Abstract:
A method and system automatically and dynamically updates the design of perforation lines in a package design file. It identifies an edge between two facets to which a perforation line is to be applied, determines a length of the edge, and uses the length of the edge and a default cut segment length to determine a number of cut segments that will be included in the perforation line. The method and system also may determine a phasing for the perforation line to ensure that the ends of the line are either a cut or spacer, depending on the desired function or placement of the line.

Description:
BACKGROUND 
       [0001]    When selecting a package for a product that is to be sold or shipped, product manufacturers and sellers typically must select a package from a specific inventory of available package sizes and shapes. However, this may result in a package that is not entirely suitable for the product. For example, when using a package that is larger than the product requires, additional packaging material may be needed to avoid damage to the product during handling. In addition, a larger package can require increased shipping and handling costs. Thus, there has been significant interest in the manufacture of personalized packaging for small volume applications. 
         [0002]    When creating a three-dimensional package, a set of cut lines and crease lines will be imparted upon a substrate to yield a package flat that may be folded into a three-dimensional package. In the personalized packaging situation, the dimensions and/or positions of such lines will need to vary from package to package. However, current systems do not have the capability to produce packages with sufficient variability to avoid issues with improperly sized and/or positioned cut and fold lines. 
         [0003]    This document describes systems and methods that present solutions to the problems discussed above, and which may also provide additional benefits. 
       SUMMARY 
       [0004]    In an embodiment, a system accesses a package design file comprising a two-dimensional representation of a three-dimensional structure. The three-dimensional structure has multiple facets. The system identifies an edge between two facets to which a perforation line is to be applied. The perforation line includes cut segments and spacers. The system determines a length of the edge, and it uses the length of the edge and a default cut segment length to determine a number of cut segments that will be included in the perforation line. If the number is not an integer, the system determines an integer number of cut segments by rounding the number up or down, setting the number of cut segments to equal the integer number, and determining a revised cut segment length based on the number of cut segments and the edge length. The system them updates the package design file to include data indicating that the perforation line will include the integer number of cut segments. 
         [0005]    In some embodiments, when determining the revised cut segment length comprises, the system will use a processor to determine that the integer number of cut segments at the default cut segment length will result in a perforation line length that exceeds the length of the edge. If so, it may implement a reduction process comprising reducing the cut segment length of at least one of the cut segments, a length of at least one of the spacers, or both. 
         [0006]    In some embodiments the reduction process may include determining that a minimum length must be preserved for a spacer that is positioned at an end of the perforation line, and if so the system may limit reduction of the length of the spacer that is positioned at the end to the minimum length, while reducing the length of at least one other spacer in the line to a length that is below the minimum length. 
         [0007]    In some embodiments, the reduction process may include determining that a minimum length must be preserved for a cut segment that is positioned at an end of the perforation line, and if so the system may limit reduction of the length of the cut segment that is positioned at the end to the minimum length, while reducing the length of at least one other cut segment to a length that is below the minimum length. 
         [0008]    In some embodiments, determining the number of cut segments to include the perforation line comprises determining whether the edge will be a crease, and if so setting the number of cut segments as an even number. In other embodiments, determining the number of cut segments to include in the perforation line comprises determining whether the edge will be a separation line, and if so setting the number of cut segments as an odd number. 
         [0009]    In some embodiments, if the system determines that a first end of the perforation line will be adjacent to another edge in the three-dimensional structure, it may ensure that a phasing of the perforation line is such that the first end will be a spacer and not a cut segment. In additional embodiments, the system may determine a length of the edge, determine an aspect ratio of cut segment length to spacer length based on the length of the edge, and assign lengths to the cut segments and spacers in the perforation line based on the aspect ratio. 
         [0010]    Any or all of the items listed above may be implemented by a package definition system that includes a data storage facility, a processor, and a computer-readable medium containing programming instructions that, when executed, instruct the processor to perform various functions. Optionally, the system also may include a user interface and/or a package generation device. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1  depicts an example of a two-dimensional package flat. 
           [0012]      FIG. 2  depicts examples of substrates that contain a crease line, a “kiss cut” line, and a perforation cut line. 
           [0013]      FIG. 3  is an illustration showing different types of phasing that may be used in perforation lines. 
           [0014]      FIG. 4  is a flowchart illustrating various steps in a process for determining how to implement a perforation cut to a substrate. 
           [0015]      FIG. 5  illustrates an example of how perforation cut segments and sizes may be established in an embodiment. 
           [0016]      FIG. 6  is a diagram showing how various types of perforation cut lines and crease lines may intersect on a substrate. 
           [0017]      FIG. 7  is a diagram showing how additional types of perforation cut lines may intersect on a substrate. 
           [0018]      FIG. 8  is a block diagram showing various equipment that may be used to implement various embodiments of the processes described in this document. 
       
