Vision Inspection of Ultrasonic Substrate Protrusion Defects
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Solution Overview
Problem
Conventional methods for unitary protrusion formation in substrates used in absorbent articles often result in defects such as holes, incomplete, or broken protrusions, leading to non-compliance with quality control standards and subsequent waste.
Innovation Solution
A vision inspection system is employed to illuminate and image the substrate with unitary protrusions, processing the data to assess compliance with quality control criteria and detect undesirable features, alongside a method involving a source of vibration energy to form protrusions in a substrate, which includes heating and cooling steps to optimize the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods for unitary protrusion formation are used, then manufacturing process is simple, but defects such as holes, incomplete protrusions, and broken protrusions occur frequently
Solution Approach 1:
The vision inspection system performs quality assessment of protrusions immediately after formation, detecting defects such as holes, incomplete protrusions, and broken protrusions before the substrate proceeds to subsequent manufacturing steps. This preliminary inspection prevents defective substrates from advancing, thereby improving overall manufacturing precision without requiring complex post-processing or rework systems.
Solution Approach 2:
The patent replaces manual or mechanical inspection methods with an automated vision inspection system that uses optical imaging and image processing algorithms. This substitution enables precise detection of protrusion defects through digital image analysis, significantly improving manufacturing precision while maintaining manageable device complexity through automated defect classification and substrate rejection mechanisms.
2Productivity
If vibration energy is applied to form protrusions, then protrusion formation efficiency is improved, but defects such as wrinkles and absent protrusions may occur
Solution Approach 1:
The vision inspection system provides real-time feedback on protrusion formation quality by detecting defects such as wrinkles and absent protrusions immediately after vibration energy application. This feedback loop enables process optimization by identifying parameter adjustments needed in the vibration energy application process, thereby maintaining high productivity while improving manufacturing precision through continuous quality monitoring and process correction.
3Manufacturing precision
If substrate inspection is performed to detect defects, then quality control is improved, but production time is increased
Solution Approach 1:
The vision inspection system performs quality assessment immediately after protrusion formation, detecting defects such as holes, incomplete protrusions, and broken protrusions before the substrate proceeds to subsequent manufacturing steps. This preliminary inspection prevents defective substrates from advancing, thereby improving overall manufacturing precision without requiring complex post-processing or rework systems.
Solution Approach 2:
The patent replaces manual or mechanical inspection methods with an automated vision inspection system that uses optical imaging and image processing algorithms. This substitution enables precise detection of protrusion defects through digital image analysis, significantly improving manufacturing precision while maintaining manageable device complexity through automated defect classification and substrate rejection mechanisms.
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
The solution effectively identifies and addresses defects in unitary protrusions, ensuring that only high-quality substrates are used in absorbent article manufacturing, reducing waste and enhancing product reliability.
Implementation Method 1
providing a second device comprising a source of vibration energy; forming a nip between the source of vibration energy and the outer surface; forming the protrusions in the portion of the substrate in the nip using the source of vibration energy
Implementation Method 2
imparting thermal energy to the portion of the substrate upstream of the nip to heat the portion of the substrate to a temperature below a melting temperature of the portion of the substrate
Data Source
Figure 1A
Figure 1B~1C
Figure 1D~1E
AI summary
A method is presented of forming protrusions in a portion of a substrate. The method may include providing a first device comprising an outer surface; providing a second device including a source of vibration energy; forming a nip between the source of vibration energy and the outer surface; conveying the substrate through the nip; forming the protrusions in the portion of the substrate in the nip using the source of vibration energy; and inspecting one or more characteristics of the substrate using a vision system.