Resin Encoder Scale Molded with Rough and Mirror Surfaces

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Solution Overview

Problem

The production of encoder scales, particularly reflection-type and transmission-type, requires complex and time-consuming processes, leading to high costs and limited usage due to the need for precise processing of glass or metallic plates, which increases the cost of encoders and restricts their application in accurate position measurement for rotation angles and linear movements.

Innovation Solution

A resin encoder scale with a scale pattern comprising a combination of low and high reflection or transmission parts, molded using a mold with a rough surface and a mirror surface, allowing for injection molding and reducing processing complexity and cost, where the low reflection or transmission parts are roughened and the high parts are mirror-finished, with a reflection or transmission film applied uniformly for enhanced accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If glass or metallic plates are used for encoder scales with complex processing, then measurement precision is improved, but manufacturing cost increases and productivity decreases

Engineering Contradiction:

Improveposition measurement accuracyVSAvoidproduction efficiency

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The invention changes the material parameter from traditional glass/metallic plates to resin material, enabling mass production through injection molding while maintaining the required measurement precision for encoder scales

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses injection molding to create precise copies of the scale pattern on resin plates, replicating the functional characteristics of traditional glass/metallic scales while enabling high-volume production

Inventive Principle:

Principle #26Copying

2Manufacturing precision

If complex processing is applied to glass or metallic plates, then manufacturing precision is improved, but manufacturing cost increases

Engineering Contradiction:

Improvescale pattern precisionVSAvoidmanufacturing complexity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The invention replaces complex mechanical processing steps (cutting, polishing, coating) with a single injection molding process that integrates pattern formation directly into the manufacturing step

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention merges multiple separate manufacturing operations (plate preparation, pattern formation, surface treatment) into a single integrated injection molding process, simplifying manufacturing while maintaining precision

Inventive Principle:

Principle #5Merging (Combining)

3Measurement precision

If traditional processing methods are used for encoder scales, then measurement accuracy is maintained, but production time increases

Engineering Contradiction:

Improveposition detection accuracyVSAvoidmanufacturing cycle time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The injection molding process preliminarily forms the complete scale pattern during the primary manufacturing step, eliminating the need for subsequent time-consuming processing operations

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Inventive Principle:

Principle #35Parameter changes

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 simplifies the production of encoder scales, reduces costs, and enables the mass production of high-accuracy encoder scales for position measurement, allowing for a broader range of applications with improved efficiency and reduced manufacturing time.

Implementation Method 1

a mold pattern which is a combination of a rough surface on which surface-roughing processing is performed and a mirror surface on which mirror-finishing processing is performed

Methodology Applied

Scientific EffectSurface roughing: Abrasion

Implementation Method 2

the scale pattern which is a combination of a low reflection part a surface of which is molded as a rough surface during resin molding and which has low reflectivity of light and a high reflection part a surface of which is molded as a mirror surface during the resin molding and which has higher reflectivity of light than the low reflection part

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentUS10288453B2Resin encoder scale, mold for resin encoder scale, method for producing resin encoder scale, and encoder

Publication Date: 2019.05.14 MAXELL LTD

AI summary

A purpose is to provide a resin encoder scale a cost of which can be reduced by making processing easy by producing the encoder scale as a resin molded piece including a scale pattern. A resin encoder scale is used in a reflection-type optical encoder and a scale pattern for position measurement is provided thereto. In the scale pattern, a low reflection part a surface of which is molded as a rough surface during resin molding and which has low reflectivity of light and a high reflection part a surface of which is molded as a mirror surface during the resin molding and which has higher reflectivity of light than the low reflection part are arranged alternately.