Thermal Imaging of Package Seals for In-Line Defect Detection
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Solution Overview
Problem
Existing packaging integrity testing methods are inefficient for detecting defects in heat-sealed packages, particularly those made of materials with high heat capacity, as they struggle to identify contamination or other defects in the sealing region due to difficulty in identifying changes in heat capacity and are prone to contamination during filling.
Innovation Solution
Utilizing thermal imaging to detect defects in the sealing region of packages before completion, specifically using infrared imaging in the 8µm-14µm wavelength range to differentiate between the sealing region and filling material, which may include heating or cooling the sealing region or filling material to enhance contrast.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional leak testing methods (vacuum or pressure decay testing) are used, then package integrity can be tested, but the testing process is too slow and impractical for fast-paced packaging lines
Solution Approach 1:
The patent replaces mechanical vacuum/pressure decay testing systems with thermal imaging systems. The thermal camera detects temperature differences in the sealing region caused by improper sealing, providing non-contact, non-intrusive detection that does not slow down the packaging line while maintaining reliability.
Solution Approach 2:
The patent introduces thermal radiation as an intermediary to detect sealing defects. Instead of directly applying vacuum or pressure to the package, the system uses thermal imaging to detect temperature variations that indicate sealing issues, enabling indirect but effective quality control.
2Reliability
If statistical sampling methods are used for leak testing, then some package integrity can be monitored, but defects caused by contamination during filling cannot be detected
Solution Approach 1:
The patent performs thermal imaging detection during the filling phase, before the sealing process is completed. This preliminary detection allows identification of contamination in the sealing region before it causes defective seals, enabling preventive quality control rather than post-hoc inspection.
Solution Approach 2:
The patent utilizes thermal radiation detection to visualize temperature differences in the sealing region. Contaminated areas show different thermal signatures compared to clean areas, allowing detection of contamination that is invisible to conventional inspection methods.
3Productivity
If thermal imaging is performed on packages made of materials with high heat capacity, then real-time detection is possible, but the materials' high heat capacity makes it difficult to identify changes in heat capacity
Solution Approach 1:
The patent focuses thermal imaging detection specifically on the sealing region rather than the entire package. By concentrating detection resources on the critical sealing area, the system can detect local temperature variations caused by improper sealing even when the package material has high heat capacity that masks overall thermal changes.
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 real-time detection of defects such as contamination, cuts, or deformations in the sealing region, preventing the distribution of improperly sealed packages and reducing the risk of low-quality sealed packages.
Implementation Method 1
utilizing thermal imaging for determining package integrity... utilizing infrared imaging... radiation emitted from a substance is detected based on the temperature and emissivity
Implementation Method 2
which may include heating or cooling the sealing region or filling material to enhance contrast
Implementation Method 3
which may include heating or cooling the sealing region or filling material to enhance contrast
Data Source
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AI summary
Methods and systems for detecting and monitoring defects in a sealing region of a container, including imaging at least part of the sealing region of the container using a camera operative at a wavelength in the range of 0.76µm - 14 µm; during and/or after the filling of the container with a filling material and prior to sealing of the container being completed; and identifying, based on at least one frame obtained from the imaging, defects in the sealing region.