Segmented Retro-Reflective Marker for Uniform Film Stretching
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Solution Overview
Problem
Current spherical retro-reflective markers have uneven reflection properties due to the stretching of reflective films during manufacturing, leading to reduced reflectivity and increased production costs, especially when trying to achieve uniform retroreflection across different viewing directions.
Innovation Solution
A spherical retro-reflective marker composed of multiple reflector body segments with a coating that includes a reflection film, where the segments are connected to form a continuous spherical surface with controlled stretching of the reflective film, ensuring uniform reflection properties across the surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single large reflector body segment is used, then manufacturing complexity is reduced, but the reflective film stretches excessively during production causing non-uniform reflection properties
Solution Approach 1:
The reflector body is divided into multiple segments (at least three) that are connected to form a complete spherical structure. Each segment is manufactured separately with controlled film stretching, then assembled to form the complete reflector body. This segmentation allows each individual segment to maintain uniform reflection properties while the complete structure provides full spherical coverage.
2Shape
If the reflective film is stretched during manufacturing to form a spherical surface, then the spherical shape is achieved, but the reflection properties become non-uniform with reduced retroreflection in edge regions
Solution Approach 1:
By dividing the spherical surface into multiple segments, each segment undergoes controlled stretching during manufacturing. The stretching is localized to each segment rather than the entire sphere, which limits the maximum strain any single area experiences. This results in more uniform reflection properties across the complete spherical surface when all segments are assembled together.
3Ease of manufacture
If retro-reflective foils are used to produce spherical retro-reflective bodies, then production is simplified, but the reflection properties vary when illuminated from different directions
Solution Approach 1:
The use of retro-reflective foils is maintained for ease of manufacture, but the foil is applied to multiple small spherical segments rather than one large segment. Each small segment is illuminated from directions that are more consistent with the foil's optimal reflection angle, reducing the variation in reflection properties when viewed from different directions.
4Measurement precision
If flat markers are used instead of spherical markers, then position determination accuracy is improved, but the field of vision is severely limited when observing from the side
Solution Approach 1:
The spherical marker is segmented into multiple facets, each acting as a small reflective surface. When viewed from different directions, different segments are visible and contribute to the overall reflection. This segmented spherical structure maintains the wide field of vision advantage of spheres while creating multiple reflection surfaces that improve position determination accuracy.
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 achieves a more uniform retroreflection with improved differential reflection values, reducing the variation in reflectivity across different viewing directions and lowering production costs by minimizing film expansion, especially in edge regions, resulting in enhanced performance and cost-effectiveness.
Implementation Method 1
In contrast to the diffuse reflection of a surface, in retro-reflection the reflected light rays are reflected essentially parallel to the incident light rays directly in the same direction - i.e. back to the light source.
Implementation Method 2
each reflector body segment (11) having a coating (12) which includes a reflection film (12)
Data Source
AI summary
The present application relates to a reflector body (10), particularly a spherical retro-reflective marker, comprising a plurality of reflector body segments (11), and the individual reflector body segments (11) comprised by such a reflector body (10), and a method for producing the reflector body segments (11) and the reflector body (10). The reflector bodies (10) comprise a coating having a reflection film (12), by which the reflector body segments (11) of the reflector body (10) are uniformly spanned, performed by suitably selecting the geometric shape of the reflector body segment (11) to be spanned, by injecting molding behind the reflection film (12) in an injection molding process and/or by producing the reflector body segments (11) in a forming process.