Dual-Laser Marking Alignment for Moving Plastic Containers
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Solution Overview
Problem
Laser marking on molded containers is challenging due to the need for precise alignment, as movement during engraving can lead to inaccurate markings, and materials like recycled plastics or additives may react to certain energy densities, causing poor legibility or rejection.
Innovation Solution
A system using two lasers with individually insufficient energy densities that combine to create markings by focusing their beams in an overlapping focal region, ensuring the combined energy exceeds the threshold for marking while avoiding individual interaction with the material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single laser with high energy density is used for marking, then marking speed and penetration are improved, but undesired markings on impurities and reactive materials occur
Solution Approach 1:
The patent combines two or more low-power laser beams to create a high energy density focal point. Multiple lasers operate simultaneously, with their beams converging at the same focal point on the container surface, achieving the marking effect of a high-power laser while avoiding the harmful effects on impurities and reactive materials.
Solution Approach 2:
The patent changes the energy distribution parameters by using multiple low-energy laser beams instead of one high-energy beam. The individual laser energy densities are kept below the threshold that causes undesired reactions, while the combined energy density at the focal point achieves the necessary marking effect.
2Productivity
If laser marking is performed on moving containers, then production efficiency is improved, but marking accuracy deteriorates
Solution Approach 1:
The patent employs dynamic beam tracking that follows the movement of the container. The laser beams are directed to move in coordination with the container's motion, maintaining precise focal positioning on the desired marking locations throughout the marking process.
Solution Approach 2:
The system uses feedback mechanisms to monitor container position and adjust laser beam targeting accordingly. Sensors detect the container's movement and the control system compensates in real-time to ensure accurate marking placement despite the moving target.
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
Improves marking accuracy and reduces container rejection by ensuring precise marking even when the container is moving, and prevents undesired markings on impurities or reactive materials.
Implementation Method 1
a first laser configured to emit a first beam along a first optical axis, the first beam having a first beam energy density when focused which is less than the threshold energy density; and a second laser configured to emit a second beam along a second optical axis
Implementation Method 2
the first beam energy density and the second beam energy density combined is greater than the threshold energy density sufficient to create the marking
Data Source
AI summary
A system for marking a product is provided. The system comprises: a first laser configured to emit a first beam along a first optical axis, the first beam having a first beam energy density when focused; and a second laser configured to emit a second beam along a second optical axis, the second beam having a second beam energy density when focused; and a beam modulator component configured to adjust at least one of: an angle between the first optical axis of the first beam and the second optical axis of the second beam, a first focusing distance of the first beam, and a second focusing distance of the second beam, such that the first beam energy density and the second beam energy density combined is greater than the threshold energy density sufficient to create the marking.