Online Cure Status Assessment Using Color Digital Imaging
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Solution Overview
Problem
Existing methods for determining the cure status of fibrous glass insulation products are limited in their ability to assess uniformity across the product depth, often relying on one-directional infrared radiation transmission, which does not provide comprehensive information about cure at various depths, leading to potential under- or over-curing issues.
Innovation Solution
A method involving capturing and analyzing color digital images or optical reflectance measurements from the surface or interior of fibrous products, allowing for the assessment of cure status by analyzing regions of interest, which can be done continuously online without removing the product from the manufacturing line, using color system variables like the LAB color system and spectrometric measurements such as UV or IR reflectance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If one-directional infrared radiation transmission is used to determine cure status, then the measurement method is simple, but it cannot provide comprehensive information about cure at various depths of the pack
Solution Approach 1:
The patent transitions from one-directional infrared transmission measurement to multi-directional measurement by capturing images from both front and back surfaces of the fibrous pack. This dimensional approach allows simultaneous assessment of cure status at different depths, providing comprehensive three-dimensional cure information without significantly increasing system complexity.
Solution Approach 2:
The patent introduces color digital images as an intermediary medium to capture and represent cure status information. By using color system variables (such as L*, a*, b* values) derived from captured images, the system translates complex internal cure states into measurable optical properties that reflect the degree of cure at different depths.
2Measurement precision
If multiple wavelengths of infrared radiation are used to monitor binder cure, then the degree of cure can be monitored, but the method cannot assess uniformity across product depth
Solution Approach 1:
The patent adds the depth dimension to cure assessment by capturing images from both front and back surfaces of the fibrous pack. This enables evaluation of cure uniformity through the product thickness, complementing the existing capability to monitor overall cure degree with multiple infrared wavelengths.
Solution Approach 2:
The patent applies local quality analysis by dividing the fibrous pack into different regions (front surface, back surface, and specific zones within each surface) and analyzing color system variables for each region separately. This allows identification of localized undercured or overcured areas, providing detailed spatial information about cure uniformity.
3Measurement precision
If destructive off-line methods are used for cure determination, then comprehensive analysis can be performed, but production efficiency is reduced
Solution Approach 1:
The patent replaces destructive mechanical analysis methods with non-destructive optical measurement using color digital imaging. This substitution maintains comprehensive cure assessment capability through color system variable analysis while eliminating the need to remove or destroy product samples, thereby preserving production continuity and efficiency.
Solution Approach 2:
The patent creates optical copies (color digital images) of the fibrous pack surfaces for analysis. These images serve as virtual replicas that can be thoroughly analyzed without physically disturbing the product, enabling comprehensive cure assessment while maintaining product integrity and production flow.
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 provides a more accurate and comprehensive assessment of the cure status, enabling manufacturers to adjust process controls to ensure uniform curing, reducing the likelihood of under- or over-cured areas and improving product quality.
Implementation Method 1
capturing a color digital image from a surface of a fibrous product using a color digital camera
Implementation Method 2
spectrometric measurements such as UV or IR reflectance
Data Source
AI summary
A method for assessing the cure status of a fibrous blanket manufactured with mineral fibers and binder is disclosed and comprises a using an online optical reflectance measurement as an assessment of cure status. The optical reflectance measurement may preferably be a color image taken of any surface, and in particular of a sectioned face, after which the image is optionally divided into multiple regions of interest (ROI) and analyzed for a color system variable that is representative of cure status. In some embodiments, the color system variable is the B value. Alternatively, the optical reflectance measurement may be UV or IR reflectance of a sectioned face. When two or more regions of interest are defined on a sectioned face, comparative information is valuable to assess cure at different levels, layers or portions of the interior of the fibrous product.