Laser-Etched 2D Codes With Shorter Marking Paths
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Solution Overview
Problem
Current laser etching methods for creating machine-readable codes on plastic bottles are time-consuming due to the extensive distance a laser must travel to mark multiple locations, especially when producing thousands of identical bottles with unique identifiers.
Innovation Solution
The use of sub-optimal 2D codes that reduce the distance a laser must travel by selecting inferior mark locations, clustering marks, and employing two lasers to etch different regions simultaneously, along with optimizing mark paths using algorithms like the Lin-Kernighan algorithm and swath-based mark selection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an ideal 2D code pattern is used to ensure high fidelity and accuracy, then the code reliability is improved, but the laser travel distance increases significantly, reducing marking speed
Solution Approach 1:
The patent applies partial action by selecting only a subset of mark locations that are most critical for code recognition, rather than marking all ideal locations. The system determines minimum necessary mark density and strategic positioning to maintain readability while reducing total mark count, thereby decreasing laser travel distance and marking time while preserving code reliability
Solution Approach 2:
The patent extracts and removes non-essential marks from the ideal code pattern. By analyzing which marks are critical for code decoding and which can be omitted, the system creates a simplified mark set that maintains functionality with reduced laser travel requirements
2Productivity
If mark locations are selected to minimize laser travel distance, then marking speed is improved, but the code pattern fidelity deteriorates
Solution Approach 1:
The patent applies local quality by varying mark selection criteria based on local code structure requirements. Different regions of the code receive different treatment - critical areas maintain high fidelity with precisely placed marks, while less critical areas use simplified mark patterns, optimizing the balance between overall code reliability and marking efficiency
Solution Approach 2:
The patent changes parameters such as mark size, mark density, and inter-mark spacing to optimize the balance between code fidelity and marking speed. By adjusting these parameters based on code requirements and laser capabilities, the system achieves acceptable code quality with reduced laser travel distance
3Device complexity
If a single laser is used to etch the entire code, then device complexity is reduced, but the marking time increases due to sequential processing
Solution Approach 1:
The patent segments the code marking task into multiple independent regions that can be processed simultaneously. By dividing the code into zones with different mark density requirements, the system can use multiple lasers to work in parallel on different segments, dramatically reducing total marking time while keeping each laser's control relatively simple
Solution Approach 2:
The patent merges multiple laser systems to work simultaneously on different portions of the same code. By coordinating multiple lasers under a unified control system, the system achieves parallel processing capability that reduces marking time while distributing the complexity across multiple independent laser units
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 approach significantly speeds up the laser etching process by reducing the path length and increasing efficiency, allowing for faster marking of large numbers of bottles while maintaining the functionality of the machine-readable codes.
Implementation Method 1
Laser etching can be used to mark a bottle with such an identifier. This typically involves a 9.3 μm carbon dioxide laser whose beam is steered by a pair of mirrors
Data Source
AI summary
A surface is laser-etched to convey a 2D machine-readable code pattern. Various strategies are detailed to minimize the etching time. Some strategies include modifying the code pattern to reduce a path length traveled by the laser. Some strategies include modifying the code pattern to make it sub-optimal, i.e., making the code pattern a less-faithful approximation of an ideal code pattern. In some embodiments the etched surface is the surface of a plastic container, and the code pattern conveys information indicating the type of plastic of which the container is manufactured. A variety of other features and arrangements are also detailed.