Sheet Lamination Alignment Using Curl Detection and Auto Correction
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Solution Overview
Problem
Existing laminating devices face issues with sheet curling due to printing conditions and environment, leading to quality degradation, increased load on printing processing, and waste of expensive laminate film due to misalignment and manual adjustments.
Innovation Solution
An image processing system with an integrated reader, laminator, and corrective mechanisms to detect and correct sheet curl, misregistration, and image defects, including decurlers, position changers, and purge systems to automate adjustments and reduce waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustment is performed to correct sheet curl, then lamination quality is improved, but production time is increased and productivity is reduced
Solution Approach 1:
The system uses the reading section to automatically detect sheet curl and misregistration, and the control section automatically calculates and applies position corrections, eliminating the need for manual inspection and adjustment by operators
Solution Approach 2:
The patent replaces manual mechanical adjustment with an automated optical detection system (reading section) and computational control system that automatically determines and applies position corrections based on detected mark image locations
2Manufacturing precision
If visual inspection is performed to detect sheet defects, then lamination quality is improved, but production time is increased and productivity is reduced
Solution Approach 1:
The reading section automatically inspects the sheet for defects and misregistration by reading mark images and image surfaces, replacing manual visual inspection with automated optical detection that operates continuously without slowing production
Solution Approach 2:
The reading section performs continuous automatic inspection of mark images and image surfaces during sheet conveyance, allowing defect detection to occur without interrupting the lamination process or requiring separate inspection steps
3Manufacturing precision
If mark image is printed for position adjustment, then image position accuracy is improved, but printing load is increased and printing quality is deteriorated
Solution Approach 1:
The patent extracts the position detection function from the main image printing process by using separate mark images that are printed with minimal impact on the primary printing load, allowing position correction without compromising main image quality
Solution Approach 2:
The system uses mark images as simplified copies or references for position detection, rather than printing the full high-quality image multiple times for alignment, reducing printing load while maintaining position accuracy
4Reliability
If manual adjustment is performed to prevent lamination errors, then lamination reliability is improved, but operation complexity is increased
Solution Approach 1:
The system performs automatic self-inspection and self-correction by detecting sheet curl and misregistration through mark images, then automatically applying position corrections without requiring operator intervention or manual adjustment procedures
Solution Approach 2:
The reading section provides real-time feedback on sheet position and curl by reading mark images, and the control section uses this feedback to automatically adjust lamination positioning, creating a closed-loop control system that improves reliability without increasing operational complexity
Data Source
AI summary
An image processing system includes a reader that reads an image surface of a flat cut sheet on which an image is formed; and a laminator that is arranged on the downstream side of the reader in a conveyance direction of the flat cut sheet and laminates an image surface of the flat cut sheet.