Defective Web Identification via Distortion Marking
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Solution Overview
Problem
Defects such as misaligned or disconnected zipper profiles in re-sealable plastic bags are difficult to detect during production, leading to unsuitable web sections being spooled into rolls.
Innovation Solution
A system comprising a sensing device and a web distortion device that deforms the web when a defect is detected, causing the defective section to be conspicuous on a roll, allowing for easy identification and removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the zipper profile is extruded onto the web without distortion marking, then the production speed is maintained, but the defective sections are difficult to detect and identify
Solution Approach 1:
The patent introduces an intermediary marking system that physically distorts the web at defective sections to create visible identification marks. This intermediary mechanism (distortion marking device) mediates between the defect detection system and the final defect identification, transforming invisible defects into visible marked sections without requiring complex imaging or analysis systems.
Solution Approach 2:
The distortion marking device creates visible changes in the web's physical appearance through distortion marks. These marks alter the visual characteristics of the web at defective sections, making them conspicuous and easily identifiable. The marking changes the web's surface geometry from flat to distorted, providing a visual signal similar to color change principles.
2Measurement precision
If a sensing device is used to detect defective zipper profiles, then defect identification capability is improved, but the ability to locate and remove defective sections becomes more difficult
Solution Approach 1:
The distortion marking device serves as an intermediary that bridges the gap between precise defect detection and easy defect location. It takes the detection signal and translates it into a physical mark on the web that is easily visible and locatable, making the transition from detection to removal straightforward for operators.
Solution Approach 2:
The distortion marks create visible changes in the web's appearance at defective sections. These marks make defective areas conspicuous and easy to locate, directly addressing the ease of operation requirement for finding and removing defective sections after detection.
3Ease of manufacture
If the web is kept flat during production, then the production process is simplified, but defective zipper profiles become invisible and difficult to identify
Solution Approach 1:
The system performs preliminary marking at the point of defect occurrence during production. The distortion marking device immediately marks defective sections as they are extruded, preserving the flat web condition for most of the production process while ensuring defect information is captured and marked before the web leaves the production line.
Solution Approach 2:
The distortion marks create visible changes in the web's physical appearance without requiring the entire web to be non-flat during production. The marks are localized to defective sections only, maintaining overall production simplicity while providing defect visibility information where needed.
Data Source
AI summary
Systems and methods of indicating to a line worker when there is a defective zipper profile extruded onto a generally flat plastic web while moving in a feed direction in a re-sealable container production line. The system includes a sensor for detecting the defective zipper profile and a web distortion device that actuates in response to the sensor detecting the defect. The web distortion device keeps the web bunched together while it spools onto a roll support device located downstream thereby making it readily apparent to a line worker that the bunched segment contains the defective segment.