Electronic patterning with registration control

• US 4,401,024 A
• Filed: 04/07/1982
• Issued: 08/30/1983
• Est. Priority Date: 04/07/1982
• Status: Expired due to Fees

• Current Assignee: Milliken Research Corporation
• Original Assignee: Milliken Research Corporation
• Inventors: Frentress, Zane
• Primary Examiner(s): Coven, Edward M.
• Assistant Examiner(s): Weresh, John A.
• Application Number:
  US06/366,119
• Time in Patent Office: 510 Days
• Field of Search: 346/140 PD, 346/153.1, 346/157, 101/1, 101/DIG. 13, 101/181, 101/248, 101/193
• US Class Current: 101/93.01
• CPC Class Codes: H04N 1/506 Reproducing the colour component signals picture-sequentially, e.g. with reproducing heads spaced apart from one another in the subscanning direction
• CPC Class Codes: Y10S 101/37 Printing employing electrostatic force

Abstract

Method and apparatus for establishing and maintaining pattern registration control in a printing system which prints an image on a relatively moving substrate. Portions of the overall image are electronically generated and printed in row-by-row (e.g. scanned) fashion at respective print stations positioned along the path of the substrate. Registration control is achieved with the aid of index markings spaced along the length of the substrate.

Claims

1. A method for maintaining correct registration in a printing system having a plurality of print application stations for printing a pattern on a relatively moving substrate wherein the desired image is a composite made from the superposition of a plurality of constituent images, each constituent image being formed as a plurality of closely spaced pattern rows and wherein each constituent image is printed in row-by-row fashion at a respective print application station spaced along the path of the substrate, said method comprising:

(a) supplying a quantity of substrate to be printed having a plurality of reference marks fixed at intervals along the substrate in the direction of substrate movement;

(b) applying, at an initial print application station and at a pre-determined print gauge, a number of consecutive pattern rows within a substrate length defined by a first and a second of said plurality of reference marks, said second mark being preceded by said first mark;

(c) measuring said substrate length at said initial print application station;

(d) measuring said substrate length at a subsequent print application station following said initial station;

(e) comparing the results of said substrate measurements at said initial and said subsequent print stations, thereby determining any change in substrate length, as measured at said initial and subsequent print stations, between said first and said second reference marks along the direction of substrate relative movement;

(f) adjusting said pre-determined print gauge for use at said subsequent print application station to permit the number of pattern rows applied between said first and said second marks at said subsequent print application station to equal the number of pattern rows applied between said first and said second reference marks at said initial print application station.

2. The method for registration control as recited in claim 1, said method further comprising:

(a) assigning, at said initial print application station, a number in continuing sequence to each consecutive pattern row entering said first station;

(b) identifying, at said initial print application station, a first numbered pattern row immediately preceding said first reference mark;

(c) assigning, at said subsequent print application station, a number in continuing sequence to each consecutive pattern row entering said subsequent station;

(d) identifying, at said subsequent print application station, a second numbered pattern row immediately preceding said first reference mark;

(e) comparing, at said subsequent print application station, said sequential number assigned at said initial print application station with said sequential number assigned at said subsequent print application station;

(f) adjusting said pre-determined print gauge at said subsequent print application station to cause said sequential number assigned to the pattern row identified with the second reference mark at said subsequent print application station to equal the sequential number similarly assigned to the pattern row similarly identified with the second reference mark at said initial application station.

3. The method for registration control as recited in claim 2, said method further comprising:

(a) associating, at said initial print application station, a first associated pattern row applied to said substrate with said first reference mark;

(b) associating, at said subsequent print application station, a second associated pattern row applied to said substrate with said first reference mark, the sequential relationship between said reference mark and its associated pattern row at each of said print application stations being held constant;

(c) measuring a first distance at said initial print application station between said first reference mark and said first associated pattern row;

(d) measuring a second distance at a subsequent print application station between said first reference mark and said second associated pattern row;

(e) determining a distance difference between said first distance and said second distance;

(f) adjusting said print gauge at said subsequent print application station to reduce said difference.

