Induction Seal Thermal Imaging for High-Speed Container Inspection
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Solution Overview
Problem
Existing methods for evaluating the sealing integrity of induction-sealed containers are inadequate, particularly due to the cap obstructing direct visualization, leading to potential contamination and safety hazards from compromised seals.
Innovation Solution
Thermal imaging is employed to assess the sealing integrity by imaging the induction seal through the cap at an angle to the container's longitudinal or transverse axis, utilizing thermal detectors and optical elements, with big data analysis to identify defects and predict sealing inefficiencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional leak testing methods (vacuum or pressure decay testing) are used to evaluate sealing integrity, then sealing quality can be monitored, but the testing process is too slow and impractical for fast-paced packaging lines
Solution Approach 1:
The patent replaces mechanical leak testing methods (vacuum or pressure decay testing) with thermal imaging technology. The thermal detector captures temperature distributions on the container surface, and image processing algorithms analyze thermal patterns to identify sealing defects. This substitution enables non-contact, high-speed evaluation that matches packaging line speeds while maintaining reliable sealing integrity assessment.
2Measurement precision
If the cap is removed to allow direct visualization of the induction seal for evaluation, then sealing quality can be assessed accurately, but the container structure is compromised and the process becomes impractical
Solution Approach 1:
The patent introduces thermal imaging technology as an intermediary that enables seal evaluation through the cap without removing it. The thermal detector captures temperature distributions that penetrate or transmit through the cap material, and image processing algorithms extract seal quality information from these thermal patterns. This intermediary approach maintains container integrity while providing accurate seal assessment.
Solution Approach 2:
The patent changes the evaluation parameter from direct visual inspection to thermal pattern analysis. By detecting temperature distributions and their variations across the container surface, the system infers seal quality without needing direct visual access to the seal. This parameter change enables evaluation through the cap while maintaining both measurement precision and operational ease.
3Reliability
If statistical sampling methods are used for leak testing, then some sealing defects can be detected, but most defects during transport cannot be identified
Solution Approach 1:
The patent implements continuous thermal imaging evaluation of all containers as they move through the packaging line, replacing intermittent statistical sampling. The thermal detector continuously captures temperature distributions, and image processing algorithms continuously analyze seal quality. This continuous monitoring ensures 100% defect detection coverage throughout transport while maintaining reliable defect identification.
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 method provides high-quality evaluation of sealing integrity, enabling real-time alerts and preventive maintenance, reducing waste and increasing productivity by detecting defects and ensuring reliable sealing.
Implementation Method 1
thermal imaging (also known, according to some embodiments, by the term "thermographic imaging") is a type of infrared (IR) imaging in which radiation emitted from a substance is detected based on the temperature and emissivity
Implementation Method 2
the container passes under an induction coil, which emits an oscillating electromagnetic field. As the container passes under the induction coil (sealing head) the conductive aluminum foil liner begins to heat due to eddy currents
Implementation Method 3
the conductive aluminum foil liner begins to heat due to eddy currents
Data Source
AI summary
Method and system for determining sealing integrity and/or contamination of the sealing region by the filling material of a heat-sealed container, including imaging at least a part of a sealing region of the container using bolometer; wherein the imaging is performed during movement and/or transport of the container at a predetermined speed, and wherein the imaging is performed while moving the field of view of the bolometer in a same direction as the container, wherein the moving of the field of view is configured to reduce the velocity of the container relative to the imaging bolometer sufficiently to reduce smearing of images obtained.