Polyhedral Embossing Tool for Low-Visibility Packaging Codes
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Solution Overview
Problem
Current methods for embossing codes onto packaging foils, particularly for tobacco and food products, face challenges in applying two-dimensional barcodes like QR codes and data-matrix codes efficiently and securely, as existing printing methods are not suitable for high-speed online production, and embossing rollers with teeth are not effective for fine structures, leading to detectability issues and mechanical stress on the foil.
Innovation Solution
An embossing tool with a male and female embossing device featuring inverse congruent polyhedral structures is used to create a combined embossing pattern that includes decorative elements and encoded information, making the codes difficult to detect by the human eye, while a reading method involving multiple light sources and image processing decodes the embossed codes effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If printing methods are used to apply barcodes onto packaging foils, then the codes can be applied with high visibility, but the method is not suitable for high-speed online production
Solution Approach 1:
The patent replaces optical printing methods with a mechanical embossing system that uses male and female embossing rollers with complementary polyhedral structures to directly imprint codes onto packaging foils during high-speed online production, eliminating the need for separate printing steps
Solution Approach 2:
The invention changes the physical state of the code application from surface printing to three-dimensional embossing, creating tactile and optical effects that enhance visibility while enabling integration into the existing embossing production line for high-speed operation
2Manufacturing precision
If embossing rollers with teeth are used to emboss codes, then the codes can be applied onto the foil, but the fine structures are not effectively created and mechanical stress is applied to the foil
Solution Approach 1:
The patent inverts the traditional embossing approach by using both male and female rollers with complementary polyhedral structures that interlock to create precise code patterns, distributing the mechanical stress evenly and preventing foil damage while achieving high manufacturing precision
Solution Approach 2:
The invention combines decorative embossing patterns with code patterns in a single integrated embossing process, creating a composite structure that serves both aesthetic and authentication functions while maintaining foil integrity through the dual-roller system
3Difficulty of detecting and measuring
If codes are embossed with high visibility, then the codes are easily readable, but the security authentication is reduced
Solution Approach 1:
The patent applies different qualities to different parts of the embossed surface: decorative patterns provide visual appeal while embedded code patterns with specific polyhedral structures provide authentication security, creating local variations in texture and reflectivity that require specialized reading methods
Solution Approach 2:
The invention introduces an intermediary reading system with specific lighting and imaging components that mediates between the embossed code structure and the authentication process, enabling secure verification while maintaining code readability through controlled optical conditions
4Shape
If decorative embossing patterns are applied onto packaging foils, then the aesthetic appearance is improved, but the additional embossing step increases production time
Solution Approach 1:
The patent merges the decorative embossing function and code application function into a single integrated embossing step using male and female rollers with combined patterns, eliminating separate production steps and maintaining high production efficiency while achieving aesthetic surface patterns
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 solution enables secure and efficient embossing of codes onto packaging foils with reduced visibility, ensuring authentication and maintaining the foil's integrity, while the reading method accurately decodes the embossed information, enhancing security and production efficiency.
Implementation Method 1
Illuminating an area of an embossed code with a first light source having a first illumination direction, arranged to create a first shadow pattern
Implementation Method 2
wherein a refractive index of the at least one first sub-code element differs from a refractive index of the at least one second sub-code element
Data Source
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Figure 6
AI summary
An embossing tool for embossing a combined embossing pattern into a packaging material, the combined embossing pattern including decoratively embossed structure and at least one embossed code, the embossing tool including a male and a female embossing device for cooperating with each other, embossing structures of the male and female embossing device formed to produce the combined embossing pattern into the packaging material in an embossing gap, the embossing structures of the male and the female embossing device include first embossing structures intended for making the at least one embossed code, which are inverse congruent male and female embossing structures having a polyhedral shape, and the decoratively embossed structures and the at least one embossed code produced by the embossing structures are arranged such that the at least one embossed code has a reduced visibility as compared to the decoratively embossed structures.