4. The method of claim 3 wherein said first and second associated pattern rows are respectively equal to said first and second numbered pattern rows.

5. The method for registration control as recited in claim 2, said method further comprising:

(a) measuring a first distance at said initial print application station between a first reference mark and a pattern row adjacent to said first reference mark;

(b) measuring a second distance at a subsequent print application station between said first reference mark and said pattern row;

(c) determining a distance difference between said first distance and said second distance;

(d) adjusting the spacing of pattern rows to be printed at said subsequent station to reduce said difference.

6. A method for printing a series of pattern rows on a moving substrate in proper registration, for use with printers having at least two print stations, said method comprising the steps of:

(a) supplying a substrate in sequence to an initial print station and then to a subsequent print station;

(b) identifying, at said initial print station, a substrate interval of known length extending in the direction of substrate travel;

(c) printing, at said initial print station, a predetermined number of pattern rows at a fixed print gauge, which pattern rows collectively span the length of said substrate interval;

(d) measuring, prior to printing at a subsequent print station, a change in length of said substrate interval;

(e) adjusting said print gauge in accordance with the measured change in interval length, to allow said predetermined number of pattern rows to be printed at said subsequent print station to span collectively the changed length of said substrate interval;

(f) printing, at said subsequent print station, said pre-determined number of pattern rows on said substrate interval at said adjusted print gauge.

7. The method of claim 6 wherein said pattern rows printed at said subsequent print station are uniformly spaced within the substrate interval.

8. A method for multi-station electronic patterning, with registration control, of a relatively moving substrate in row-by-row fashion, said method comprising the steps of:

(a) supplying a length of uncharged substrate to be patterned, said substrate carrying a barrier layer on a surface of said substrate, said substrate further carrying a plurality of reference marks fixed at intervals along said length of said substrate in the direction of substrate movement;

(b) applying, at an initial print application station and a pre-determined gauge, a number of pattern rows within a substrate interval defined by a first and a second of said plurality of reference marks, said second mark being preceded by said first mark, by

(1) providing a marking material which is substantially immiscible with said barrier layer,

(2) displacing, in row-by-row fashion, said barrier layer on said substrate surface within said substrate interval according to patterning information directed to said initial print application station;

(3) permitting said marking material to contact said substrate surface where said barrier layer has been displaced, thereby patterning said substrate;

(c) measuring the length of said substrate interval at said initial print application station;

(d) measuring the length of said substrate interval at a subsequent print application station;

(e) comparing the results of said measurements at said initial and said subsequent print stations, thereby determining any significant change in substrate dimension, as measured at said initial and subsequent print stations, between said first and said second reference marks along the direction of substrate movement;

(f) determining a new print gauge for use at said subsequent print application station to permit the number of pattern rows applied within said substrate interval at said subsequent print application station to equal the number of pattern rows applied within said substrate interval at said initial print application station;

(g) applying, at said subsequent print application station, at said new print gauge, said number of consecutive pattern rows within said substrate length as measured at said subsequent print station, by

(1) applying a new barrier layer to said substrate surface carrying print rows previously applied at said initial print application station;

(2) providing a marking material substantially immiscible with said new barrier layer;

(3) displacing, in row-by-row fashion, said new barrier layer according to patterning information directed to said subsequent print application station;

(4) permitting said marking material to contact said substrate surface where said new barrier layer has been displaced, thereby patterning said substrate in registration with patterning applied at said initial print station.

