Flexible Packet Leak Detection Using Structured Illumination
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing leak detection systems for flexible packets, such as blister packs and sachets, fail to provide the required accuracy for detecting leaks, which can impair the efficacy and shelf-life of contents like pharmaceuticals.
Innovation Solution
A system and method using a pressure chamber to apply varying pressures, structured illumination, and image analysis to determine volume changes in flexible portions of packets, comparing these changes against thresholds to detect leaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional vacuum decay test methods are used for leak detection, then the detection process is simple, but the leak detection accuracy is insufficient
Solution Approach 1:
The patent replaces conventional mechanical vacuum decay measurement methods with an optical measurement system. A camera captures images of the flexible packet surface, and image processing algorithms calculate surface height variations to detect leaks. This substitution of mechanical measurement with optical measurement enables high-precision leak detection while maintaining operational simplicity.
Solution Approach 2:
The patent introduces an intermediary optical system between the vacuum chamber and the measurement process. By using light reflection and image capture as an intermediary, the system translates physical surface deformations caused by pressure changes into measurable optical signals, thereby achieving accurate leak detection without direct mechanical contact or complex pressure sensing.
2Measurement precision
If pressure changes are applied to detect leaks, then leak detection sensitivity improves, but packet deformation measurement becomes more challenging
Solution Approach 1:
The patent replaces direct mechanical measurement of surface deformation with optical image analysis. By capturing images of the packet surface under different pressure conditions and processing these images computationally, the system achieves sensitive detection of even minor deformations without the complexity of mechanical displacement sensors.
Solution Approach 2:
The patent changes the measurement parameter from direct physical displacement to optical image intensity and position data. By analyzing changes in image characteristics (such as pixel intensity distributions and feature point positions) before and after pressure application, the system converts difficult mechanical measurement into straightforward image processing tasks.
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
Accurately distinguishes between leak-free and leaky packets by measuring volume changes under different pressures, effectively identifying leaks as small as 3 µm to over 50 µm.
Implementation Method 1
a pressure chamber containing the test bed and the packet which applies a first pressure to the packet producing a first volume of the flexible portion of the packet and then applies a second pressure to the packet producing a second volume of the flexible portion of the packet
Implementation Method 2
an illumination detector which captures illumination reflected from the packet at the first pressure and produces a first image dataset of the packet and which captures illumination reflected from the packet at the second pressure and produces a second image dataset of the packet
Data Source
Figure 1
Figure 2
Figure 3a~3e
AI summary
A leak detection system (1) for detecting leaks in flexible packets is provided, comprising a test bed (3) which supports at least one packet (15) comprising at least one flexible portion, a pressure chamber (5) containing the test bed and the packet which applies a first pressure to the packet producing a first volume of the flexible portion of the packet and then applies a second pressure to the packet producing a second volume of the flexible portion of the packet, an illumination source (9) which produces structured illumination which is incident on the packet at the first pressure and the second pressure, an illumination detector (11) which captures illumination reflected from the packet at the first pressure and produces a first image dataset of the packet and which captures illumination reflected from the packet at the second pressure and produces a second image dataset of the packet, a processor (13) connected to the illumination detector to receive the first and second image datasets of the packet and which determines the first volume of the flexible portion of the packet at the first pressure, determines the second volume of the flexible portion of the packet at the second pressure, uses the first volume and the second volume to determine a change in volume of the flexible portion of the packet between the first and second pressures, compares the change of volume with a threshold and when the change of volume is greater than the threshold determines that the packet is leak-free and when the change of volume is less than the threshold determines that the packet has at least one leak. A method of detecting leaks in flexible packets is also provided.