Electrical Connector Indicia With Dark Background for Reliable Scanning
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Solution Overview
Problem
Existing labeling solutions for high voltage electrical connectors face challenges in providing sufficient contrast for accurate scanning by digital scanners, especially due to variations in orange color shades and harsh environments.
Innovation Solution
A method involving laser printing of machine-readable indicia onto electrical connectors, where a darker background is printed around the indicia, providing a consistent contrast ratio of at least 20% to ensure accurate reading by digital scanners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive labels are used for marking electrical connectors, then the marking can be applied easily, but the labels can peel off over time in harsh environments
Solution Approach 1:
The patent replaces adhesive mechanical bonding with laser-based marking that creates permanent marks through material modification. The laser process directly etches or alters the surface of the connector housing, eliminating the need for adhesive labels that can peel off, thereby solving the durability issue while maintaining ease of application through automated marking processes.
2Reliability
If embossed markings are used on the connector surface, then the markings are permanent, but they do not provide sufficient contrast for accurate scanning
Solution Approach 1:
The patent employs color contrast by marking the indicia in a color that differs significantly from the orange connector housing. The system selects marking colors that provide adequate contrast against the varying shades of orange, ensuring that digital scanners can accurately read the markings. This resolves the contradiction by maintaining permanence through laser marking while adding color differentiation for scanning accuracy.
Solution Approach 2:
The patent modifies the optical parameters of the marking by controlling the laser process to create indicia with specific color properties. By adjusting marking parameters such as laser power, speed, and material interaction, the system produces marks with optimal contrast characteristics that enhance scanning accuracy while maintaining permanence.
3Reliability
If laser etching is used to create machine-readable indicia, then the markings are permanent, but they lack sufficient contrast between the indicia and the surface
Solution Approach 1:
The patent transitions from monochromatic laser etching to a system that produces multi-color or high-contrast markings. The laser process is controlled to create indicia with color properties that provide sufficient contrast against the orange housing, ensuring both permanence and scanning accuracy. This may involve selective material removal, deposition, or alteration that creates visible color differentiation.
4Ease of manufacture
If standard digital scanners are used with varying orange connector shades, then manufacturing costs are reduced, but the scanners cannot accurately read markings on all orange colored connectors
Solution Approach 1:
The patent optimizes the marking parameters to ensure consistent readability across varying orange shades. By controlling the contrast ratio between the indicia and the background to be at least 20%, the system ensures that standard digital scanners can accurately read markings regardless of the specific orange shade used in manufacturing, thereby maintaining both cost-effectiveness and reading accuracy.
5Measurement precision
If higher-cost digital scanners capable of resolving wider contrast ranges are used, then reading accuracy on all orange connectors is improved, but manufacturing costs increase
Solution Approach 1:
The patent optimizes the marking contrast parameters to fall within the readable range of standard, lower-cost digital scanners. By ensuring a minimum contrast ratio of 20% between the indicia and the orange background, the system makes accurate reading possible with conventional scanners, eliminating the need for expensive high-contrast resolution scanners while maintaining reading accuracy.
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
This solution ensures reliable and efficient data capture by eliminating the need for higher-cost digital scanners and reducing material waste, while maintaining readability across various lighting conditions and connector shades.
Implementation Method 1
printing a background onto a surface of a product using a laser printing method and printing machine readable indicia onto the background using the laser printing method
Data Source
Figure 1~2
Figure 3
AI summary
The present disclosure presents an electrical connector comprising a connector housing (100) with machine-readable indicia (102) printed on its surface. The indicia (102) is bordered by a darker background (104) on the surface, ensuring ample contrast for accurate reading by a digital scanner. This innovative design enhances the readability and reliability of the indicia (102), facilitating efficient data capture and identification processes.