    
    
     DETAILED DESCRIPTION 
       [0019]    This disclosure is not limited to the particular systems, devices and methods described, as these may vary. The terminology used in the description is for the purpose of describing the particular versions or embodiments only, and is not intended to limit the scope. 
         [0020]    As used in this document, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used in this document have the same meanings as commonly understood by one of ordinary skill in the art. As used in this document, the term “comprising” means “including, but not limited to.” 
         [0021]    As used in this document, the term “multi-functional device” refers to a machine or group of machines comprising hardware and associated software for printing, copying, facsimile transmitting or receiving, scanning, or performing other actions on document-based data. A “print device” is a device that performs printing based on digital data, or a multi-functional device in which one of the functions is printing based on digital data. A “package generation system” is a machine or group of machines that combines the features of a print device with one or more tools for imparting a cut, crease, and/or perforation on a printed substrate so that the substrate may be folded into a three-dimensional package, or other folds or structures. 
         [0022]    Package production may be performed by a package generation system that is capable of performing printing operations on, and applying creases and cuts to, a substrate. The system also may perform other actions such as coating and/or stacking the substrate. Examples of automated package production systems include those in the iGen® series of digital production printing presses, available from Xerox Corporation, in connection with corresponding finishing devices. Other systems may include smaller printing devices, such as a Xerox DocuColor® 250, or a digital cutter as offered by a variety of manufacturers. 
         [0023]    One aspect in the creation of a package is that the printing device operates on a two dimensional sheet or “flat.” The actual three-dimensional shape of the package is subsequently created by folding and connecting the facets that make up the flat. Here it is understood that various types of folds may create a three-dimensional structure or shape in the language of this application. This imposes a variety of restrictions on the structure both in its two dimensional form, as well as in its three dimensional form. The substrate is typically a paper material, such as cardstock, cardboard, or paper having sufficient thickness to provide structural support when folded into a three-dimensional shape. 
         [0024]      FIG. 1  shows an example of a package flat  10  that may be formed into a three-dimensional package. This package flat  10 , in this case a rectangular box, includes a variety of faces  11 - 16 . Faces  11 - 14  may be considered sides, while faces  15  and  16  may be considered to be the top and bottom lids of the package. Each of the faces may be considered to be an exterior-facing facet, or a structural element of the final package Facets also may include various functional elements that provide a connecting or other structural function for other elements of the package. Functional elements may include folds, lids, lips, tabs, flaps, receptacles, or other structures that either extend into or are received by a face or a corresponding functional element. Examples shown in  FIG. 1  include flaps  18 ,  20  and  21 , along with locking tabs  23 ,  24  and a corresponding lip  18  with slots  24 ,  25  that receive the tabs when the package is folded. 
         [0025]    The outer edges of the package are cut from a substrate, while various cut lines and/or crease lines may be imparted on the substrate within the outer edges of the package to distinguish the various facets and allow the facets to be folded into a three dimensional shape. Examples include a crease line  29  that will enable flap  21  to be folded toward face  16 , a crease line  28  that will serve to form a fold line that will enable flap  20  to be folded toward face  15 . These creases might be implemented in a variety of different ways as a function of hardware capability and fold properties. As shown, crease line  29  is formed as a standard crease line or kiss cut (described in more detail below), while crease line  28  is formed as a perforation line, where each perforation line includes perforation cut segments, with spacers of uncut substrate positioned between the perforation cut segments and/or the end of the perforation line. 
         [0026]      FIG. 2  illustrates examples of substrates on which different crease lines are imparted. In the side view of the first substrate  50 , a standard crease line has been imparted. When creating a standard crease line, a tool such as a roller or other item containing a dull tip is used to compress the substrate. With a standard crease line, the fibers of the substrate are compressed but largely remain intact. In the side view of the second substrate  52 , a cut line has been imparted. However, the cut does not fully extend trough the substrate. Rather, the top surface has been scored to a limited depth. A functional crease that is implemented through this type of cut line may be referred to as a score line, or “kiss cut,” and it may serve as a fold line in a substrate. A kiss cut may be imparted with a knife by subjecting the knife to a pressure that is less than that required to fully cut through the substrate. Either or both types of creases (compression vs. kiss cut) may be used, or only one may be used depending on hardware capabilities of the available equipment. 
         [0027]    In the top view of substrate  54 , another functional crease has been generated through the use of a perforation cut line. The perforation cut line consists of a line of perforation cut segments imparted on the substrate, with a portion of the substrate remaining intact between each cut. Each such intact portion may be referred to as a “spacer.” In  FIG. 2 , the perforation line applied to substrate  54  has different properties at its top and the bottom end. The top end  61  of the perforation line is a cut segment that extends to the edge of the facet, while the bottom end  63  of the perforation line does not include a cut segment that extends to the edge. If such a perforation line were used to serve as a fold line, it would promote tearing away of the two sections of the facet at the top end  61 . If such a perforation line were used to serve as a separation line, it would not allow the sections of the facet to be cleanly separated from each other at the bottom end  63 . In this document, the characteristic of a perforation line that indicates whether or not its cut segments extend to an edge of the facet (i.e., the end of the cut line) is referred to as “phasing” of the line, and the example of  FIG. 2  shows a perforation line with two different types of phasing. 
