NZ754152B2 - Processes and systems for in-line inspection of functional film layer containing detectable component - Google Patents
Processes and systems for in-line inspection of functional film layer containing detectable componentInfo
- Publication number
- NZ754152B2 NZ754152B2 NZ754152A NZ75415218A NZ754152B2 NZ 754152 B2 NZ754152 B2 NZ 754152B2 NZ 754152 A NZ754152 A NZ 754152A NZ 75415218 A NZ75415218 A NZ 75415218A NZ 754152 B2 NZ754152 B2 NZ 754152B2
- Authority
- NZ
- New Zealand
- Prior art keywords
- layer
- film
- web
- tape
- functional layer
- Prior art date
Links
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Classifications
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- B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
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- B29C35/0866—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using particle radiation
- B29C2035/0877—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using particle radiation using electron radiation, e.g. beta-rays
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C2948/00—Indexing scheme relating to extrusion moulding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2948/00—Indexing scheme relating to extrusion moulding
- B29C2948/92—Measuring, controlling or regulating
- B29C2948/92009—Measured parameter
- B29C2948/92247—Optical properties
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2948/00—Indexing scheme relating to extrusion moulding
- B29C2948/92—Measuring, controlling or regulating
- B29C2948/92009—Measured parameter
- B29C2948/92295—Errors or malfunctioning, e.g. for quality control
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2948/00—Indexing scheme relating to extrusion moulding
- B29C2948/92—Measuring, controlling or regulating
- B29C2948/92009—Measured parameter
- B29C2948/92304—Presence or absence; Sequence; Counting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C2948/00—Indexing scheme relating to extrusion moulding
- B29C2948/92—Measuring, controlling or regulating
- B29C2948/92323—Location or phase of measurement
- B29C2948/92428—Calibration, after-treatment, or cooling zone
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2948/00—Indexing scheme relating to extrusion moulding
- B29C2948/92—Measuring, controlling or regulating
- B29C2948/92323—Location or phase of measurement
- B29C2948/92438—Conveying, transporting or storage of articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/001—Combinations of extrusion moulding with other shaping operations
- B29C48/0013—Extrusion moulding in several steps, i.e. components merging outside the die
- B29C48/0015—Extrusion moulding in several steps, i.e. components merging outside the die producing hollow articles having components brought in contact outside the extrusion die
- B29C48/0016—Extrusion moulding in several steps, i.e. components merging outside the die producing hollow articles having components brought in contact outside the extrusion die using a plurality of extrusion dies
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C48/001—Combinations of extrusion moulding with other shaping operations
- B29C48/0018—Combinations of extrusion moulding with other shaping operations combined with shaping by orienting, stretching or shrinking, e.g. film blowing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/001—Combinations of extrusion moulding with other shaping operations
- B29C48/0019—Combinations of extrusion moulding with other shaping operations combined with shaping by flattening, folding or bending
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/07—Flat, e.g. panels
- B29C48/08—Flat, e.g. panels flexible, e.g. films
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/09—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
- B29C48/10—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels flexible, e.g. blown foils
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/16—Articles comprising two or more components, e.g. co-extruded layers
- B29C48/18—Articles comprising two or more components, e.g. co-extruded layers the components being layers
- B29C48/185—Articles comprising two or more components, e.g. co-extruded layers the components being layers comprising six or more components, i.e. each component being counted once for each time it is present, e.g. in a layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/16—Articles comprising two or more components, e.g. co-extruded layers
- B29C48/18—Articles comprising two or more components, e.g. co-extruded layers the components being layers
- B29C48/21—Articles comprising two or more components, e.g. co-extruded layers the components being layers the layers being joined at their surfaces
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
- B29C48/91—Heating, e.g. for cross linking
- B29C48/9105—Heating, e.g. for cross linking of hollow articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
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- B29C48/911—Cooling
- B29C48/9115—Cooling of hollow articles
- B29C48/912—Cooling of hollow articles of tubular films
- B29C48/913—Cooling of hollow articles of tubular films externally
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
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- B29C48/919—Thermal treatment of the stream of extruded material, e.g. cooling using a bath, e.g. extruding into an open bath to coagulate or cool the material
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
- B29C55/22—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of tubes
- B29C55/26—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of tubes biaxial
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
- B29C55/28—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of blown tubular films, e.g. by inflation
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C71/00—After-treatment of articles without altering their shape; Apparatus therefor
- B29C71/04—After-treatment of articles without altering their shape; Apparatus therefor by wave energy or particle radiation, e.g. for curing or vulcanising preformed articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0037—Other properties
- B29K2995/0065—Permeability to gases
- B29K2995/0067—Permeability to gases non-permeable
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/89—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles
- G01N21/892—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles characterised by the flaw, defect or object feature examined
- G01N21/896—Optical defects in or on transparent materials, e.g. distortion, surface flaws in conveyed flat sheet or rod
Abstract
The continuity of a functional layer of a web is assessed by forwarding the web, detecting the presence of the functional layer and a discontinuity and/or a thin region in the functional layer, and generating a signal in response to the discontinuity and/or thin region. The functional layer comprises a detectable component in a thermoplastic composition. The detecting is carried out by a machine vision system capable of detecting the detectable component in the functional layer. The detectable component can be active or passive. Also included are systems for carrying out the process. s a detectable component in a thermoplastic composition. The detecting is carried out by a machine vision system capable of detecting the detectable component in the functional layer. The detectable component can be active or passive. Also included are systems for carrying out the process.
Description
PROCESSES AND SYSTEMS FOR IN-LINE INSPECTION OF FUNCTIONAL
FILM LAYER CONTAINING DETECTABLE COMPONENT
Background
The present invention relates to a process for inspecting films for quality
assurance, to ensure that the film is suitable for its ed use.
Many films, particularly packaging films, are made by ing one or
more thermoplastic materials from a die. The thermoplastic als emerge from
the die as a molten . For a variety of reasons, there can be anomalies in the
film layer or layers, including discontinuities in one or more film layers. Some
anomalies are in the shape of continuous die lines running in the machine direction
of the film. Other anomalies are in the shape of a spot. Spot discontinuities can
result from the als used, orfrom material ng up in the extruder or the die,
with the material passing out through the die opening to become part of the film,
g a discontinuity in the film. Polymer gels can form in the extruder or die and
pass through the die to become spot discontinuities (i.e., voids) in the film. The die
may have a nick or other damage or buildup which can result in a die line, or material
may slough off of the extruder and block a portion of the die opening, resulting in a
die line.
Packaging films include both monolayer and multilayerfilms. In a
multilayer film, each film layer has a function, such as, for example, a strength layer,
a heat seal layer, an abuse layer, a gloss layer, a barrier layer, an easy-open layer,
and a tie layer for adhering two othenNise incompatible layers to one another. The
above-described tinuities may be t in one or more layers of a multilayer
film.
Quality assurance methods commonly require that a portion of the film
be removed and subjected to off-line analysis. This is time-consuming, laborious,
and is frequently destructive of the film sample tested. Moreover, such quality
nce methods check only a small portion of the film. It would be desirable to be able to
check one or more layers of the film, over a substantial portion of the film, in order to know the
frequency and character of any discontinuities present in one or more layers of the film.
Moreover, it is desirable to conduct this quality check quickly and efficiently, without
interrupting the process of making the film and without destroying any portion of the film.
Summary of the Invention
[0005] The present invention provides a process by which one or more layers of a film
can be inspected for the frequency and character of any discontinuities present, and/or for the
suitability of the film layer for carrying out its intended function. er, the tion can be
carried out over a ntial portion of the film, and can be carried out for one or more layers of
the film. Moreover, this quality check is quick and efficient, without interrupting the process of
making the film as it can be carried out on the moving web. Still further, the process does not
destroy any portion of the film. The process is fied by adding one or more indicator
components to one or more layers of the film to allow an automated inspection system to detect
discontinuities in the one or more layers of the film. Various embodiments of the process allow
continuous, in-line inspection of the entire film to detect any discontinuities down to a small size,
such as 2mm or even less in at least one direction.
An aspect is directed to a process for assessing continuity of a onal layer of
a web. The process comprises g the web by extruding a thermoplastic material h an
annular die to form an annular tape, quenching the tape, and collapsing the tape into lay-flat
uration, which is fter converted to a plurality of bags; forwarding the web at a speed
of at least 5 meters per minute, detecting the presence of the functional layer and a discontinuity
in the functional layer by inspecting the web with a machine vision system capable of detecting
the presence or absence of a able component in the functional layer, and generating a
signal in response to the discontinuity in the functional layer. The functional layer comprises a
blend of a thermoplastic composition and a detectable component, the able component
being present at a detectable level in the functional layer, the annular tape is reheated to its
softening point and oriented while in the solid state after quenching, and inspecting the web
is carried out as an inspection of the web in its lay-flat characterization by scanning the
r tape while the tape is in motion, wherein the scanning is carried out by a camera
oned downstream of a point at which the tape is quenched and collapsed into the layflat
configuration.
In an embodiment, the web is a monolayer web. In another embodiment, the web
is a ayer web sing the functional layer and at least one additional layer.
In an embodiment, for an unoriented annular tape the machine vision system can
generate a signal in response to a layer discontinuity having a size down to at least as small as 2
mm in the machine direction and having a size down to at least 1 mm in the transverse direction.
In an embodiment, for an ed heat shrinkable film tubing the machine vision system is
e of generating a signal in response to a layer discontinuity having a size down to at least
as small as 7 mm in the machine direction and 3.5 mm in the transverse direction.
In an embodiment, for an unoriented annular tape the machine vision system can
generate a signal in response to a layer discontinuity having a size down to at least as small as 1
mm in the machine direction and having a size down to at least 0.5 mm in the transverse
direction. In an embodiment, for an oriented heat able film tubing the machine vision
system is capable of generating a signal in response to a layer discontinuity having a size down to
at least as small as 3.5 mm in the machine direction and 1.8 mm in the transverse direction.
