Non-Destructive In-Line Seal Inspection for Packaging Integrity
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Solution Overview
Problem
Current seal integrity testing methods for packaging are labor-intensive, destructive, and limited to offline processes, failing to effectively check seals in-line during packaging production.
Innovation Solution
A non-destructive in-line seal quality monitoring process using a vision system with image capture and analysis, including fluorescence-based indicators and multiple vision systems (thermography, photoelasticity, and ultraviolet) to assess seal continuity and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional destructive testing methods are used, then seal strength can be measured, but the packaging article is destroyed and only limited offline testing is possible
Solution Approach 1:
The patent replaces mechanical destructive testing systems with optical vision systems that use light-based detection methods. The vision system captures images of seals and uses image analysis to detect defects non-destructively, eliminating the need to physically destroy packaging articles for testing while maintaining measurement capability through visual inspection of seal characteristics.
Solution Approach 2:
The patent creates visual copies (images) of the seal for inspection purposes. By capturing images of the actual seal and analyzing these optical copies, the system enables multiple inspections of the same seal without physical destruction, allowing high-volume testing while preserving the original packaging article.
2Reliability
If traditional offline testing is performed, then seal defects can be detected, but the process is labor-intensive and cannot be performed in-line during production
Solution Approach 1:
The patent replaces manual offline testing operations with an automated vision system that can be integrated into the production line. The system uses optical sensors and image processing algorithms to automatically detect seal defects, eliminating labor-intensive manual inspection while enabling in-line deployment during packaging production.
Solution Approach 2:
The vision system performs self-inspection of seals without requiring external manual intervention. The system automatically captures images, processes them through image analysis algorithms, and identifies defects autonomously, enabling seamless integration into automated production lines without adding operational complexity.
3Reliability
If multiple vision systems are deployed for comprehensive seal analysis, then detection reliability improves, but device complexity increases
Solution Approach 1:
The patent combines multiple vision systems into an integrated inspection platform. By merging thermography, photoelasticity, and ultraviolet vision capabilities into a single coordinated system, the patent achieves comprehensive seal analysis through multiple detection modalities while managing complexity through unified system architecture and centralized control.
Solution Approach 2:
The vision system is designed with multi-functionality to perform various types of seal inspections using different optical methods. The same platform can switch between thermography for temperature-based defect detection, photoelasticity for stress analysis, and ultraviolet for fluorescence detection, eliminating the need for separate dedicated systems for each inspection type.
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
Enables rapid, non-destructive, and reliable detection of seal defects, ensuring packaging integrity and preventing air penetration and spoilage, with the ability to analyze seals before packaging completion.
Implementation Method 1
exposing the packaging article to incident radiation to excite the fluorescence-based indicator so that the fluorescence-based indicator fluoresces
Implementation Method 2
a thermography vision system, the thermography vision system comprising an infrared imaging device
Implementation Method 3
a photoelasticity vision system, the photoelasticity vision system comprising a light source, a first linear polarizer, a second linear polarizer, and an imaging device
Data Source
AI summary
A process for monitoring seal quality of a packaging article. In one embodiment, the process for monitoring the seal quality includes sealing a film to form packaging article and forming a seal area. The seal area is analyzed by a vision system to acquire image data of the seal area. A vision inspection engine analyzes the image date to determine the continuity of the seal, the strength of the seal, or both.