         [0028]    In certain designs, when creating a package flat, it is often desirable that a given perforation line have a single type of phasing at both of its ends. The type of phasing used (i.e., cuts at the ends, or spacer at the ends) will depend on whether the perforation line is intended to serve as a fold line or a separation line in the final package. This is conceptually shown in  FIG. 3 , where a simple example shape  201  includes three facets  202 ,  203  and  204 , with facets  202  and  203  being separated by dynamic perforation line  205  and facets  203  and  204  being separated by dynamic perforation line  206 . As can be seen from the phasing of  205  and  206 , the facet  202  is easily detachable whereas the perforation line  206  has its edges protected keeping facets  203  and  204  together. It is understood that in a real application where a facet is intended to be detached, one would also alter the aspect ratio of the perforation line, i.e.: the relative size of cut and spacer, to yield a lower physical strength. This has been omitted in  FIG. 3  for simplicity. 
         [0029]    The problem of different types of phasing in a perforation line may occur quite often in a personalized packaging system. Although a personalized packaging system may start with a template or other data that contains initial design details for a package flat, those details may change as the package size changes. This document describes a system that ensures proper phasing of a perforation line as the design details of a package flat are changed. 
         [0030]    Various parameters for construction of a package may be embodied in a package design file, which is a set of data that can be used by a package generation system to create a package flat from a substrate. The package design file may contain rules and/or parameters relating to sizes of facets; connecting relationships of pairs of facets; location, size and type of various cut lines and/or crease lines. The system may use a package generation rule set in the design file, or it may apply parameters from the file to a separate rule set, to construct a package flat from a substrate. 
         [0031]      FIG. 4  is a flowchart describing various elements of a process of dynamically determining characteristics of a perforation line for a package design file as the package&#39;s facets are modified in terms of size and/or location. Referring to  FIG. 4 , a processor accesses a package design file  301 , such as by retrieving it from a memory or receiving it via an electronic communication. The package design file contains data corresponding to a two-dimensional representation of a three-dimensional structure that has multiple facets. In other words, the three-dimensional structure is that of a package, and the two-dimensional representation includes data for creating a two-dimensional package flat that may be used to form the three-dimensional package. 
         [0032]    The system accesses the data in the file to identify an edge between two facets to which a perforation cut line is to be applied  305 . This may be done based on actual data in the file indicating that an edge is to contain such a perforation line. Alternatively, this determination may be done based on the application of one or more package design rules to data in the file or received from a user to determine that a particular edge should contain a perforation line in accordance with the rules. 
         [0033]    The system then determines the length of the edge  310 , which also may be based on actual data in the file, or it may be calculated by applying one or more package design rules to data in the file or data received from a user. The system may then determine a number of perforation cut segments that will be applied to the edge  315  as a perforation line based on the length of the edge and a default perforation cut segment length, and it may also determine whether the number is an integer  317 . This process will be described in more detail below. If the number is an integer, the system may update the package design file with data indicating that integer number of cut segments should be applied to the edge  350 . If the number is not an integer, the system may determine an integer number of perforation cut segments by rounding the determined number of cut segments up or down  319 , setting the number of perforation cut segments to equal the integer  321 , and determining a revised perforation cut segment length based on the set number of cut segments and the edge length  323 , Optionally, if the system receives an update  350  from a user or other external source that results in a modification of the package design, the process may re-start. Otherwise, the system may use the package design file to create a two-dimensional package flat or transmit a message to a package generation system for such use  360 . 
         [0034]    When determining a number of cut segments for a perforation line (step  315  above), the determination may be based on any suitable criteria. For example, for a given paper thickness, the system may have a default or preferred cut segment length (i.e., a lateral dimension for each cut segment) and spacer length (i.e., a lateral dimension for each spacer between cut segments and/or between a cut segment and the end of the cut line). The ratio between the default cut segment length and the default spacer length may be considered to be a perforation aspect ratio—i.e., a ratio of the default cut segment length to the default spacer length. As an example, if the perforation aspect ratio=1, the system may calculate a number of perforation elements N (cut segments plus spacer elements) for a particular perforation line using the following formula: 
         [0000]    
       