In an embodiment, for an unoriented annular tape the machine vision system can
te a signal in response to a layer discontinuity having a size down to at least as small as 0.2
mm in the machine direction and having a size down to at least 0.1 mm in the erse
direction. In an embodiment, for an oriented heat shrinkable film tubing the machine vision
system is capable of generating a signal in response to a layer discontinuity having a size down to
at least as small as 0.7 mm in the machine direction and 0.35 mm in the transverse direction.
[0011] In an embodiment, the process further comprises detecting an amount of the
detectable component in the functional layer, wherein the amount of the detectable component is
proportional to a thickness of the functional layer.
In an ment, the functional layer is a member selected from the group
ting of an oxygen barrier layer, an organoleptic barrier layer, and a moisture barrier layer.
In an ment, the functional layer is an oxygen barrier layer comprising at least one member
selected from the group consisting of vinylidene chloride copolymer, fied ethylene/vinyl
acetate copolymer, polyamide, polyester, ed polypropylene, and ethylene lymer.
In an embodiment, the inspecting of the web is carried out over at least 10% of the
web.
In an embodiment, the s further comprises forming the web by extruding
the thermoplastic material through an annular die to form an annular tape, quenching the tape,
and collapsing the tape into lay-flat configuration, with the inspecting of the tape being carried
out by scanning the annular tape while the tape is in motion and in a lay-flat configuration, the
scanning being carried out by a camera positioned downstream of a point at which the tape is
quenched and collapsed into the lay-flat configuration.
In an embodiment, the detecting of the presence the functional layer and
discontinuities in the onal layer are carried out by inspecting the web with a machine vision
system capable of detecting the presence or absence of the able component in the
functional layer, including the capability of detecting the presence or absence of the detectable
component in both lay-flat sides of the annular tape while the annular tape is in the lay-flat
configuration.
[0016] In an embodiment, the detecting of the presence the functional layer and
discontinuities in the onal layer are carried out by inspecting the web with a machine vision
system capable of detecting the ce or absence of the detectable component in the
functional layer, including the capability of detecting the presence or absence of the detectable
component 360 degrees around the while the annular tape is in a round configuration.
In an embodiment, the scanning is carried out by a camera positioned downstream
of a point at which the annular tape is subjected to solid state orientation to form an annular film
tubing, the camera being positioned am of a point at which the annular film is wound up or
slit.
In an embodiment, the detecting of the presence of the functional layer and
discontinuities in the functional layer are carried out by inspecting the annular film tubing with a
machine vision system capable of detecting the presence or e of the detectable component
in the functional layer, including detecting the presence or absence of the detectable component
in both lay-flat sides of the annular film tubing.
[0019] In an embodiment, the annular film tubing can be heat-shrinkable.
In an embodiment, the detecting of the presence of the functional layer and
discontinuities in the functional layer can be carried out by a camera positioned downstream of a
point at which a roll of the annular tape or annular film is being unrolled.
In an embodiment, the r tape is subjected to solid state orientation to form
an annular film which is thereafter converted to a plurality of bags, and the camera is positioned
to scan the bags before a product is placed inside the bags.
[0022] In an ment, the detectable component comprises at least one member
ed from the group consisting of ultraviolet-indicator, infrared-indicator, dye, pigment,
optical brightener, fluorescent whitening agent, and iophenediylbis(5-tert-butyl-1,3-
benzoxazole). 2,5-Thiophenediylbis(5-tert-butyl-1,3 benzoxazole) is marketed as an optical
brightener by a plurality of suppliers, including BASF Corporation (TINOPAL OP© 2,5-
enediylbis(5-tert-butyl-1,3-benzoxazole) fluorescent brightening agent) and Mayzo, Inc
(BENETEX OB PLUS® 2,5-thiophenediylbis(5-tert-butyl-1,3-benzoxazole) fluorescent
brightening agent).
In an embodiment, the detectable component is t in the functional layer at a
level of at least 1 part per million.
In an embodiment, the detectable component is of a type which, if d to
radiation at a first peak wavelength, emits radiation at a second peak wavelength.
In an embodiment, the signal generated in response to the discontinuity is used to
activate at least one member selected from the group consisting of an alarm, film ng,
displaying an image of a discontinuity, displaying data pertaining to one or more discontinuities,
and generating a report of the discontinuity data.
In an embodiment, the signal generated in response to the discontinuity includes
at least one member selected from the group consisting of geometric characteristic of the
discontinuity, location of the discontinuity, frequency of occurrence of a plurality of
discontinuities, severity of discontinuity.
In an embodiment, the signal in response to the discontinuity is ted and
activates the alarm, flagging, discontinuity image display, discontinuity data, report of
discontinuity data, etc while the web remains in motion, i.e., instantaneously and online.
Alternatively, the signal in response to the discontinuity is generated after production is
complete, i.e., offline. The signal in response to the discontinuity can include electronic
messaging, email, data log, and .
In an embodiment, the process is d out wherein: a) the web is forwarded at a
speed of at least 30 meters per minute; b) the detectable component is present in the
thermoplastic composition at a level of from 0.5 to 150 ppm; c) the detecting of the presence the
functional layer and the tinuity in the functional layer are carried out by inspecting the web
with a machine vision system capable of generating a signal indicating the presence or absence of
the detectable ent in the functional layer, by scanning transversely across the web and
ting a signal in response to the presence, absence, and amount of the detectable component
present in a functional layer of the web, wherein: (c)(i) the e vision system comprises a
line-scan camera scanning at a speed of from 50 to 1000 rtz and at an exposure time of
from 2 x 10-3 second to 1 x 10-5 second; (c)(ii) in an unoriented annular tape the machine vision
system is e of ting a signal in response to a layer discontinuity having a size down to
at least as small as 2 mm in the machine direction and having a size down to at least 1 mm in the
transverse direction, or in an oriented heat-shrinkable film tubing the machine vision system is
capable of generating a signal in response to a layer discontinuity having a size down to at least
as small as 7 mm in the machine direction and at least as small as 3.5 mm in the transverse
direction; and (c)(iii) the machine vision system scans with a pixel count of from 500 to 50,000
per scan.
In an ment, the process is carried out wherein: a) the web is forwarded at a
speed of at least 50 meters per minute; b) the detectable component is present in the
thermoplastic composition at a level of from 1 to 20 ppm; c) the detecting of the presence the
functional layer and the discontinuity in the functional layer are carried out by inspecting the web
with a machine vision system capable of generating a signal indicating the presence or absence of
the detectable component in the functional layer, by scanning transversely across the web and
generating a signal in response to the presence, absence, and amount of the detectable M
component present in a onal layer of the web, wherein: (c)(i) the e vision system
comprises a line-scan camera ng at a speed of from 100 to 750 megahertz and at an
exposure time of from 7 x 10-3 second to 3 x 10-5 second; (c)(ii) in an unoriented annular tape the
machine vision system is capable of generating a signal in se to a layer discontinuity
having a size down to at least as small as 1 mm in the machine direction and having a size down
to at least 0.5 mm in the transverse direction, or in an oriented heat-shrinkable film tubing the
machine vision system is e of ting a signal in response to a layer discontinuity
having a size down to at least as small as 3.5 mm in the machine direction and at least as small as
1.8 mm in the erse direction; and (c)(iii) the machine vision system scans with a pixel
count of from 1,000 to 15,000 per scan.
[0030] In an embodiment, the process is carried out n: a) the web is forwarded at a
speed of from 60 to 150 meters per minute; b) the detectable component is present in the
thermoplastic composition at a level of from 2 to 10 ppm; c) the detecting of the ce the
functional layer and the discontinuity in the functional layer are carried out by inspecting the web
with a machine vision system capable of generating a signal indicating the presence or absence of
the detectable component in the functional layer, by scanning transversely across the web and
generating a signal in response to the presence, absence, and amount of the able component
present in a functional layer of the web, n: (c)(i) the machine vision system comprises a
line-scan camera scanning at a speed of from 200 to 500 megahertz and at an exposure time of
from 2 x 10-4 second to 5 x 10-5 second; (c)(ii) in an unoriented annular tape the machine vision
system is capable of generating a signal in response to a layer discontinuity having a size down to
at least as small as 0.2 mm in the machine direction and having a size down to at least 0.1 mm in
the erse direction, or in an oriented heat-shrinkable film tubing the machine vision system
is capable of generating a signal in response to a layer discontinuity having a size down to at
least as small as 0.7 mm in the machine ion and at least as small as 0.35 mm in the
transverse direction; and (c)(iii) the machine vision system scans with a pixel count of from
3,000 to 9,000 per scan.
There is described herein a process for assessing continuity of a functional layer
of a film, comprising forwarding the film at a speed of at least 5 meters per minute, detecting the
presence of the functional layer and a thickness of the functional layer by inspecting the film
with a machine vision system e of detecting the presence or absence of the detectable
component in the functional layer and an amount of the detectable component in the functional
layer; and generating a signal in response to the amount of the detectable component in the
functional layer. The functional layer comprises a thermoplastic composition and a detectable
ent, the detectable component being present in the thermoplastic composition so that the
detectable component is present at a detectable level in the functional layer. The process can
utilize one or more es of the various embodiments disclosed above for the previous aspect.
Another aspect is directed to a system for assessing layer continuity in a moving
web in accordance with the previously described aspect, the system comprising (A) a web
forwarding device forwarding the web at a speed of from at least 5 meters per minute, the web
having a functional layer comprising a plastic composition having a detectable component
therein and being formed in a process comprising extruding a plastic al through an
annular die to form an r tape, quenching the tape, and collapsing the tape into a lay-flat
configuration; (B) an image generator for ting image data of the detectable ent in
the functional layer of the moving web as the web is being forwarded by the web forwarding
device , wherein the image generator is a camera positioned downstream of a point at which
the tape is quenched into the lay-flat configuration to inspect the oriented annular tape; (C) a
data ition system for acquiring the image data of the web from the image generator; and
(D) a vision inspection engine for receiving and analyzing the image data to identify and classify
the presence and absence of defects in the web using the image data received from the data
acquisition system, the vision inspection system generating an alert fying the presence or
absence of a defect in the web. This aspect can utilize one or more features of the various
embodiments disclosed above for the previous aspect.
