formation device and method that includes a misregistration check image formation unit, a correction amount input unit, and a controller to form misregistration check patterns on the medium, allowing for manual or automatic correction of misregistration, even in roll-to-roll mode by printing patterns on the medium after printing is complete.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If the transport belt is driven during standby to form misregistration detection patterns, then misregistration can be detected and corrected, but the printer cannot perform continuous post-printing processing in roll-to-roll mode

Engineering Contradiction:

Improvemisregistration detection precisionVSAvoidcontinuous processing capability

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The misregistration detection pattern is formed on the recording medium during the print operation itself, before the actual printing is complete. This allows the pattern to be prepared in advance without requiring separate standby time, enabling both detection capability and continuous processing in roll-to-roll mode.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The misregistration detection pattern formation is merged with the normal printing operation. The same image formation units that print the actual content are used to form the detection pattern, combining two functions into one continuous operation without requiring separate mechanisms or standby periods.

Inventive Principle:

Principle #5Merging (Combining)

2Productivity

If the transport belt stops during standby in roll-to-roll mode, then continuous processing is maintained, but misregistration cannot be corrected at appropriate timing

Engineering Contradiction:

Improvecontinuous processing efficiencyVSAvoidmisregistration correction reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

A feedback mechanism is implemented where the formed detection pattern is read by a sensor, and the misregistration amount is calculated and fed back to the control unit. This closed-loop feedback allows real-time correction decisions to be made during continuous operation, maintaining both productivity and reliability.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The mechanical approach of stopping the transport belt to perform detection is replaced with an electronic/optical system. The detection pattern is formed and read during continuous motion, substituting mechanical interruption with optical detection and electronic processing, thereby maintaining continuous operation while enabling correction.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Extent of automation

If misregistration detection pattern is formed on transport belt in roll-to-cut mode, then automatic detection is possible, but the system cannot accommodate roll-to-roll continuous processing requirements

Engineering Contradiction:

Improveautomatic misregistration detectionVSAvoidoperation mode flexibility

Core Design Contradiction:

Extent of automationVSAdaptability or versatility

Solution Approach 1:

The image formation units are designed to perform multiple functions: they can print normal content, form misregistration detection patterns, and operate in both roll-to-cut and roll-to-roll modes. This multi-functionality allows the same hardware to serve different operation modes without requiring mode-specific components, achieving both automation and adaptability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system dynamically adapts its behavior based on the operation mode. In roll-to-cut mode, the transport belt can stop for detection; in roll-to-roll mode, the pattern is formed during continuous motion. The system's operational characteristics change dynamically to suit the required mode, providing both automation and versatility.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS9618893B2Image formation device using long medium and capable of correcting misregistation

Publication Date: 2017.04.11 OKI ELECTRIC INDUSTRY CO LTD

AI summary

An image formation device includes: an image formation unit configured to perform image formation processing of forming a print image based on a print job on a medium using developers of different colors; a misregistration check image formation unit configured to control the image formation unit to cause the image formation unit to form a misregistration check pattern on the medium; a misregistration correction amount input unit configured to receive input of an amount of misregistration correction to be applied to the image formation unit; and a controller configured to correct misregistration in the image formation processing by the image formation unit, based on the amount of misregistration correction received by the misregistration correction amount input unit.