9. An apparatus for maintaining correct registration in a printing system having a plurality of print application stations for printing a pattern on a relatively moving substrate wherein the desired image is a composite made from the superposition of a plurality of constituent images, each constituent image being formed as a plurality of closely spaced pattern rows and wherein each constituent image is printed in row-by-row fashion at a respective print application station spaced along the path of the substrate, said apparatus comprising:

(a) an initial and a subsequent print application station;

(b) means for supplying a quantity of substrate to be printed, said substrate having a plurality of reference marks fixed at intervals along the substrate in the direction of substrate movement;

(c) means for applying, at said initial print application station and at a pre-determined print gauge, a number of consecutive pattern rows within a substrate length defined by a first and a second of said plurality of reference marks, said second mark being preceded by said first mark;

(d) means for measuring said substrate length at said initial print application station;

(e) means for measuring said substrate length at said subsequent print application station following said initial station;

(f) means for comparing the results of said substrate measurements at said initial and said subsequent print stations, thereby determining any change in substrate length, as measured at said initial and subsequent print stations, between said first and said second reference marks along the direction of substrate relative movement;

(g) means for adjusting said pre-determined print gauge for use at said subsequent print application station to permit the number of pattern rows applied between said first and said second marks at said subsequent print application station to equal the number of pattern rows applied between said first and said second reference marks at said initial print application station.

10. The apparatus for registration control as recited in claim 9, said apparatus further comprising:

(a) means for assigning, at said initial print application station, a number in continuing sequence to each consecutive pattern row entering said first station;

(b) means for identifying, at said initial print application station, a first numbered pattern row immediately preceding said first reference mark;

(c) means for assigning, at said subsequent print application station, a number in continuing sequence to each consecutive pattern row entering said subsequent station;

(d) means for identifying, at said subsequent print application station, a second numbered pattern row immediately preceding said first reference mark;

(e) means for comparing, at said subsequent print application station, said sequential number assigned at said initial print application station with said sequential number assigned at said subsequent print application station;

(f) means for adjusting said pre-determined print gauge at said subsequent print application station to cause said sequential number assigned to the pattern row identified with the second reference mark at said subsequent print application station to equal the sequential number similarly assigned to the pattern row similarly identified with the second reference mark at said initial application station.

11. The apparatus for registration control as recited in claim 10, said apparatus further comprising:

(a) means for associating, at said initial print application station, a first associated pattern row applied to said substrate with said first reference mark;

(b) means for associating, at said subsequent print application station, a second associated pattern row applied to said substrate with said first reference mark, the sequential relationship between said reference mark and its associated pattern row at each of said print application stations being held constant;

(c) means for measuring a first distance at said initial print application station between said first reference mark and said first associated pattern row;

(d) means for measuring a second distance at a subsequent print application station between said first reference mark and said second associated pattern row;

(e) means for determining a distance difference between said first distance and said second distance;

(f) means for adjusting said print gauge at said subsequent print application station to reduce said difference.

12. The apparatus for registration control as recited in claim 10, said apparatus further comprising:

(a) means for measuring a first distance at the initial print application station between a first reference mark and a pattern row adjacent to said first reference mark;

(b) means for measuring a second distance at a subsequent print application station between said first reference mark and said pattern row;

(c) means for determining a distance difference between said first distance and said second distance;

(d) means for adjusting the spacing of pattern rows to be printed at said subsequent station to reduce said difference.

13. An apparatus for printing a series of pattern rows on a moving substrate in proper registration, for use with printers having at least two print stations, said apparatus comprising:

(a) an initial and a subsequent print station;

(b) means for supplying a substrate to said initial print station and then to said subsequent print station;

(c) means for identifying, at said initial print station, a substrate interval of known length extending in the direction of substrate travel;

(d) means for printing, at said initial print station, a predetermined number of pattern rows at a fixed print gauge, which pattern rows collectively span the length of said substrate interval;

(e) means for measuring, prior to printing at a subsequent print station, a change in length of said substrate interval;

(f) means for adjusting said print gauge in accordance with the measured change in interval length, to allow said predetermined number of pattern rows to be printed at said subsequent print station to span collectively the changed length of said substrate interval;

(g) means for printing, at said subsequent print station, said predetermined number of pattern rows on said substrate interval at said adjusted print gauge.