There is further described herein a system capable of detecting a detectable
component in a moving web, the system comprising: (A) an image generator for generating
image data of a detectable component in the web as the web is being forwarded from a web
supply; (B) a data acquisition system for M acquiring the image data from the image generator,
the image data being of the detectable component in the web; and (C) a vision inspection engine
for receiving and analyzing the image data from the web, the vision inspection engine identifying
and classifying the presence and e of s in the web using the image data from the web
received from the data acquisition system, the vision inspection system generating an alert
identifying the presence or absence of a defect in the web. The system can utilize one or more
features of the various embodiments disclosed above for the previous aspect.
There is also described herein a system capable of detecting a detectable
ent in a moving web, the system comprising: (A) a detector oriented and adapted to
generate sensed film data of a detectable component in a film being forwarded towards the
detector from a film supply; (B) a data acquisition system that acquires and collects the sensed
film data from the detector; and (C) an inspection engine that es and analyzes the sensed
film data and compares at least one characteristic of the sensed film data against at least one
threshold to fy and classify the ce and e of defects in the film using the sensed
film data, the inspection system generating an alert identifying the presence or absence of a
defect in the web. The system can e one or more es of the various embodiments
disclosed above for the previous aspect.
In an embodiment, the or can detect a discontinuity in a film layer
containing the detectable component. In an ment, the detector can be a UV sensor, a
sensor array, or a sensor matrix. In an embodiment the system may comprise an encoder to
correlate the position of a discontinuity or film thinning on the web while the web is being
forwarded at a film processing speed.
Brief Description of the Drawings
is a schematic of a web production s for extruding an annular web
which is coated to make a multilayer annular tape.
is a schematic of a process for scanning a web with a machine
vision system while the web is being forwarded at a processing speed.
is a schematic of a further web production process for
converting the annular tape produced in into an annular heat-shrinkable film
illustrates both (i) a scan signal charts for coated annulartapes
made from Film Nos. 1, 2, and 3 in y-side relationship, er with (ii) the
corresponding image of the three corresponding lay-flat tapes also in side-by-side
relationship.
[0040] rates transverse scan signal charts for coated annular tapes
made from Film Nos. 7 and 8 in side-by-side relationship.
illustrates scan signal charts for coated annular tapes made
from Film Nos. 8 and 9 in y-side relationship.
illustrates a scan signal chart for a coated annular tape made
from Film No. 10, the scan being taken with the first lay-flat side up.
is an image of the scanned section of the coated annular tape
of Film No. 10, the image being taken with the first lay-flat side up.
both illustrates a scan signal chart for the coated annular tape
made from Film No. 10, the scan being taken with the second lay-flat side up, and
above the scan an image of the coated annular tape of Film No. 10, the image being
taken with the second lay-flat side up.
illustrates a scan signal chart for the annular heat-shrinkable
film made from Film No. 10, the scan being taken with the first lay-flat side up.
is an image of a portion of the scanned section of the annular
heat-shrinkable film made from Film No. 10, the image being taken with the first lay-
flat side up.
is a schematic of a system for assessing continuity of a
functional layer of a web, including a flow diagram for data acquisition, data
processing, and an alert for identifying the presence or absence of a defect in the
web.
is a schematic of a n of a coextrusion die having four
blockages therein.
[0049] is a plot of position across the lay-flat web (x-axis) against
signal intensity (y-axis) for Film No. 12, described above.
is a plot of ness (Y axis) as a function of time (X axis) in
the machine vision tion of Film No. 12. A film anomaly data point was
recorded each time the vision system detected a discontinuity in the r layer.
[0051] is a plot of brightness (Y axis) as a function of time (X axis) in
the machine vision inspection of Film No. 11.
Detailed Descfiption
As used herein, the term “film” is inclusive of plastic web, regardless of
whether it is fi|m (up to 10 mils thick) or sheet (greaterthan 10 mils thick). In an
embodiment, the ation of a web in the solid state to produce a heat shrinkable
film can be carried out by first extruding a monolayer or multilayer thermoplastic
annular “tape,” which is thereafter quenched and collapsed into its lay-flat
configuration, and fter optionally irradiated (to crosslink the polymer) and
optionally extrusion coated with one or more additional thermoplastic layers,
following which the r tape is reheated to its ing point and then biaxially
oriented (i.e., stretched in the transverse direction and drawn in the machine
direction) while in the solid state in a trapped bubble process to result in a heat-
able film, as described in es below and as illustrated in FIGS. 1A and
1C. The result is a heat-shrinkable film tubing, Le, a film having a total (i.e.,
udinal plus transverse, L+T) free shrink of at least 10% at 185°F (85°C).
As used herein, the phrase “machine ion” and “MD” referto the
direction in which the film is made as it is produced, i.e., the direction of the melt
stream coming out of the die during extrusion. As used , the phrase
“transverse direction” and “TD” refer to the direction which is perpendicular to the
machine ion.
As used herein, the phrase “functional layer” refers to a layer of
monolayer or multilayer film that has one or more functions, such as, for example, a
strength layer, a heat seal layer, an abuse layer, a gloss layer, a barrier layer, a
shrink layer, an easy-open layer, or a tie layer for adhering two othenNise
incompatible layers to one another. The functional layer comprises a thermoplastic
polymer. The above-described discontinuities may be present in one or more layers
of a multilayerfilm.
As used herein, the term “barrier”, and the phrase “barrier layer”, as
applied to films and/orfilm layers, are used with reference to the ability of a film or
film layer to serve as a barrier to one or more gases. In the packaging art, oxygen
(i.e., gaseous Oz) barrier layers have ed, for example, hydrolyzed
ne/vinyl acetate copolymer (designated by the abbreviations “EVOH” and
“HEVA”, and also referred to as “ethylene/vinyl alcohol copolymer”), polyvinylidene
chloride, amorphous polyamide, polyamide MXD6, polyester, polyacrylonitrile, etc.,
as known to those of skill in the art. In addition to the first and second layers, the
heat-shrinkable film may further comprise at least one barrier layer.
The phrase “oxygen transmission rate” ) is defined herein as the
amount of oxygen in cubic centimeters (cm3) which will pass through 100 square
inches of film in 24 hours at 0% relative humidity and at 23° C. The thickness
(gauge) of the film has a direct relationship on the oxygen transmission rate.
ing films which are useful as an oxygen barrier are required to have an OTR
value of from about 0 to 10.0 cm3/100 in2 over 24 hr at 0% relative humidity and 23°C
at 1.0 mils or less. Oxygen transmission may be measured according to ASTM D-
3985-81 which is incorporated herein by reference.
As used herein, the phrase sing the continuity of the functional
layer” includes both assessing the functional layerforthe ce of tinuities,
as well as assessing the functional layerforthe regions which are thin enough that
the function of the layer is substantially diminished.
As used herein, the term “inspecting” refers to taking one or more
images of the web (i.e., tape or film) with a point source device or by scanning the
film.
As used herein, the term “scanning” refers to the use of a sensor array
or sensor matrix, or a moving sensor, to te a series of signals indicating the
presence or e of a able component in a small region across a plurality
of spatially arranged areas. In an embodiment, the spatially arranged areas are
across the film or web.
As used herein, the phrase “detectable component” refers to any
component that is added to a thermoplastic material extruded to make a film layer,
which component is detectable by a detector, machine vision, or any other means for
determining the presence or absence of the component in a particular area of the
film.
As used herein, the term “blend,” as applied to the able
component, includes the physical blending of the detectable component with one or
more polymers used in the film layer, or modifying one or more of the polymers used
in the film layer by ng the detectable component with the polymer chain, or
blending the detectable component with one or more monomers which are thereafter
polymerized to produce the polymer in the film or film layer.
As used herein, the phrase “in-line” refers to carrying out the scanning
of the web while the web is being fonNarded, and without having to remove a portion
of the web for the analysis, and without having to destroy any portion of the web
while carrying out the analysis. The fonNarding can be between extrusion and
orientation, after ation but before windup, or in subsequentfilm processing.
Scanning can be carried out with one or more cameras. Scanning can
be performed on an open film tape ortubing (i.e., in circular configuration) or in lay-
flat configuration. A film tape or tubing in lay-flat configuration may be scanned with
a single in-line camera, a film tape or tubing in circular configuration may require at
least two cameras in order to be scanned.
As used herein, the phrase in the signal is generated in
response to discontinuities at least as small as 2 mm in a designated direction”
refers to a system capable of generating a signal in response to tinuities
greater than 2 mm in the designated direction (i.e., in the machine direction and/or
the transverse direction), as well as tinuities of 2 mm in the designated
direction, and optionally tinuities even less than 2 mm in the designated
direction. That is, this phrase means that the e vision system is capable of
generating a signal in response to tinuities down to at least as small as the
specified size in the designated direction.
In an embodiment, for an unoriented annular tape the machine vision
system is e of generating a signal in response to a layer discontinuity having a
size down to at least as small as 2 mm in the machine direction and having a size
down to at least 1 mm in the transverse direction. In an ment, for an
unoriented annular tape the machine vision system is capable of generating a signal
in response to a layer discontinuity having a size down to at least as small as 1 mm
in the machine direction and having a size down to at least 0.5 mm in the transverse
ion. In an embodiment, for an unoriented annular tape the machine vision
system is capable of ting a signal in response to a layer discontinuity having a
size down to at least as small as 0.2 mm in the machine direction and having a size
down to at least 0.1 mm in the transverse direction.
