NIR Resin Layer Sensing for Fast Multi-Parameter Inspection
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Solution Overview
Problem
Existing methods for determining parameters of resin layers in carrier materials, such as resin-impregnated paper layers, are inefficient and time-consuming, particularly in fast-running systems, leading to increased production downtime and material loss due to the need for manual and selective testing of multiple parameters.
Innovation Solution
A method using Near Infra-Red (NIR) spectroscopy with a multi-measuring head to simultaneously determine parameters like resin quantity, degree of curing, moisture content, and abrasion resistance by analyzing NIR spectra, combined with multivariate data analysis, enabling real-time, non-contact measurement and plant control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurement methods are used to determine parameters of resin layers, then measurement precision can be maintained, but time loss increases significantly
Solution Approach 1:
The patent replaces manual mechanical measurement methods with automated optical measurement systems (NIR spectroscopy). The measuring head automatically scans the resin layer and captures spectral data, eliminating the need for manual sampling and laboratory analysis. This substitution enables continuous, real-time measurement without interrupting production, resolving the contradiction between measurement precision and time loss.
Solution Approach 2:
The patent creates a spectral copy of the resin layer's chemical composition by capturing NIR reflectance spectra. Instead of physically extracting samples for analysis, the system creates an optical fingerprint that contains all necessary information about resin content, curing degree, and composition. This copying approach enables instantaneous measurement while maintaining accuracy, directly addressing the time-loss problem.
2Loss of information
If multiple individual measuring systems are used to determine different parameters, then measurement comprehensiveness improves, but device complexity increases
Solution Approach 1:
The patent implements a universal measuring head that performs multiple measurement functions simultaneously. A single NIR spectrometer captures spectral information that can be analyzed to determine resin content, curing degree, moisture content, and compositional parameters. This multi-functional approach eliminates the need for separate measuring devices for each parameter, reducing system complexity while maintaining comprehensive parameter coverage.
Solution Approach 2:
The patent merges multiple measurement capabilities into a single integrated system. The NIR measuring head combines light source, detector, and spectral analysis functions in one device. Additionally, the evaluation system merges data from different spectral regions to simultaneously extract multiple parameters, consolidating what would otherwise require separate measuring systems into a unified apparatus.
3Productivity
If selective testing is performed to reduce time loss, then productivity improves, but measurement precision deteriorates
Solution Approach 1:
The patent implements continuous measurement throughout the production process. The measuring head travels along with the material web, continuously scanning and capturing spectral data at every point. This continuous measurement ensures that every section of the resin layer is evaluated, maintaining comprehensive precision while enabling high-speed production without selective sampling gaps.
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
Facilitates rapid, multi-parameter determination without reducing production speed, improving plant control, reducing downtime, and enhancing product quality through immediate data availability and AI-assisted process optimization.
Implementation Method 1
A method using Near Infra-Red (NIR) spectroscopy with a multi-measuring head to simultaneously determine parameters like resin quantity, degree of curing, moisture content, and abrasion resistance by analyzing NIR spectra
Implementation Method 2
NIR radiation is generated and directed onto the carrier material sample to be analysed, on which one or more resin layers are deposited, where the NIR radiation interacts with the components of the sample and is reflected or scattered
Implementation Method 3
NIR radiation is generated and directed onto the carrier material sample to be analysed, on which one or more resin layers are deposited, where the NIR radiation interacts with the components of the sample and is reflected or scattered
Implementation Method 4
An NIR detector captures the reflected or scattered NIR radiation and produces an NIR spectrum that contains the desired chemical information of the sample
Data Source
AI summary
Provided is a method for the simultaneous determination of parameters, in particular of at least two, three or four parameters, of at least one resin layer applied to at least one carrier material by recording and evaluating at least one NIR spectrum in a wavelength range between 500 nm and 2500 nm, preferably between 700 nm and 2000 nm, more preferably between 900 nm and 1700 nm, and particularly advantageously between 1450 nm and 1550 nm, using at least one NIR measuring head, in particular at least one NIR multimeter head.