Segmented Sealing Contour for Real-Time Seam Quality Detection
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Solution Overview
Problem
Existing packaging technologies face challenges in reliably evaluating the quality of heat-sealed plastic packages due to defects such as improper sealing surfaces, material defects, and contaminants, which can lead to leaks and poor bond strength, especially in packages like blister packs for pharmaceuticals and contact lens packages.
Innovation Solution
A method and device that divide the sealing contour into segments, using heating and sensor elements to detect parameters like resistance, temperature, or power demand, allowing for immediate evaluation of seam quality by comparing actual values to nominal values, thereby identifying and addressing issues like contamination or incorrect sealing temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If optical inspection devices with cameras are used to detect sealing surface contaminants, then the detection capability is improved, but the device complexity and cost increase
Solution Approach 1:
The patent combines the inspection function with the existing sealing device by integrating sensors directly into the sealing contour segments. This merging eliminates the need for separate optical inspection devices and cameras, reducing overall system complexity while maintaining detection capability through the segmented sensor arrangement that monitors sealing parameters in real-time
Solution Approach 2:
The sealing device is designed to perform multiple functions: it both seals the packaging and simultaneously inspects the sealing surface for contaminants. The segmented sealing contour with integrated sensors enables the same device to execute sealing and quality inspection tasks, eliminating the need for additional dedicated inspection equipment
2Manufacturing precision
If the sealing contour is divided into multiple segments with individual sensors, then the manufacturing precision and defect detection are improved, but the device complexity increases
Solution Approach 1:
The sealing contour is divided into multiple segments, with each segment equipped with its own sensor. This segmentation enables precise local monitoring of sealing parameters at different positions along the seal line, improving manufacturing precision by detecting defects in specific segments while keeping the overall device complexity manageable through modular design
3Manufacturing precision
If additional cleaning steps are added to remove droplets from sealing surfaces, then the sealing quality is improved, but the productivity decreases
Solution Approach 1:
The patent implements preliminary inspection of the sealing surface for contaminants before the sealing operation occurs. By detecting droplets or other contaminants in advance using the segmented sensor system, the process can identify and flag defective areas before sealing, preventing rework and maintaining productivity while ensuring sealing quality
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
This approach enables precise and reliable detection of sealing defects, ensuring high-quality seams and leakproof packages by identifying deviations in real-time during the sealing process without increasing the complexity or cost of packaging machinery.
Implementation Method 1
sealing the lidding film to the formed part along a sealed seam surrounding the at least one product cavity by means of a sealing device
Implementation Method 2
heat-sealed plastic package
Implementation Method 3
detecting, by means of the sealing device, a parameter characteristic of a sealing quality of the seam in each segment of the plurality of segments along the seam
Data Source
AI summary
A method for producing and inspecting a package comprising at least one product cavity of a formed part sealed by a lidding film comprises the steps of: (a) sealing the lidding film to the formed part along a seam by means of a sealing device, which comprises a sealing contour with a plurality of segments; (b) detecting, by means of the sealing device, a parameter characteristic of the sealing quality of the seam in each segment; and (c) detecting a problem with the sealing according to step (a) based on the parameter detected according to step (b) in each segment.