In an embodiment, for an oriented hrinkable film tubing the
machine vision system is capable of ting a signal in response to a layer
discontinuity having a size down to at least as small as 7 mm in the machine
direction and 3.5 mm in the transverse direction. In an embodiment, for an oriented
heat-shrinkable film tubing the machine vision system is capable of generating a
signal in response to a layer discontinuity having a size down to at least as small as
3.5 mm in the machine ion and 1.8 mm in the transverse direction. In an
embodiment, for an oriented heat-shrinkable film tubing the machine vision system is
capable of generating a signal in response to a layer discontinuity having a size
down to at least as small as 0.7 mm in the machine direction and 0.35 mm in the
transverse ion.
The signal can be an analog signal or a digital . In an
embodiment, the signal is processed to detect the presence or absence of the
detectable component in a region of the functional layer, thereby detecting whether a
discontinuity is present in the region of the functional layer to which the signal
applies. In another embodiment, the signal is processed to detect the amount of the
detectable component in a region of the functional layer, thereby ing the
thickness of the functional layer in the region of the film to which the signal applies.
In an ment, scanning is carried out using line-scan vision
technology in which a series of images (each image contains 4096 pixels) in a line is
taken across 100% of the width of the web, with each image covering only 1/4096 of
the width of the web if the camera is set so that the length of the line is the same as
the width of the web. However, as the length of the line is generally set to be
somewhat longer than the width of the web, each image generally covers from about
0.025% (i.e., 1/4000t“) to about 0.1% (i.e., 1/1000t“) of the distance across the web.
Moreover, as the web is generally traveling between 30 and 300 meters per minute
(i.e., 0.5 to 5 m/sec). Thus, if images are taken at a rate of 1x104 images/sec, each
image generally covers a web length of 0.05 mm to 0.5 mm.
In an ment, the combination of the identity and concentration of
the detectable component in the functional layer, the thickness of the functional
layer, and the identity of the machine vision system, is capable of detecting
discontinuities down to at least as small as 2 mm in at least one direction. The
phrase “discontinuities down to at least as small as 2 mm in at least one direction”
refers to the degree of tion of the combination. Alternatively, the ation
is capable of detecting discontinuities down to at least as small as 1.5 mm in at least
one direction, or down to at least as small as 1 mm in at least one direction, or down
to at least as small as 0.8 mm in at least one ion, or down to at least as small
as 0.5 mm in at least one direction, or down to at least as small as 0.4 mm in at least
one direction, or down to at least as small as 0.3 mm in at least one direction, or
down to at least as small as 0.2 mm in at least one direction, or down to at least as
small as 0.1 mm in at least one direction, or down to at least as small as 0.05 mm in
at least one direction. Discontinuities can be categorized as small, medium, and
large discontinuities. A small tinuity is below 2 mm in at least one direction. A
medium sized discontinuity is from 2 to 5 mm in at least one direction. A large
discontinuity is at least 5 mm in at least one direction.
If the detectable component is ly undetected in the film, it could
be because (i) because the functional layer (e.g., barrier layer) is entirely absent
from the film, or (ii) because the functional layer is thinned down overall orjust in one
or more areas, with the ng down being to a degree that the level of the
detectable component is too low to be detectable or below a pre-set threshold level.
This could occur if the wrong film is produced or selected, Le, a film without the
functional layer, or a film in which the entirety of the functional layer is thinner than
the desired thickness of the functional layer, or a film in which one or more portions
of the functional layer are thinner than the d thickness of the functional layer.
As used herein, the term “discontinuity” refers to any discontinuity in
the functional layer of a film containing the functional layer, with the discontinuity
being represented by a thinner functional layer beginning at a thickness just below a
minimum acceptable level, all the way down to the complete absence of the
functional layer in the film or in one or more regions of the film, or at least down to
below the m detectable limit of the indicator per unit area of the functional
layer. The term “discontinuity” includes any one or more of the following: (i) any
detectable lack of uity of the indicator within an indicator-containing functional
layer of a film, (ii) any detectable reduction in the level of the indicator in a ic
region of the film, (iii) the ion of an undesirable object in the flm that does not
contain the indicator (iv) the te absence of the indicator from the functional
layer of the film, and (iii) the indicator being entirely absent from the film, regardless
of whether or not the functional layer is present. The meaning of the term “anomaly,”
as used herein, is the same as the meaning of the term “discontinuity” as used
herein.
The camera can be a monochrome camera or a color camera, and can
be an area scan camera or a line-scan camera. Line-scan cameras are preferred
because they are more ical and the data from a line-scan camera is easier
and faster to process. Regardless of whether the camera is a color camera or a
monochrome camera, the camera should be set to receive the wavelength of
irradiation transmitted from or reflected by the detectable component. The image is
sed by ting the es, with an alarm or report or label being activated
if a discontinuity is detected in the signal. The extracted features in the image data
can be processed by comparing the extracted features with the stored defect
features.
As used herein, the phrase “vision system” includes optical systems as
well as ic systems to detect the presence or absence of the detectable
component in the functional layer.
In an embodiment, the process can be carried out while the film is
being forwarded at a speed of at least 10 m/min, or at least 20 m/min, or at least 40
m/min, or at least 60 m/min, or at least 80 m/min, at least 100 m/min, or at least 120
m/min, or at least 140 m/min. In an embodiment, the process can be carried out
while the film is being forwarded at a speed of from 1 to 1,000 m/min, orfrom 25 to
500 m/min, or from 40 to 300 m/min, or from 60 to 200 m/min, or from 80 to 180
m/min, 100 to 160 m/min, or from 110 to 140 m/min.
A web, extruded from an annular die as an annular “tape,” is extruded
relatively thick if a heat-shrinkable film is ultimately desired. The annular tape is
designed to subsequently undergo solid state orientation for the making of the
r heat shrinkable film tubing.
The annular tape can be a fully coextruded, or can be prepared by
ion coating, as described in the examples below. In an embodiment, the
annular tape can have a thickness of at least 11 mils, or at least 15 mils, or at least
20 mils; or from 11 to 50 mils, or from 15 to 40 mils, or from 20 to 30 mils.
The annular tape can be stretched and drawn in the solid state to
produce a heat shrinkable film tubing. In an embodiment, the hrinkable film
tubing has a total thickness of at least 0.5 mil, or at least 1 mil, or at least 1.5 mils, or
at least 2 mils, or at least 2.5 mils, or at least 3 mils, or at least 5 mils, or at least 7
mils. In an embodiment, the heat-shrinkable film tubing has a thickness of from 0.5
to 10 mils, or from 1 to 7 mils, orfrom 1.2 to 5 mils, or from 1.3 to 4.5 mils, or from
1.4 to 4 mils, or from 1.5 to 3.5 mils, or from 1.6 to 3 mils, or from 1.7 to 2.5 mils.
The annular tape emerging from the annular die can be ed and
fter reheated to its ing point and oriented while in the solid state. The
inspecting for discontinuities and/or layer thickness can be carried out on the r
tape before it is oriented in the solid state. Moreover, the inspecting can be carried
out on the annulartape in its lay-flat configuration. Alternatively, the inspection can
be carried out on the oriented film afterthe solid state orientation. In an embodiment
the inspection of the oriented film can be carried out as an inspection of the oriented
film tubing in its at configuration.
Alternatively, the film can be extruded as a flat tape from a slot die. If a
heat-shrinkable flat film is desired, the flat tape can thereafter be heated to its
softening point and oriented while in the solid state, for example via tenterframe, to
produce the heat-shrinkable flat film. The flat tape can be ted before it is
oriented, or after the solid state orientation.
In an embodiment, the process is carried out by inspecting through the
full thickness of the film over an area of at least 10% of the surface of the film. In
alternative ments, the process is carried out by inspecting through the full
thickness of the film, at least 20%, or at least 30%, or at least 40%, or at least 50%,
or at least 60%, or at least 70%, or at least 80%, or at least 90%, or at least 95%, or
at least 98%, or at least 99%, or at least 99.5%, or at least 99.9%, or 100% of the
multilayer film.
[0081] In an ment, the functional layer functions as a barrier layer. The
barrier layer can be an oxygen barrier layer, an leptic barrier layer (barrier to
aroma and/orflavor components), a moisture barrier layer, or any other barrier layer
known to those of skill in the film art.
Suitable moisture barrier layers include ethylene-based polymers such
as high y polyethylene, polypropylene (especially biaxially oriented
polypropylene), polyester, yrene, and polyamide.
Suitable thermoplastic oxygen barrier layers include polyvinylidene
chloride (PVDC), saponified ethylene/vinyl acetate copolymer (also commonly
referred to as ethylene/vinyl l copolymer, or EVOH), polyamide, polyester,
oriented polypropylene, and ethylene homopolymer.
Inspecting an oxygen barrier layer of a film provides added value to the
film e the ingress of oxygen into a package containing an oxygen-sensitive
product can shorten the shelf life of the product or render the product inoperable for
its intended use. Pharmaceuticals, medical devices, corrodible metals, analytical
chemicals, electronic devices, foods (including meat), beverages, and many other
products ence shed shelf life, spoil, or become inoperable if stored too
long in the presence of oxygen. To combat this m, packaging materials and
packaging systems have been developed to protect these products by providing a
package environment, or “headspace,” with reduced oxygen levels.
[0085] Reduced oxygen levels can be obtained by packaging under vacuum,
or by displacing the atmosphere and substituting a modified atmosphere (e.g., low in
oxygen) around the product. In some cases, the low oxygen level that can be
obtained with these packaging systems is still insufficient to provide the d shelf
life.
[0086] In food packaging, the purpose of the barrier layer is to ntially
increase the shelf life of the food and prevent food spoilage. The barrier layer can
be extremely thin in some multilayer food packaging film. A low-defect-Ievel or
defect-free barrier layer assists in extending the shelf life of the ed food
product. If a vacuum package or modified atmosphere package has a significant
discontinuity and the oxygen barrier layer and allows heric oxygen to enter
the package, ultimately the atmospheric oxygen content within the e will
se, reducing the shelf life of the product.
