Reduced Barcode Expansion for Postal Indicia Printing
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Solution Overview
Problem
High-volume postal systems face challenges in efficiently printing barcoded postal indicia due to alignment difficulties, slow printing rates, and excessive ink usage, particularly because existing systems require multiple pens and high resolution to print small barcodes.
Innovation Solution
A method is introduced to produce a reduced barcode with a limited set of unique information, which is then expanded to a larger size, allowing for printing at lower resolution and with less ink, using a single pen, and applying it to mail pieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a barcode is printed at high resolution (300 DPI) using multiple pens and printheads, then the barcode readability and information density are improved, but the alignment precision becomes difficult to achieve and maintain
Solution Approach 1:
The barcode is divided into two separate printing operations: a low-resolution preliminary print that establishes the basic barcode structure, and a high-resolution supplemental print that adds only the necessary detail elements. This segmentation allows each pen to focus on specific portions of the barcode, making alignment easier while maintaining overall readability.
Solution Approach 2:
The system performs a preliminary low-resolution printing pass before the final high-resolution pass. This preliminary action creates a framework that guides the subsequent detailed printing, ensuring that alignment requirements are met without requiring all elements to be aligned perfectly in a single operation.
2Measurement precision
If a barcode is printed at high resolution (300 DPI), then the barcode readability is improved, but the printing speed decreases
Solution Approach 1:
The printing process is segmented into two passes: a fast low-resolution print that covers the majority of the barcode area, and a slower high-resolution print that adds only the critical detail elements. This segmentation allows the system to achieve high printing speeds for the bulk of the work while maintaining high-resolution quality where needed.
Solution Approach 2:
The system applies high resolution only partially to the portions of the barcode that require it, rather than applying high resolution uniformly across the entire barcode. This partial application of high resolution maintains readability while significantly improving overall printing speed.
3Measurement precision
If a barcode is printed at high resolution (300 DPI), then the barcode quality is improved, but the ink consumption increases
Solution Approach 1:
The printing process segments ink consumption into two phases: a low-ink low-resolution print that establishes the basic barcode structure, and a supplemental high-resolution print that uses minimal additional ink only for the detail elements. This segmentation dramatically reduces total ink consumption compared to printing the entire barcode at high resolution.
Solution Approach 2:
The system applies high resolution and high ink consumption only to the partial portions of the barcode that require it, rather than uniformly across the entire barcode. This partial application significantly reduces overall ink consumption while maintaining barcode quality.
Data Source
AI summary
A method of producing a barcode includes collecting a set of information for producing the bar code, using an indicator to designate the set of information, encoding the indicator in the barcode, expanding the barcode to a particular size, and printing the bar code.