Prism Sensor Segmented Polycarbonate Reflector Assembly
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Solution Overview
Problem
Existing prism sensors in check depositing ATMs are costly and difficult to assemble due to the challenges of molding thick acrylic materials without sink, which affects light reflection intensity, and require careful handling to avoid glue contamination on reflective surfaces.
Innovation Solution
A prism sensor design with a light emitter, three reflecting surfaces, and a light receiver, where the reflecting surfaces are molded from clear polycarbonate to maintain light intensity and ease of assembly, with a cored out area to allow misalignment and visibility of debris in the check transport path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thick acrylic material is used for the prism reflector to account for misalignment tolerances and enclose the light path, then the sensor reliability is improved, but the manufacturing complexity and cost increase due to difficulty in molding without sink
Solution Approach 1:
The prism reflector is divided into multiple segments or sections that can be molded separately and then assembled together. This segmentation allows each segment to be molded with thinner material, avoiding sink issues, while the complete assembly still provides the necessary thickness and tolerance accommodation for reliable operation.
Solution Approach 2:
The patent employs composite construction by combining multiple materials or material layers in the prism reflector assembly. This allows the use of materials optimized for specific functions (e.g., reflective surfaces, structural support, light transmission) rather than requiring a single thick homogeneous material, thereby reducing manufacturing difficulties while maintaining reliability.
2Reliability
If thick acrylic material is molded to fully enclose the light path, then the light path enclosure is improved, but the manufacturing cycle time increases due to sink issues
Solution Approach 1:
The light path enclosure is achieved through segmented construction where multiple components work together to enclose the light path. Each segment can be manufactured independently with shorter cycle times, and the assembled structure provides complete enclosure without requiring any single component to be excessively thick.
Solution Approach 2:
Instead of relying solely on increasing material thickness in one dimension to enclose the light path, the patent uses multi-dimensional approaches such as layered structures, multi-faceted geometries, or distributed reflective surfaces that achieve enclosure through spatial arrangement rather than material volume, thereby reducing manufacturing cycle time.
3Ease of manufacture
If glue is used to assemble the prism sensor components, then the assembly is improved, but the risk of glue contamination on reflective surfaces increases which reduces light reflection intensity
Solution Approach 1:
The harmful element (glue) is extracted or eliminated from the assembly process near the reflective surfaces. Alternative assembly methods such as mechanical fastening, snap-fits, magnetic attachment, or adhesive application on non-reflective surfaces are used, allowing glue to be taken out of the critical vicinity of the reflective surfaces and thus preventing contamination while maintaining assembly ease.
Solution Approach 2:
An intermediary structure or component is introduced between the adhesive and the reflective surface. This intermediary acts as a barrier that allows the adhesive to perform its bonding function while preventing direct contact with and contamination of the reflective surface, thereby maintaining light reflection intensity while enabling easy assembly.
4Illumination intensity
If acrylic material is used for the prism reflector, then the light transmission is improved, but the cost increases due to long manufacturing cycle times required to avoid sink
Solution Approach 1:
The acrylic reflector is segmented into multiple thinner components that can be manufactured more quickly with reduced sink issues. Each segment maintains sufficient optical clarity for its specific function, and the assembled structure provides the cumulative light transmission and reflection performance of a single thick piece, thereby reducing manufacturing cost while maintaining reflected light intensity.
Solution Approach 2:
The patent uses composite material construction combining acrylic with other materials that have different manufacturing characteristics. This allows the acrylic portions to be optimized for light transmission while other materials handle structural or protective functions that would be difficult or expensive to manufacture in acrylic, thereby reducing overall manufacturing cost while maintaining optical performance.
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 design provides a low-cost, easy-to-assemble prism sensor that maintains light intensity and reduces the risk of glue contamination, enhancing the reliability and efficiency of check detection in ATMs.
Implementation Method 1
Light from the emitter is directed across the check transport path to the reflector. The light is then reflected off of the reflector and directed back across the check transport path to the receiver.
Data Source
AI summary
A prism sensor is provided for detecting presence or absence of a document in a document transport path. The prism sensor comprises a light emitter disposed on a first side of the document transport path and for emitting light across the document transport path to a second side of the document transport path, a reflector including (i) a first reflecting surface for receiving light from the light emitter and for providing first reflected light in response thereto, (ii) a second reflecting surface for receiving the first reflected light from the first reflecting surface and for providing second reflected light in response thereto, and (iii) a third reflecting surface for receiving the second reflected light from the second reflecting surface and for providing third reflected light in response thereto, and a light receiver for receiving the third reflected light from the third reflecting surface and for providing a signal which is indicative of presence or absence of a document in the document transport path.