In an embodiment, a detectable ent (e.g., an ultra-violet (UV)
fluorescing agent) is blended with an oxygen barrier resin such as PVDC or EVOH,
or even included with the reactants which polymerize to form the PVDC or EVOH. .
Providing the detectable component within the barrier resin at a tent level so
that the detectable component is homogeneously dispersed throughout the resin
(and thereby dispersed throughout the resulting film layer) allows for accurate
monitoring and identification of discontinuities in the barrier layer. Homogeneity can
be accomplished by blending and/or compounding steps as known to those of skill in
the art of blending additives into polymers or preparing polymers in the presence of
additives. For example, making a homogeneous blend of 15 ppm indicator with a
thermoplastic polymer can be carried out using staged ng, as follows. In a first
blending stage, 3 parts by weight indicator masterbatch are blended with 97 parts by
weight primary polymer, resulting in a first stage blend containing indicator at a level
of 30,000 ppm. In a second blending stage, part or all of the first stage blend is
diluted 20:1 with the y polymer, resulting in a second stage blend containing
indicator at a level of 1500 ppm. In the third stage blend, part or all of the second
stage blend is diluted 100:1 with the y polymer, resulting in a third stage blend
which ns indicator at a level of 15 ppm indicator. In each stage, blending is
carried out to a high degree of uniformity by using, for e, a high shear mixer.
The neity of the resulting blend also allows the barrier resin to retain its
barrier function in the barrier layer of the film.
[0088] The detectable component can be added at a low level (e.g., 20 ppm)
such that the layer retains its barrier property but the detectable component is
t at a level high enough that it is readily detectable by the machine vision
. If a UV-fluorescing agent is used, upon receiving UV ion that s
the fluorescing agent, the UV agent is provided at a level high enough that its
fluorescence can be readily detected by the machine vision system, but at the same
time at a level low enough that the presence of the UV agent does not substantially
reduce the oxygen barrier character of the oxygen barrier polymer from which the
barrier layer is made.
The detectable component / barrier material blend can then be
extruded alone or in combination with one or more additional melt streams, to form a
yer or multilayer film. In an embodiment, during the film manufacturing
process the vision system can be employed in-line to generate a signal that is used
to identify discontinuities that may be present in the barrier layer by detecting the
presence and absence of the detectable component. In an embodiment, the output
signal from the machine vision system can be used to monitor the thickness of the
barrier layer to ensure that the layer es adequate oxygen barrier hout
the film structure, and s of the barrier layer which are too thin may not provide
the level of oxygen barrier required to obtain the desired protection or desired shelf
life.
Although the presence of the detectable component in the packaged
product is preferably not readily visible to a consumer, if a UV-fluorescing agent is
used as the detectable ent, a product packager using a roll of such a film to
package product is able to vely confirm the ce or absence of the barrier
layer in the film by simply illuminating the roll of film with a UV-light (e.g., UV
flashlight) to cause the UV agent to fluorescence, thereby confirming the ce or
absence of the oxygen barrier layer in the film based on whether the desired
fluorescence is observed.
The ability to ately fy a barrier layer in a film is important
because a wide variety of films are utilized for packaging, with some of the films
requiring a barrier layer and other packaging films not requiring a barrier layer. If a
non-barrier film is inadvertently mislabeled as a barrier film, or inadvertently utilized
to package a product which requires a barrier film, the shelf life of a product
packaged in the film may be compromised, potentially resulting in product damage.
The presence of, for example, the UV fluorescing agent in an oxygen r layer of
the film, allows for quick and accurate testing to positively confirm the presence or
absence of the barrier layer in the film, thereby minimizing the chance that an
oxygen-sensitive product is packaged in a film g an oxygen barrier layer.
In addition to using the presence of the indicator to instantly assess
whether the barrier layer (or any functional layer containing the indicator) is present,
and in addition to using the indicator in the functional layer to assess the film for
discontinuities in the functional layer, the presence of the indicator in a functional
layer can be used to assess the thickness of the functional layer, and to assess the
functional layer for the presence of areas which are thicker and/or thinner than the
desired thickness of the functional layer. In a functional layer in which the
concentration of, for example, a fluorescing indicator is evenly dispersed, a thin
region will fluoresce less than (i.e., be darker than) a region at the desired ess;
a thick region will fluoresce more than (i.e., be brighter than) a region at the desired
thickness.
In an embodiment, the combination of the detectable component in the
r layer and the vision system allow uous monitoring of the barrier layer as
the film is produced or processed. The process can identify the presence of barrier
layer discontinuities (i.e., barrier layer defects), can optionally be designed to fy
the defects based on size and type, can optionally be designed to map the location
of the defects and even tag the film at any region(s) at which a defect is located, can
optionally count and record the number and classification of the defects, including
cumulative defect counts. In an embodiment this process of monitoring can be
carried out e, i.e., on a moving web. In an embodiment the process can monitor
100% of the barrier layer.
[0094] Numerous mechanisms can e a discontinuity in a functional
layer of a film, or substantial thinning of a region of a onal layer of the film.
Discontinuities and substantially thinned regions can be caused by, for example, lack
of barrier material in the extrusion system, bubbles or voids in the melt stream, die
lines, and contaminants (non-barrier materials) passing through the die with the
barrier polymer. The discontinuities or thinned regions can be elongated, as in the
case of die lines, or circular or odd-shaped regions void of barrier material, as due to
a bubble or void or non-barrier contaminant passing h the die. The
discontinuities can occupy a region of that portion of the film which is intended to be
the barrier layer.
[0095] In an embodiment, the s can be used to inspect the film in a
manner that reveals the thickness of the barrier layer containing the able
component. er, as with the detection of discontinuities, the monitoring of the
thickness of the barrier layer can be carried out on a moving web, and may be
carried out over the entire web. Thinned regions of the film can result from a variety
of causes, such as the p of material on the die lip. Although a thinned region is
not a discontinuity of the barrier layer, the thinned region can decrease the barrier
property of the barrier layer to an extent that the portion of the film having the thinned
barrier layer is unfitforthe desired ing end use.
It has been found that the detectable component, such as a UV-
fluorescing agent, can be provided at a level which allows the machine vision system
to both detect discontinuities in the barrier layer, as well as to quantify the ess
of the barrier layer. Maintaining a desired minimum thickness level of the barrier
layer provides the desired low oxygen transmission rate through the film. The
process and system of the invention can generate a signal which indicates whether
the barrier layer of the film is below the minimum acceptable thickness.
The process can also be used to inspect additional kinds of film barrier
layers, such as hazardous al r layers. For example, film layers made
from s cyclic olefin copolymers have been used as alcohol barriers. Such
layers can have a detectable component added so that they can be inspected by a
machine vision system in the same manner as the inspection of the film having an
oxygen r layer, i.e., as described above.
In addition, packaging designed to e a microbial barrier may
contain an active agent that neutralizes microbes, as described in US 2012/0087968
A1 and , each of which is hereby incorporated, in its entirety, by
reference thereto. Some of these films are designed for food packaging. Others are
designed for non-food-contact end uses. Food-contact films containing materials
approved for food use may include, for example, naturally derived materials such as
otic, bacteriocin, an, enzyme, natural extract, peptide, polysaccharide,
n, and/or allylisothiocyanate.
Other films may have a layer containing one or more acids such as:
acetic acid, citric acid, cinnamic acid, lactic acid, lauric acid, octanoic acid, propionic
acid, sorbic acid, and/or benzoic acid. Such a layer can be provided with a
detectable component added so that the layer can be inspected by a machine vision
system in the same manner as the inspection of the film having an oxygen barrier
layer, i.e., as described above.
Still otherfilms may have a layer containing acid salt, bacteriocin,
bacteriophage, 1,2—Benzisothiazolinone, BHA/BHT, cety| pyridinium chloride,
an, ne dioxide, imazalil, lysozyme, and/or lactoferrin. Such a layer can be
provided with a detectable component therein so that the layer can be inspected by a
machine vision system in the same manner as the inspection of the film having an
oxygen barrier layer, i.e., as described above.
[00101] Still otherfilms may have a layer containing a metal or metal salt (e.g.,
silver, , or zinc), metal oxide, and/or monolaurin. Such a layer can be
provided with a able component added so that the layer can be inspected by a
machine vision system in the same manner as the inspection of the film having an
oxygen barrier layer, i.e., as described above.
[00102] Stil| otherfilms may have a layer containing a natural oil or extract such
as thymol, eugenol, vanillin, garlic oil, grape seed extract, cinnamon, onion, basil,
oregano, bay, and/or clove. Such a layer can be provided with a detectable
ent added so that the layer can be inspected by a machine vision system in
the same manner as the inspection of the film having an oxygen barrier layer, i.e., as
described above.
Stil| ilms may have a layer containing polyhexamethylene
biguanide hydrochloride, paraben, grafted silane-quaternary amine, triclosan, and
zeolite of silver, copper, and/or zinc. Such a layer can be provided with a able
component added so that the layer can be inspected by a machine vision system in
the same manner as the inspection of the film having an oxygen barrier layer, i.e., as
described above.
The addition of a detectable component to a film layer allows the film
layer to be detected by a sensor system. Without the detectable component, the
sensor system would not be able to detect the presence of the film layer. The
detectable component may be passive, Le, a responding system, such as simple
absorption by a pigment or dye. The detectable component may be reactive, or
active, i.e., responsive to irradiation with thermal IR, near IR, visible, or UV light by
mechanisms such as phase change (thermochromic als), fluorescence, or
photochromism. A e detectable component does not require an external
source of energy to m its intended detectability function, whereas an active
component is excited by an external source of energy and ts that energy to
perform its intended detectability function. In an embodiment, the detectable
component is non-migratory, i.e., it does not migrate from one layer of a film to
another, or from the interior of a film layer to the surface of the layer.
An active sensor system can be designed to sweep across a broad
geographic area. The detectable component generates a unique reply making the
detectable component (and hence, the layer) stand out to the sensor system.