         
           
             N 
             = 
             
               
                 
                   ⌊ 
                   
                     L 
                     
                       
                         l 
                         c 
                       
                       + 
                       
                         l 
                         p 
                       
                     
                   
                   ⌋ 
                 
                 × 
                 2 
               
               + 
               1 
             
           
         
       
     
         [0035]    In this formula: 
         [0036]    L=length of the edge; 
         [0037]    l C =the default or preferred cut segment length, based on data in the package design file and/or the application of one or more rules to user input data; and 
         [0038]    l P =the default or preferred spacer length, based on data in the package design file and/or the application of one or more rules to user input data; 
         [0039]    If the edge is to be a fold, the number of cut segments N C =N/2 (an even number) and the number of spacer elements N P =N/2+1 (an odd number) based on the aforementioned phasing requirements. If the edge is to be a separation line then these calculations are reversed and the number of cut segments N C =N/2+1 (an odd number) while the number of spacer elements N P =N/2 (an even number). 
         [0040]    By way of example, if an edge length L is 50 mm, the default cut segment length l C  is 5 mm, the default spacer length l P  is also 5 mm, and the line is to be a crease, then using the formula above N=11, the number of cut segments N C =6 and the number of spacer elements N P =5. This results in an initial perforation line length of 55 mm, which is 5 mm more than the edge length L. Thus, the system must adjust the number and/or size of the perforation elements. 
         [0041]    In one embodiment, the system may make this adjustment by decreasing the lengths of the perforation line elements to be less than the default lengths. For example, the perforation line for a crease cut with eleven elements described above may be represented by the sequence PCPCPCPCPCP, where P=paper (or other substrate) spacer element and C=cut segment element. In one embodiment, the system may do this by dividing the edge length by the number of perforation line elements, resulting in L=(length of edge)/N, in this case 4.54 mm. Optionally, the system may make the adjustment for all elements that do not reach the end of the line, while preserving the length of the perforation elements that are positioned at the ends of the perforation line, resulting in P1 and P11=5 mm, while all other perforation elements have a length l=(L−(2×5 mm))/(N−2)=4.44 mm. 
         [0042]    Thus, before updating the package design file, the system may determine whether the length of the perforation line using the number of perforation elements (N P *l P +N C *l C ) exceeds the length of the edge  325 . If so, the system may reduce  334  the length of the cut segments, the length of the spacers, or both so that the total length of all elements does not exceed that of the edge. Optionally, when performing this function the system may determine whether the length of one or more end elements must be preserved  332 , either at a default size or at least to a minimum size. If so, it will preserve the length of those end elements to at least the minimum size while reducing the length  334  of one or more interior elements of the cut line. 
         [0043]    In some embodiments, when determining a size and number of cut segments to apply to an edge as a perforation line, the system may apply one or more rules that are based on the characteristics such as a function of the edge, length of the edge, or category of facet to which the edge is adjacent. For example, some edges may be so small that no perforation line should be applied if the default cut length and spacer lengths were applied to the edge. If so, the rule may be to apply no perforation unless the length of the edge is at least a minimum threshold value. In addition, small edges (such as those that attach a small tab to a much larger face) may require a lower aspect ratio (i.e., low ratio of cut segment length to spacer length) to maintain structural integrity. If so, edges having a length under a threshold value may receive a perforation cut line with a lower aspect ratio, while longer edges may receive a perforation line with a higher aspect ratio. As another example, if the two facets connected by an edge are intended to be a lid and a lip, then the rule may require that a perforation cut line suitable for a fold (with no cut segments reaching either end of the edge) be applied. On the other hand, if one of the two facets is intended to be a removable section, then the rule may require that a separation cut line be applied (with cut segments reaching each end of the edge). 
         [0044]    The rule set may be in any form, such as a table of rules that apply based on various characteristics of the edge and/or adjacent facets. For example, consider the following table: 
         [0000]    
       
         
               
