Laser Engraving Mold Inner Surface for Photorealistic Tire Sidewall
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Solution Overview
Problem
Existing methods for creating realistic, three-dimensional structures on the outer surface of pneumatic vehicle tires fail to effectively replicate the light absorption and reflection properties of photorealistic representations, leading to a lack of detail and realism in the designs.
Innovation Solution
A method involving a digital raster graphic with at least 256 different gray levels is used, where the local laser energy is correlated with the gray levels of the pixels to create a detailed, uneven peak and valley contrast structure on the inner surface of the vulcanization mold, allowing for a realistic and true-to-detail image reproduction on the tire's outer surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional laser engraving methods are used on the vulcanization mold, then textured surface elements can be created on the tire outer surface, but the light absorption and reflection properties are insufficient to achieve photorealistic representation
Solution Approach 1:
The patent applies local quality by varying the surface structure parameters (depth, width, spacing) of the textured elements at different locations on the tire sidewall according to a grayscale map. Each pixel's gray level determines the specific geometric properties of the corresponding textured elements, creating location-specific optical properties that reproduce the original image's light absorption and reflection characteristics photorealistically.
2Illumination intensity
If the laser engraves deeper into the mold material to increase light absorption, then darker areas are achieved, but the manufacturing complexity and time increase
Solution Approach 1:
The patent changes multiple parameters of the textured elements (depth, width, spacing between elements) rather than relying solely on depth. This allows the laser to achieve varying light absorption levels by adjusting a combination of parameters, reducing the need for excessively deep engraving while maintaining photorealistic light interaction properties.
3Manufacturing precision
If high resolution raster graphics with at least 1000x1000 pixels are used, then exceptional detail is achieved, but the data processing and engraving time increase
Solution Approach 1:
The patent segments the high-resolution image into individual pixels and processes them systematically. The grayscale value of each pixel is determined independently, and corresponding textured elements are generated for each pixel location. This segmentation allows parallel processing of different image regions and enables the use of high resolution without proportionally increasing total processing time.
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 method enables the creation of a highly detailed, realistic three-dimensional representation on the tire's surface with varying light absorption and reflection properties, enhancing the visual fidelity and recognition of the image, with a laser engraving depth of up to 0.5 mm and a roughness value that varies based on the gray levels of the raster graphic.
Implementation Method 1
the engraving is correlated with the grayscale levels of the pixels of the digital photograph in such a way that it is reproduced as an uneven, grayscale-depicting mountain and valley contrast structure on the inner surface of the molded part
Implementation Method 2
due to similarly varying light absorption and reflection properties, the representation is a particularly realistic and detailed image of the underlying 'picture'
Implementation Method 3
due to similarly varying light absorption and reflection properties
Data Source
Figure 1
Figure 2~3b
Figure 4
AI summary
The invention relates to a method for creating an engraving on the inner surface of a molded part of a vulcanization mold for a vehicle pneumatic tire based on a digital raster graphic consisting of pixels with a plurality of, in particular at least 256, different shades of gray, comprising the following steps, which are carried out successively and optionally also in parallel: scanning the digital raster graphic to determine the shade of gray of each pixel, engraving the inside of the molded part, wherein the engraving correlates with the shades of gray of the pixels of the raster graphic in such a way that it is reproduced as an uneven, gray-scale-representing peak and valley contrast structure on the inside of the molded part.