The addition of the detectable component may also provide the film
layer with a high signal-to-noise ratio. The detectable component may operate with a
phenomenology and in a g band where noise is uncommon, thereby further
enhancing the effective -to-noise ratio. The signal-to-noise ratio can also be
affected by the intensity of the incident light used to excite an active detectable
component. The incident light intensity can be increased or decreased, by trial and
error, until the average signal to noise ratio is 10 or higher.
] Sound can also be used as the active ena for the detectable
component. For example, the detectable component can emit an onic acoustic
wave, or operate within the electromagnetic spectrum. Sound as the active
ena operates upon sensing the resulting pressure wave propagating through
. The detectable component may be acoustic-based, e.g., providing an
ultrasonic sensing lity. As such, the detectable component may be a
piezoelectric transducer (PZT).
The electromagnetic spectrum can be the active phenomena for the
detectable component. In a system utilizing the electromagnetic um as the
active phenomena for the able component, the term “detectable” refers to
detection in the visible spectrum, or in the infrared spectrum, or in the ultraviolet
spectrum, or in any portion of the electromagnetic um outside of those
spectrums. A significant advantage of working within the electromagnetic spectrum is
the very high propagation velocity for the signals involved, i.e., the speed of light.
[00109] The able component can be present in the functional layer at any
level that is detectable by the detector while allowing the onal layer to maintain
its intended function. Too much able component can interfere with layer
function. Too little detectable component can become undetectable to the detector.
In an embodiment, the detectable component can be present at a level of at least 0.5
parts per n (ppm). As used herein, the phrase “part per million” and the
equivalent expression “ppm” refer to the weight of the detectable component versus
the total weight of the layer (weight detectable component + weight of remainder of
components in the layer). Of course, the majority component of the layer is one or
more thermoplastic rs which are a solid at room temperature. Both the
detectable component and the thermoplastic polymer of the layer can be solids at
room temperature. In an embodiment, the detectable component can be present at
a level of at least 1 ppm, or at least 1.5 ppm, or at least 2 ppm, or at least 3 ppm, or
at least 5 ppm, or at least 10 ppm, or at least 20 ppm, or at least 40 ppm, or at least
80 ppm, or at least 120 ppm, or at least 160 ppm, or at least 200 ppm, or at least 300
ppm, or at least 500 ppm. In an embodiment, the detectable component can be
present in the layer at a level of from 0.5 to 40 ppm, orfrom 1 to 20 ppm, or from 1.5
to 10 ppm, or from 2 to 5 ppm. In order for a film to be suitable for food contact end
use, the detectable component must be present in the layer in an amount of not
more than 150 ppm.
In an embodiment, the detectable component is a composition capable
of emitting electromagnetic radiation. The emitted radiation can be from any portion
of the electromagnetic spectrum, such as radio waves, infrared light, visible light,
ultraviolet light, X—rays, gamma rays, etc. The detectable component can be excited
by incident electromagnetic radiation which causes the detectable component to emit
electromagnetic radiation. The incident radiation to excite the detectable
component, and the emitted radiation from the detectable component, may be
unique to the detectable component, and depending upon the identity of the
detectable component, may be from any portion of the electromagnetic spectrum.
[00111] A UV-based detectable component is a UV—absorbing compound with
distinctive absorption and / or fluorescence properties. Preferred UV-absorbing
detectable component has a unique optical signature that is not present in nature
and not easily confused with signals from natural s. A preferred UV-
detectable component has multiple unique absorption or fluorescent features in its
UV a. For example, as used , electromagnetic radiation at 375
nanometers was used as incident radiation to excite a detectable ent known
as 2,SJihicphenediyibis£5~ter®butyi~f ,B-henzcxezcle), which ie assigned (3A8
registry number 71285, and which is else kncwn as: 2,2‘~(2,5~
thiophenediyl)bisiSntertbutyihenzoxazcle}; 2,5nbie~2(5ntert—butyiw
benzcxelyi)thicphene; 2,“Cu—bi5(5-t—butyE-2—henzoxazciyifihicphene; 2,5—bis~(5-t—
enzexazoiylifiylh—thiophene; 2,Sebie-(S—tertebutyi-Z—benzcxezci-2—
cphene; 2,5—bis(5’—ten—hutyl~2—benzcxazcl~2~yhthicphehe; s{5‘—tert~butyi—2'—
benzoxezoiyifihiophene; 2,Suhisi5—tert—huiyi—2~benzcxezoiyiiihiophene; 2,5~bis(5—tertw
butyl—benzcxazcE-Z—yi)thiephene; 2,5—bis(5—tert—butyihenzoxazcyl)—2-thiophene; 2,5—
di(5—ten—hutylbenzexazei~2~yi>thicphene; 2,2'—(2,fi—thicpheiiediyi)bis{§—(t ,t—
diniethyiethyii—benzcxezoie; 2,Suhi3(5'mtertnbutyi~2~benzoxezoiyi)thiophene; and 2,5—
thiophenediyihis(5—ten—huiyi—’i ,B—benzcxezole). The absorption cf the incident
radiation 31375 nanometers caused the excited icphenediyibie(5—tert~butyi—i ,3—
benzcxezeie) i brightener able component to emit ion at 435
nanometers. The optical brightener was uniformly blended into a PVDC resin which
was used to produce an oxygen r layer of a multilayer film. Exposing the
resulting annular tape and/or heat-shrinkable film tubing to incident ion at 375
nm excited the 2,§—thiophenediyibisifi~tert~butyi~1 ,3~benzoxazole) optical brightener
able component to emit radiation at 435 nanometers. The emitted 435 nm
radiation was detected by a machine vision system, which revealed the presence,
continuity, and thickness of the PVDC barrier layer of the tape and a multilayer film
tubing.
] The second aspect is directed to an inspection system. In an
embodiment, the inspection system hardware includes: (i) one or more cameras in a
camera network (ii) lighting (iii) one or more signal processors (iv) an operator
interface (v) an input/output interface (vi) an encoder, and (vii) an industrial
er. In an embodiment, the system configuration can be such that the
ation of the (s) and onics does not require a computer on each
film production line (or film processing line). Rather, a single server can be used for
many lines.
[00113] In an embodiment each camera in the camera network communicates
digital data to a signal processor residing in the industrial computer where image
processing and e learning algorithms are employed to complete the
inspection tasks.
In an embodiment the lighting can be an ultraviolet backlight with
software for controlling shutter speed and light intensity. In embodiments in which
the process is designed to simultaneously inspect multiple film layers at the same
time for the same film, multiple lights can be used with one or more controls for
shutter speed and light ity.
In an embodiment, computer-based signal processors conduct
processing tasks such as image segmentation, image de-noising, contrast
enhancement, thresholding, and/or pattern recognition. The processing tasks can
include feature extraction, e selection, and/or feature fusion, to achieve defect
detection and defect classification. The signal processor(s) can achieve parallel
processing tasks.
ne embodiment of a machine vision system that can be adapted to
carry out the tion of the moving web is a system marketed by lsra Surface
Vision Inc. This system operates at 320 megahertz. With the 4K line-scan color
camera, using the standard lens, each scan has 4096 pixels across. Each pixel has
a gray scale value of from 0 to 255, with 0 being white, 255 being black, and 1-254
being shades of grey. An alternative embodiment employs a 4K line scan
monochrome camera. Using the standard lens with the monochrome camera, each
scan has 4096 pixels across.
Not every discontinuity is necessarily in need of detection and
reporting. A threshold value can be set so that only defects above the threshold size
are d for removal. For example, the threshold can be set at a discontinuity or
thin region having a size of at least 2 millimeters in at least one direction, Le, a
discontinuity orthin region having a size of at least 2 millimeters in the machine
direction and/or at least 2 mm in the erse direction. Alternatively, the threshold
can be set at a size of at least 1 eter in at least one direction, Le, a
discontinuity orthin region of at least 1 millimeter in at least one direction. Such a
threshold can be set even if the system has the capability to see tinuities down
to a size of as low as 10 microns in at least one direction. The setting of the
threshold value is ent from the capability of the machine vision system to detect
a discontinuity thin region down to at least a particular size in at least one
direction. Rather, the setting of the threshold value is the setting of the minimum
value of the size of the discontinuities/thin spots which trigger the generation of the
signal in response thereto. That threshold can be set at any desired value, and is
different from the capability of the machine vision system to detect discontinuities
down to at least a specified size.
An embodiment of a vision system design including a data flow
m for data ition and data analysis is set forth in The vision
system design of includes a data flow diagram including one or more
cameras, a data acquisition system, a vision inspection engine, an in-Iine action
system, and a database management system. These components together made
up a system which was employed as barrier layer defect detection.
The camera may be a color camera or a monochrome camera. The
lighting used with the camera may have adjustable intensity. Although the camera
may be an area-scan camera or a line-scan cameral, the can camera is
preferred because it produces less data that can be ed more y. gh
the camera may have 4K or 8K pixels per line, 4K is adequate to inspect a flat tape,
a flat film, an annular tape, an annular hot-blown film (a non-heat shrinkable film that
is oriented at a temperature above the melting point), and/or an annular heat-
shrinkable film tubing. Annulartapes and films can be inspected in lay-flat
configuration, with the images providing data on the continuity of both lay-flat sides
of the tape or film.
[00120] Using an appropriate combination of camera head, lighting, and lens
configuration, a series of images are acquired and fed into the acquisition system
where the data is buffered and transferred to the inspection engine for further
processing. A series of signal processing tasks are conducted such as image
segmentation, image de-noising, st enhancement, thresholding, pattern
recognition (including feature extraction, feature selection, and feature fusion), to
achieve defect ion and defect classification. The detection results are further
fed into an in-Iine action system to set up pre-determined alarms, film flagging,
displaying an image of a discontinuity, displaying data pertaining to one or more
tinuities including displaying data related to ric teristics of the
discontinuity, location of the discontinuity, degree of ence of discontinuities;
severity of discontinuities, and/or generating a report of discontinuity data. Data
ning to discontinuities can be displayed instantaneously and online, or after
production is complete, i.e., offline, i.e., not on the fly, the data being accessible in an
offline database management . Using data mining, the data can be
manipulated, visualized, and organized into any and report forms desired.
