IR-Reflective Ink Coatings for Near-Infrared Component Detection
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Solution Overview
Problem
Existing automated assembly systems face challenges in accurately placing small components due to difficulties in differentiating between similar objects in the visible light spectrum, particularly with black pressure sensitive adhesive tapes, and there is a lack of non-azo based inks suitable for high image contrast in the near-infrared light range.
Innovation Solution
Development of near-infrared reflective inks comprising inorganic black and colored pigments that reflect near-infrared light, applied as thin coatings or tapes, which can be differentiated by optical systems using near-infrared light, enabling precise component placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visible light optical systems are used to differentiate between black components and backgrounds, then the system can detect visual contrasts, but it fails to differentiate between similar black objects and backgrounds
Solution Approach 1:
The patent changes the detection parameter from visible light wavelength to near-infrared wavelength. By using inorganic pigments that reflect near-infrared light, the system creates a new detection dimension where black components have distinct optical properties from black backgrounds, enabling reliable differentiation and edge definition in automated assembly operations.
2Manufacturing precision
If optical guides or cues are placed onto substrates to aid robotic positioning, then component alignment improves, but the tape thickness must be extremely small (few microns or less)
Solution Approach 1:
The patent applies near-infrared reflective inorganic pigments to the tape surface, creating an optical cue that changes the tape's optical properties in the near-infrared spectrum. This allows the tape to provide detection contrast for robotic positioning while maintaining extremely thin thickness (5-20 microns), as the optical functionality is achieved through pigment properties rather than thickness.
3Illumination intensity
If conventional black inks are used for printing, then visible appearance is achieved, but high image contrast in near-infrared light range cannot be obtained
Solution Approach 1:
The patent uses composite inorganic pigments containing multiple metal oxides (such as chromium oxide, cobalt aluminate, manganese titanate) that are inherently reflective in the near-infrared spectrum. These composite pigments maintain visible black appearance while providing high near-infrared reflectivity, enabling both aesthetic requirements and optical detection requirements to be satisfied simultaneously.
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 near-infrared reflective inks and tapes provide high image contrast and accurate component alignment, reducing defects in assembly processes by allowing optical systems to distinguish between components and backgrounds in the near-infrared range, even at very thin thicknesses.
Implementation Method 1
near-infrared reflective inks comprising inorganic black and colored pigments that reflect near-infrared light
Data Source
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AI summary
The present application is drawn to infrared reflective ink formulations, infrared reflective dried coatings prepared from such inks, and IR-reflective substrates and adhesive tapes prepared from such inks and coatings. The inks are suitable for printing by gravure or flexo methods onto polymeric substrates such as PET, paper, or other substrate materials. The coatings are reflective in the near-infrared range. The coatings and tapes are well suited for use in manufacturing methods. The coatings and/or the tapes are ultrathin, on the order of a few micrometers, making them attractive for use in different industrial applications.