               
               
               
               
               
               
             
           
               
                   
               
               
                 Line Length 
                 l c   
                 l p   
                 N c   
                 N P /unprotected 
                 N 
                 P 1 , P N   
               
               
                   
               
             
             
               
                 13 mm 
                 1 mm 
                 1 mm 
                 2 
                 3/1 
                 5 
                 5 mm 
               
               
                 16 mm 
                 2 mm 
                 2 mm 
                 2 
                 3/1 
                 5 
                 5 mm 
               
               
                 20 mm 
                 2 mm 
                 2 mm 
                 3 
                 4/2 
                 7 
                 5 mm 
               
               
                   
               
             
          
         
       
     
         [0045]    In this example, using (i) a default perforation cut segment length of 5 mm and (ii) a rule that the sizes of the endmost spacers (P N  P) must remain at 5 mm, the element combinations (size and number) listed in the table may result for the illustrated line (edge) length. In essence, this protects the outside of the perforation line and sets a minimum number (2) for the inside cuts. In addition, it reduces the length of each perforation cut element and unprotected (i.e., non-endmost) spacer from 5 mm to 2 mm or 1 mm, based on the length of the edge. An example of this is shown in  FIG. 5  with elements P  370 , P N    380  and lp  390  having example sizes for purpose of illustration only. 
         [0046]    In some embodiments, two crease and/or cut lines may intersect in a package flat. This is shown by way of example in  FIG. 6 , where a non-perforation crease line  401  meets a perforation line  402 . It may be desirable to avoid the result shown by this combination, as the centermost cut segment in the perforation line  402  is adjacent to the end of crease line  401 . When the package is folded, this intersection could result in structural weakness and/or an undesired opening. To avoid this, the system may adjust the perforation line  402  by dividing it into two separate cut lines  412  and  422 , each having a phasing that ensures that a spacer area (substrate) is present at the end. This ensures that the adjacent end points of each perforation line  412  and  422  are not adjacent to the end of crease  401 . In this situation, the rule set may include a hierarchy, giving priority to preserving the crease over the perforation cut. 
         [0047]    As another example,  FIG. 6  also illustrates the intersection of two perforation lines  441  and  442 . Here, the longer of the two perforation lines  442  is given priority, where it may have any phase but the shorter line  441  is forced into a phasing that ensures that a spacer area (substrate) is present at the end. 
         [0048]    Any suitable rule set may be applied, using a hierarchy, conditions based on edge type, or other criteria to determine which of the two intersecting lines is given priority, and what phasing or other adjustments are applied to the lower priority line. Another example is shown in  FIG. 7 , where three intersecting perforation cut lines  501 ,  502  and  503  each have a cut segment at the point of intersection. To avoid this result, each line may be adjusted to have a phasing that ensures that a spacer area (substrate) is present at the end point (i.e., the intersection). 
         [0049]    To create a package, the system may apply the package design file and a rule set that may include, for example, a set of cutting and/or scoring instructions that a package generating device may use to apply cut lines and/or crease lines to a substrate. The instructions may be saved to a computer readable memory such as a package generation file. The instructions may include a series of instructions to either (a) apply a cut or crease line to the substrate, or (b) move the cutting or creasing tool to a new position on the substrate without altering the substrate. The system may then use a package generation device to apply the package generation rule set by imparting cut lines and crease lines to a substrate to yield a package flat. 
         [0050]      FIG. 8  depicts a block diagram of hardware and/or electronics that may make up a package definition and/or production system. One or more communications lines  600  such as a bus or network interconnect the illustrated components and allow data and/or signals to flow between the components. Central processing unit (CPU)  605  is a processor that performs calculations and logic operations required to execute a program. Any number of processors may be available, and they may access a tangible, computer-readable memory device  603  containing programming instructions, along with a data storage facility  605  such as a database that stores the package generation templates and/or rule sets. 
         [0051]    A user interface  607  provides output to, and receives input from, a user. The user interface may include a display, audio output, a printer, or another element that provides information to a user. The user interface  607  also may include a touch-sensitive component, microphone, audio port, keyboard, mouse, touch pad, or other input mechanism that is capable of receiving user input. 
         [0052]    The system also may include a package generation device, which may include some or all of the following elements: a print device  611 ; a knife, laser or other cutting device  613 ; and a roller or other device  615  capable of imparting a crease in a substrate. 
         [0053]    The features and functions disclosed above, as well as alternatives, may be combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations or improvements may be made by those skilled in the art, each of which is also intended to be encompassed by the disclosed embodiments.