Digital Code Pattern on Rubber Articles via Molded Structure Pixels
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Solution Overview
Problem
Existing methods for providing rubber articles with digital code patterns face challenges in achieving high-quality, efficient, and cost-effective implementation, particularly in ensuring the digital code pattern's optical reflectivity and durability.
Innovation Solution
A method involving the generation of a transfer pattern by rasterizing a digital code pattern definition using structure pixels, where the size of light and dark portions is an integer multiple of the rasterizing width, resulting in an array of structure pixels with different optical reflectivities, enhancing the quality and readability of the digital code pattern on rubber articles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If laser engraving is used to mark digital code patterns on rubber articles, then the digital code can be applied to the surface, but the manufacturing complexity and cost increase due to adjustable mounting mechanisms and multiple plane adjustments
Solution Approach 1:
The patent replaces complex mechanical laser positioning systems with a molding-based approach. Digital code patterns are integrated directly into the mold cavity, allowing the code to be formed during the rubber vulcanization process itself. This eliminates the need for separate laser marking equipment, adjustable mounting mechanisms, and multi-plane positioning systems, while producing durable codes that are permanently embedded in the rubber article surface.
2Loss of information
If N/C drilling is used to create data matrix barcodes, then machine readable data can be encoded, but the manufacturing time and productivity decrease due to series of partially drilled holes
Solution Approach 1:
The patent incorporates the digital code pattern design into the mold cavity before the rubber vulcanization process begins. The mold cavity pre-defines the complete digital code pattern geometry, including all light and dark portions. During vulcanization, the rubber material is molded into this cavity in a single operation, forming the complete code pattern simultaneously rather than through sequential drilling operations. This preliminary preparation of the code geometry in the mold enables rapid production without sacrificing data encoding capability.
3Loss of information
If digital code patterns are applied to rubber articles, then identification capability is improved, but the optical reflectivity and readability may be insufficient
Solution Approach 1:
The patent creates digital code patterns with spatially varying surface properties by forming light portions and dark portions with different optical reflectivities directly in the rubber article surface. The light portions have higher reflectivity while dark portions have lower reflectivity, creating high contrast that enhances readability. This local differentiation of optical properties within the code pattern ensures reliable detection and reading of the digital code.
4Reliability
If existing marking methods are used, then digital codes can be applied, but manufacturing cost and inefficiency increase
Solution Approach 1:
The patent merges the digital code pattern formation process with the rubber article manufacturing process. The digital code pattern is integrated into the mold cavity design, so that the code is formed simultaneously with the rubber article during vulcanization. This consolidation of processes eliminates separate marking operations, reduces manufacturing steps, and improves overall efficiency while ensuring reliable code application as part of the primary manufacturing process.
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 improves the quality and equivalence of the digital code pattern on rubber articles, ensuring better optical reflectivity and durability, thereby addressing the inefficiencies and cost issues of existing methods.
Implementation Method 1
The marking tool is configured for modifying a surface of a target... a laser beam which in turn generates the structure elements
Implementation Method 2
each type of structure pixel defines a certain surface structure on the rubber article, the surface structure causing a certain optical reflectivity of the structure pixel
Data Source
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AI summary
Described is in particular a method of generating a transfer pattern (110) defining a digital code pattern. According to the described method, a digital code pattern definition (104) defining a plurality of light and dark portions is received, wherein each of such portion has a size A. The transfer pattern (110) is generated by rasterizing the digital code pattern definition (104) with structure pixels, in particular by mapping the digital code pattern definition into an array of equally sized structure pixels, wherein the size A of the light and dark portions is an integer multiple of a size B of the structure pixels. The array of structure pixels comprises at least two different types of structure pixels. Each type of structure pixel defines a certain surface structure on the rubber article, the surface structure causing a certain optical reflectivity of the structure pixel. Further, at least two types of structure pixels have a different optical reflectivity.