The data processing software was set up to accommodate different
concentration levels with minimum need for on-the-fly adjustment of parameters
such as exposure time and light intensity. The system was designed to detect
discontinuities present as the film was moving in the machine direction, and also to
distinguish discontinuities from other defects and contamination.
The film images could be carried out using a 2-D pixel matrix image as
captured by an area scan camera or via a 1-D pixel line as captured by a line scan
camera. Web Edge Tracking was used to track the edges of the continuous web for
the purpose of interest-area selection and image segmentation. Image
tation was used to crop the images based on detected web edges and to
select the areas of interest. Through image pre-processing, the differentiation
between the baseline and the defect(s) was maximized. Different features (e.g., the
ry features, pixel grey scale value thresholds, etc) were extracted, selected
and fused into composite features. Using data mining, detection of r defects
was achieved, together with the classification and separate treatment of other
s and/or contamination located, or the fication and ignoring of other
defects and/or contamination.
Two pattern recognition algorithms were utilized to e detection in
different channels: Dark Feature Detection (dark spots and light spots) and Streak
Detection. Dark Feature Detection and Light Feature Detection were based on grey
scale value thresholds. Streak Detection was based on ry features.
ng was confined to an area inside the edges of the lay-flat film
tubing. Data pertaining to the outer 1-2 millimeters of the film tubing was discarded
because the lay-flat film tubing exhibited irregular or regular oscillating lateral
movements of about 1 mm as it was being forwarded during production. lf ng
was extended to the edge, the ating lateral movement would likely have caused
false positives in the detection of a discontinuity in the barrier layer.
In an ment the operator ace software runs on the industrial
computer. Defect data is displayed on the interface and archived in a resident
database. Defect data and images are displayed real time on the interface.
Instantaneous, historical, and statistical data can be viewed and on the
interface. The system can be setup to selectively detect and accurately classify
barrier-related film defects such as barrier thin spots or s, missing barrier, and
barrier discontinuities ing discontinuity geometric characteristics. Images of
each defect can be classified, stored, and displayed. A high-resolution image of each
defect can be captured in real time. Discrete defect information such as individual
defect geometric information and statistics of group defects can be ed for
taneous decision-making and actions ing process improvement and
monitoring such as defect alarming. Various outputs for marking /flagging and
alarming can be set for different defect severity levels. Data can be exported, for
example, to MS Excel and/or a SQL database located anywhere on the network, with
data mining software ng various reports to be easily generated automatically
and/or on-demand. Defect data is processed on a processing unit such as a digital
processing board. Flagging can be used in conjunction with rewinding the film with
one or more defects followed by using slitter to cut out the defects in the film.
Flagging can be carried by applying a label to the film at (or corresponding with) the
location of the defect in the film. The application of a metal label to the film allows
the roll of film to be readily scanned before the roll of film is placed into commerce or
used for packaging products or other end use in which the presence of a defect
would be detrimental to the objectives to be ed in the use of the film.
In an embodiment, the standard input/output interface allows for
external signal inputs such as new roll indication, web break indication, and pause
inspection indication. Outputs for alarms on user-defined defect alarm criteria are
also handled h the input/output interface. Outputs can also be initiated to
control downstream flagging or g devices. Alarms can be activated for defects
of different pre-defined severities or criteria. Alarm and defect information can be
sent via OPC (i.e., software interface standard) to the plant network, programmable
logic controller (PLC), or supervisory control and data acquisition / human machine
interface (SCADA/HMI).
In an embodiment, the encoder is used to measure the web speed so
that the location of a detected defect is ascertainable, ularly down the length of
the tape or tubing or flat film being inspected. A series of pulses from the encoder is
received by the system and counted. The count is sent to the processor to ine
the distance down the web at which the detected defect is located.
] Below is information on the identity of various resins and other
components t in films of the examples set forth hereinbelow.
[00129] SSPE1 was AFFINITY® PL 1281G1 homogeneous ethylene/octene
copolymer having a density of 0.900 g/cm3 and a melt index of 6.0 dg/min, ed
from The Dow Chemical Company.
SSPE2 was AFFINITY® PL 1850G homogeneous ethylene/octene
copolymer having a density of 0.902 g/cm3 and a melt index of 3.0 , obtained
from The Dow Chemical Company.
SSPE3 was EXCEED® 1012HJ homogeneous ethylene/hexene
copolymer having a density of 0.912 g/cm3 and a melt index of 1.0 dg/min, obtained
from ExxonMobil.
VLDPE1 was XUS 61520.15L very low density hylene having a
density of 0.903 g/cm3 and a melt index of 0.5 dg/min, obtained from The Dow
Chemical Company.
LLDPE1 was LL 3003.32 heterogeneous ethylene/hexene copolymer
having a density of 0.9175 g/cm3 and a melt index of 3.2 dg/min, obtained from
Exxon Mobil.
] LLDPE2 was DOWLEX® 2045.04 linear low density polyethylene
having a density of 0.920 g/cm3 and a melt index of 1.0 dg/min, obtained from The
Dow Chemical Company.
LLDPE3 was XUS 61520.21 linear low density polyethylene having a
density of 0.903 g/cm3 and a melt index of 0.5 dg/min, obtained from The Dow
Chemical Company.
EVA1 was A ethylene/vinyl acetate copolymer (14% vinyl
acetate) having a density of 0.934 g/cm3 and a melt index of 3.5 dg/min, obtained
from Westlake al.
[00137] EVA2 was NE® LP761.36 ethylene/vinyl e copolymer
(26.7% vinyl e) having a density of 0.951 g/cm3 and a melt index of 5.75
dg/min, obtained from Exxon Mobil.
EVA3 was 592AA ne/vinyl acetate copolymer (10.5% vinyl
acetate) having a density of 0.931 g/cm3 and a melt index of 2.0 dg/min, obtained
from Westlake Chemical.
PVDC—1 was SARAN® 806 vinylidene chloride/methyl acrylate
copolymer having a density of 1.69 g/ cm3, obtained from The Dow Chemical
Company.
PVDC-2 was IXAN® PV910 vinylidene chloride/methyl acrylate
copolymer having a density of 1.71 g/ cm3, obtained from Solvin.
OB was BENETEX OB PLUS® 2,5-thiophenediylbis(5-tert-butyl-1,3-
benzoxazole fluorescent agent, obtained from Mayzo Inc.
MB 1 was 100458 masterbatch of fluoropolymer in linear low density
polyethylene, having a y of 0.93 g/ cm3 and a melt index of 2.3 g/10 min,
obtained from Am pacet.
MB 2 was lP-1121 masterbatch of fluoropolymer in linear low density
polyethylene, having a density of 0.92 g/ cm3 and a melt index of 2 g/10 min,
obtained from Ingenia Polymers.
Films Nos. 1-6 and Inspection of Film Nos. 1-3
Film Nos.1 through 6 were prepared and ted using the
processes illustrated in Figs 1A, 1B, and 1C. Figs 1A and 1C schematically illustrate
the process used for making the heat-shrinkable films ed in the examples
herein. schematically illustrates the laboratory process used for inspecting
the oxygen barrier layers for each of the coated annular tapes corresponding with
the structures of Film No. 1, No.2, and No. 3.
In the process illustrated in , solid polymer beads (not
illustrated) were fed to a plurality of extruders 28 (for simplicity, only one extruder is
rated). Inside extruders 28, the polymer beads were fonNarded, melted, and
ed, following which the ing bubble-free melt was fonNarded into die
head 30, and extruded through an annular die, resulting in annular tape 32, which
was about 15 mils thick.
] After cooling and quenching by water spray from cooling ring 34,
r tape 32 was collapsed into lay-flat configuration by nip rollers 36. When
collapsed, the annular tape had a lay-flat width of about 2.5 inches. Annular tape 32
in lay-flat configuration then passed through irradiation vault 38 surrounded by
shielding 40, where annular tape 32 was irradiated with high energy electrons (i.e.,
ng radiation) from iron core transformer accelerator 42. Annular tape 32 was
guided through irradiation vault 38 on rolls 44. Preferably, the irradiation of annular
tape 32 was at a level of about 64 kGy.
After irradiation, irradiated annular tape 46 was directed through pre-
coating nip rollers 48, following which irradiated r tape 46 was slightly ed,
resulting in trapped bubble 50. At d bubble 50, irradiated annulartape 46 was
not significantly drawn longitudinally, as the surface speed of post-coating nip rollers
52 was about the same as the surface speed of pre-coating nip rollers 48.
Furthermore, irradiated tape 46 was inflated only enough to place the annular tape
into a substantially circular configuration without significant transverse orientation,
i.e., without transverse stretching.
Irradiated tape 46, slightly inflated by bubble 50, was passed through
vacuum chamber 54, and thereafter forwarded through coating die 56. Annular
g stream 58 was melt extruded from coating die 56 and coated onto inflated,
ated annular tape 46, to form coated annular tape 60. Coating
stream 58 comprised an rier layer made from PVDC, together with additional
layers, all of which did not pass through the ionizing radiation. r details of the
above-described coating step were generally as set forth in US. Pat. No. 4,278,738,
to BRAX et. al., which is hereby incorporated by reference thereto, in its entirety.
After irradiation and coating, coated annular tape 60, now having a
thickness of about 25 mils, was wound up onto windup roll 62. As illustrated in , removed windup roll 62A of coated annular tape 60 in lay-flat configuration was
unrolled, and assessed for continuity of the oxygen barrier layer as it was forwarded
at a speed of 400 feet per minute, and nd into windup roll 623. In reality,
each of coated annular tapes 60 of Film No. 1, Film No.2, and Film No. 3 were
unrolled in side-by-side uration and all were assessed for continuity of the
oxygen r layer at the same time, by the same equipment. Each lay-flat coated
annulartape 60 had a width of2.5 inches. Even though all three coated annular
tapes 60 were set up and assessed side-by-side at the same time with the same
equipment, is a schematic illustration of the setup for the ment ofjust
one of the annular coated tapes.
