Vector-Based Printing Plate Patch Segmentation
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Solution Overview
Problem
The existing process for creating printing plates for large corrugated cardboard boxes is inefficient due to the high thickness of polymer flexo printing plates, leading to significant waste and high costs, as well as the time-consuming analysis of bitmap image formats which often includes spurious data.
Innovation Solution
A method and system that utilize vector format image files to identify and separate image patches with precise boundary coordinates, allowing for automatic creation and placement of patches on a substrate, reducing waste and processing time by using raster image processing and register marks to optimize plate material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If bitmap format images are used for plate creation, then image information can be processed, but processing time increases significantly and spurious data remains in the image
Solution Approach 1:
The patent uses vector format images as a copy representation of the actual image data, allowing the system to work with simplified geometric representations (paths, curves, shapes) rather than processing every pixel in the bitmap. This copying approach enables faster processing while maintaining image information integrity.
Solution Approach 2:
The patent extracts only the essential image information (image areas, boundaries, and content) from the full bitmap data by using vector format. This extraction removes spurious data and unnecessary pixel information, leaving only the critical elements needed for plate creation, thus reducing processing time.
2Reliability
If full-size polymer plates are used for corrugated boxes, then complete image coverage is achieved, but polymer material waste increases significantly
Solution Approach 1:
The patent segments the full-size polymer plate into multiple smaller patches, each containing specific image information. These patches are then separated and mounted onto the carrier substrate only where needed, rather than using a single full-size plate. This segmentation dramatically reduces the amount of polymer material required while maintaining complete image coverage.
Solution Approach 2:
The patent merges multiple image patches from different locations on the polymer plate onto a single carrier substrate in the correct positions. This combining approach allows efficient use of the substrate space and reduces the total polymer material needed compared to using separate full-size plates for each image area.
3Loss of information
If patches are manually analyzed and processed from bitmap images, then image information can be extracted, but the process becomes time-consuming and resource-intensive
Solution Approach 1:
The patent replaces manual mechanical analysis of bitmap images with automated computer processing of vector format data. The system automatically extracts image information, identifies boundaries, and processes patches without human intervention, dramatically improving efficiency while maintaining accuracy through algorithmic processing.
4Loss of time
If vector format images are used instead of bitmap, then processing time is reduced and spurious data is eliminated, but additional software complexity is required
Solution Approach 1:
The patent changes the fundamental parameter of image data representation from bitmap (pixel-based) to vector format (geometry-based). This parameter change transforms the processing approach, allowing the system to work with mathematical descriptions of shapes and lines rather than grids of pixels, thereby reducing processing time and eliminating spurious data.
Data Source
AI summary
A method and system for creating a printing plate from a vector format image file having image and non-image areas. A boundary in vector coordinates is identified via a user interface that defines each image area corresponding to an image patch. The image file is raster image processed (RIPped) to create RIPped image information associated with the vector coordinates corresponding to the image patches. The RIPped image information and associated vector coordinates are processed to create RIPped image patches, register marks attached to each RIPped image patch, and the RIPped image patches with register marks and corresponding vector coordinates stored in a processing file. The system includes a computer memory, an interface for providing the image file, a user interface, and a computer processor configured to perform the method.