Laminate Air-Pocket Detection via Optical Imaging
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Solution Overview
Problem
Conventional methods for evaluating the quality of laminates, particularly in applications like airbags, are cumbersome and destructive, requiring mechanical means to break the laminate, making them inefficient and difficult to implement in-line during manufacturing.
Innovation Solution
A method involving the acquisition of a two-dimensional image of the laminate to detect air-pocket regions, determining characteristic values related to these regions, and using those values to evaluate the laminate's quality non-destructively, allowing for in-line evaluation and feedback to adjust manufacturing conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional mechanical peeling methods are used to evaluate bond strength, then measurement accuracy is improved, but device complexity and operation difficulty increase
Solution Approach 1:
The patent replaces mechanical peeling methods with optical imaging and image processing techniques. A two-dimensional image acquisition device captures images of the laminate, and image processing detects air-pocket regions to evaluate bond strength without mechanical contact, thereby simplifying the device while maintaining measurement accuracy
Solution Approach 2:
The patent creates an optical copy (image) of the laminate's internal structure, particularly air-pocket regions between layers. By analyzing this optical representation rather than physically manipulating the laminate, the system achieves accurate bond strength evaluation without complex mechanical apparatus
2Measurement precision
If destructive mechanical testing is used to evaluate laminate quality, then measurement accuracy is improved, but productivity decreases due to sample destruction
Solution Approach 1:
The patent substitutes destructive mechanical testing with non-destructive optical imaging. The image acquisition device captures two-dimensional images of the laminate surface, and image processing algorithms detect air-pocket regions that indicate bonding quality, enabling accurate evaluation without destroying the sample and allowing continuous production
Solution Approach 2:
The patent implements a feedback mechanism where image processing results provide real-time information about laminate quality. The evaluation results can be fed back to adjust manufacturing parameters, enabling continuous improvement and maintaining high productivity through non-destructive inline inspection
3Measurement precision
If conventional peeling methods are used to evaluate bond strength, then measurement accuracy is improved, but ease of operation deteriorates due to complicated procedures
Solution Approach 1:
The patent replaces complex mechanical peeling operations with simple image acquisition and automated image processing. The system captures images and automatically detects air-pocket regions through algorithmic analysis, eliminating the need for manual peeling operations and significantly improving ease of operation while maintaining measurement accuracy
Solution Approach 2:
The patent enables the evaluation system to perform its own measurement function automatically. The image processing device autonomously detects air-pocket regions and calculates bond strength metrics without requiring manual intervention or complex operational procedures, making the system easy to operate
Data Source
AI summary
A method of evaluating a laminate formed of two or more layers bonded to each other includes an image obtaining step of obtaining a two-dimensional image of the laminate; a detecting step of detecting air-pocket corresponding regions from a two-dimensional image; a characteristic value obtaining step of determining a characteristic value related to areas of the air-pocket corresponding regions; and an evaluation step of evaluating the laminate based on the characteristic value. is a method of evaluating a laminate.