Compact DPM Illuminator with Dome Diffuser and Reflective Sleeve
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Solution Overview
Problem
Conventional DPM scanners face challenges with bulky and power-hungry illuminator assemblies, high specular reflection hot spots, and inefficiencies in scanning high-density 2D codes on smooth substrates, limiting their compactness and handheld usability.
Innovation Solution
A compact DPM illuminator with dual-field, multi-color, multi-directional, and multi-distance capabilities, utilizing a front edge illuminator with customized LED optics, a dome diffuser, and a reflective sleeve, along with a printed circuit board assembly featuring six color LEDs for dark field and four white/blue LEDs for bright field illumination, effectively eliminating specular reflection hot spots and reducing power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If large amounts of LEDs and complicated multi-piece optical systems are employed to satisfy DPM scanning requirements, then illumination coverage and scanning capability are improved, but device size becomes bulky and power consumption increases
Solution Approach 1:
The patent combines multiple illumination functions (dark field, bright field, color, broad spectrum, single and multi-direction, near and far distance) into a single integrated illuminator assembly. This merging of previously separate optical components and LED arrays into one compact unit achieves full DPM scanning capability while dramatically reducing device volume and eliminating the need for bulky multi-piece optical systems
Solution Approach 2:
The illuminator assembly is designed to perform multiple illumination functions simultaneously using a unified structure. A single LED array with carefully designed optics provides dark field, bright field, color, broad spectrum, single and multi-direction, and near/far distance illumination capabilities, making the device universal for all DPM scanning requirements without needing separate specialized components
2Illumination intensity
If large amounts of LEDs are employed to provide adequate illumination, then illumination intensity is improved, but power consumption increases and light efficiency decreases
Solution Approach 1:
The patent optimizes illumination efficiency by changing key parameters: using a minimal number of LEDs (4-6) with enhanced optical design, adjusting LED wavelength selection (violet, blue, white), modifying optical path geometry, and tuning the arrangement of diffusers and reflectors. These parameter changes enable adequate illumination intensity with dramatically reduced power consumption compared to conventional arrays of many LEDs
3Device complexity
If conventional single-point illumination is used, then device structure is simple, but specular reflection hot spots appear on smooth or laminated substrates
Solution Approach 1:
The patent segments the illumination source into multiple spatially separated LED emitters arranged in specific patterns. This segmentation of the light source, combined with multiple diffusers and reflectors, creates multiple illumination angles that distribute reflected light evenly, eliminating the concentrated hot spots caused by single-point illumination while maintaining relatively simple device structure
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides efficient, compact, and low-power illumination for DPM scanners, enabling effective scanning of high-density codes with reduced energy consumption and improved manufacturability, while preventing specular reflection hot spots.
Implementation Method 1
a dome diffuser, an LED assembly, and a reflective sleeve at least partially surrounding the dome diffuser
Implementation Method 2
a reflective sleeve at least partially surrounding the dome diffuser
Implementation Method 3
front edge illuminator with customized LED optics
Data Source
Figure 1A~1B
Figure 1C
Figure 2A~2B
AI summary
A compact illuminator for a direct part marking (DPM) scanner is provided to perform dual-field, multi-color, multidirectional, multi-distance illumination functions. The illuminator can selectively provide dark field and bright field illumination with broad spectrum white or narrow band color, in combination with directions for near contact distance as well as far distance barcode readings. Specifically, illuminator includes a front edge illuminator with customized LED optics, a dome diffuser, an LED board assembly, and a reflective sleeve surrounding the dome diffuser. The board assembly can further include an alternative on/off plural point source bright field spot illuminating system. A method for scanning DPM indicia focuses on generating illumination light using an illumination assembly, illuminating the DPM indicia, detecting reflected and/or scattered light, and capturing under different illumination conditions and combining at least two consecutive images of the DPM indicia, followed by processing and decoding the obtained image.