In , wound up roll 62A (i.e., windup roll 62 detached from the
s illustrated in ) had coated annular tape 60 tape thereon, with coated
annulartape 60 being unwound, forwarded over ultraviolet light source 61 and under
camera head 63 and rewound as wound up roll 623. Once unwound from roll 62A,
coated annular tape 60 in lay-flat uration passed over ultraviolet (UV) light
source 61 and was impinged from below by incident radiation at 375 nanometers
(nm) from UV-Iight source 61, with the 375 nm radiation exciting the optical
brightener in the PVDC layer of the film. At the same moment that coated annular
tape 60 ed the incident radiation, coated annular tape 60 passed under color
line-scan camera head 63 located over coated annular tape 60, in a position directly
across and the location at which ht source 61 was under annular tape 60. As
illustrated in , vision system color camera head 63 was positioned above lay-
flat tape 60 in a position directly over UV—Iight source 61, and was set to scan across
coated lay-flat tape 60 mmed to look only at the blue channel ugh the
color camera saw red, green and blue divided into 256 discrete colors), i.e., to look
only at a wavelength of about 435 nanometers. The camera re time was
about 100 microseconds, and the camera resolution was 4096 pixels per scan along
each scan line, which scan line was in the transverse direction relative to the
ation of the coated film tapes being inspected. The field of view was adjusted
to be ly longer than the transverse distance across all three coated tapes in
side-by-side relationship to one another, the tapes being separated from each other
by a few eters. Images taken from the camera, processed by the signal
processors residing in the industrial computer 65, enabled production of a scan
signal chart providing an assessment of the continuity of the oxygen barrier layer in
coated annular tapes 60.
Thereafter, as illustrated in , windup roll 623 installed as
unwind roll 64, on a second stage in the process of making the desired heat-
shrinkable film tubing. Coated annulartape 60 was unwound from unwind roll 64,
and passed over guide roll 66, after which coated annular tape 60 was passed into
hot water bath tank 68 containing hot water 70. Coated tubular film 60, still in lay-flat
configuration, was immersed in hot water 70 (preferably at a temperature of from
about 185°F to 210°F) for a period of from about 10 to about 100 seconds, i.e., long
enough to bring annulartape 60 up to its softening point, i.e., the desired
temperature for biaxial orientation while the coated annular tape was in the solid
state.
] Thereafter, coated annular tape 60 was directed h nip rolls 72,
and bubble 74 was blown, thereby transversely solid state stretching coated annular
tape 60. Furthermore, while being blown, i.e., transversely stretched, nip
rolls 76 drew r tape 60 in the longitudinal ion, as nip rollers 76 had a
e speed higher than the surface speed of nip rollers 72. As a result of the
transverse stretching and longitudinal drawing, annular tape 60 was biaxially
oriented in the solid state to form biaxially-oriented, heat-shrinkable film tubing
78. Heat-shrinkable film tubing 78 was stretched transversely at a ratio of 3.6:1, and
drawn longitudinally at a ratio of 3.6:1, for a total orientation of about 13X. While
bubble 74 was maintained between pairs of nip rollers 72 and 76, the ing blown
film tubing 78 was collapsed into lay-flat configuration by rollers 80. Blown film
tubing 78 had a lay-flat width of about 10 inches. Film tubing 78 in lay-flat
configuration was thereafter conveyed through nip rollers 76 and across guide
roll 82, and then rolled onto wind-up roll 84. ld|er roll 86 assures a good wind-up.
Each of Film No. 1 through Film No. 6 was a multilayer heat-shrinkable
film having a layer arrangement, layer composition, layerthickness, and layer
function as generally set forth in Table 1, below. The seal layer, 1St bulk layer, and
1St tie layer were all coextruded together and ted to high energy irradiation in
vault 38. The r layer, 2nOI tie layer, 2nOI bulk layer, and abuse layer were put on
in the coating step, i.e., were not irradiated. The heat-shrinkable film tubing made
from Films No. 1 through 6 had the following layer arrangement, composition, and
thickness:
Table l
Layer Film Tubing for Film No. 1, Film No. 2, Film No. 3, Film No. 4, Film No. 5, and Film No. 6
function Seal lSt Bulk lSt Tie Banier 2‘101 Tie 2‘101 Bulk Abuse
Com— 80% SSPEl 70 % EVAl PVDC EVAZ 70% 80% SSPEZ
position 20% VLDPEl VLDPEl 20%
LLDPEl 30% EVAl 30% EVAl LLDPEZ
Each of Film No. 1 through Film No. 6 contained an oxygen barrier
layer composed of the polyvinylidene chloride (PVDC) resin identified above. For
each of Film No. 1 h Film No. 6, the PVDC resin was uniformly blended with a
detectable componentwhich was an optical brightener. More particularly, Film Nos.
1 through 6 each contained 2,2’-(2,5-(thiophenediyl)-bis(5-tert-butylbenzoxazole))
optical brightener as the able component. More particularly, the optical
brightener was BENETEXT'VI optical brightener ed from Mayzo, Inc of 3935
Lakefield Court, Suwanee, GA. The optical brightener was blended into the PVDC
used to make the oxygen barrier layer for each of Film Nos. 1 through 6, with the
blend being made at the following : 6.25 ppm (Film No. 1), 12.5 ppm (Film No.
2), 18.75 ppm (Film No. 3), 25 ppm (Film No.4), 37.5 ppm (Film No. 5), 50 ppm
(Film No. 6), with each blend being a uniform blend of the optical brightener with the
PVDC. None of the other layers of the film contained any optical brightener, as was
also the case for Film Nos. 7 through 10, bed below.
rates: Top portion 91 illustrating (i) a scan signal chart 90,
believed to be the coated annular tape of Film No. 1; (ii) scan signal chart 92,
believed to be coated annulartape of Film No. 2; and (iii) scan signal chart 96,
believed to be the coated annular tape of Film No. 3. Top portion 91 appears as a
single chart because the lay-flat annular tapes of each web were forwarded at about
400 feet per minute while located side-by-side, with a single scan from a single
camera going across all three lay-flat coated tapes at the same time. In top
portion 91 shows three samples of filtered detection signal amplitudes in the
transverse direction, i.e., scan signal charts of transverse direction scans of the
coated annulartapes of Film No. 1, Film No. 2, and Film No. 3 in side-by-side
relationship. In bottom portion 93 shows the corresponding images of the
coated annular tapes of Film Nos. 1, 2, and 3, running in the machine direction from
top to bottom. It is believed that no scan signal charts were made for Film Nos. 4, 5,
and 6.
Each scan signal chart ( was ed by impinging incident
radiation at 375 nanometers from UV—Iight source 61 () located below the
three y-side annular coated tapes 60 in lay-flat configuration. Radiation from
ht source 61 excited the optical brightener in the PVDC layer of the film.
Vision system color camera head 63 was positioned above lay-flat annular coated
tapes 60 in a on directly above UV—Iight source 61, and was set to scan across
the lay-flat coated tapes at the wavelength of 435 nanometers to produce the above-
described scan signal charts 90, 92, and 96.
[00157] As is apparent from the relationships of the three scan signal charts
present in the annular coated tape of Film No. 1, having an oxygen r
layer containing 6.25 ppm BENETEXTIVI optical brightener, exhibited the lowest scan
signal intensity. The coated tape of Film No. 2, having an oxygen barrier layer
containing 12.5 ppm BENETEXTIVI l ener, exhibited a higher scan signal
intensity than Film No. 1, but less scan signal intensity than that of the coated tape of
Film No. 3, which had an oxygen barrier layer containing 18.75 ppm BENETEXT'VI
optical brightener.
In the relatively uniform scan signal 90 tes that the
oxygen barrier layer of coated tape of Film No. 1 had no detected discontinuities in
the barrier layer. The scan was taken across the coated tape in lay-flat
configuration, i.e., the scan was taken in the transverse direction relative to the
direction of tape extrusion (as was the case for all of the scans taken for tapes and
webs of Film Nos. 2-10, described below). This is nt from scan signal 90
because no portion of scan signal 90 exceeded a predetermined threshold value
corresponding with a discontinuity or void, or any region of the barrier layer exhibiting
excessive thinning of desired layerthickness. ln orderto detect discontinuities in the
barrier layer or areas of excessive thinning in the barrier layer, the threshold value
must be set at a level greater than the noise level associated with the scan.
gh threshold level can be set at any desired level, unless the signal deviates
substantially from the noise level, no discontinuity or ively thin region is
detected. The signal spikes corresponding with the film edges were differentiated
from spikes corresponding with layer discontinuities by e learning algorithms
which can be readily developed by those of skill in the computer programming art.
[00159] Scan signal 92 of Film No 2 appeared to be within the predetermined
threshold value over a majority of the area inspected, but had a small portion which
could be deemed to t an out-of-threshold signal valley 94 (the phrase “signal
” refers to a dip in the signal ude in the scan chart) corresponding with a
thinning or discontinuity at a particular location of the barrier layer in Film No. 2.
However, the deviation from the noise level at signal valley 94 was so small (i.e.,
signal-to-noise ratio was so low) that it was difficult to determine whether a
discontinuity existed outside of the normal noise level. It is believed that the lack of
ability to positively assess the signal deviation as a tinuity (or thick or thin
region) was due to the relatively low level of the detectable component in the barrier
layer of the r tape of Film No. 2. However, in fact signal valley 94 was present
because the die used to extrude the coating onto the uncoated annular tape of Film
No. 2 was modified by insertion of a blockage that ed die line 97 in image 95
of the coated tape of Film No. 2, as shown in the bottom middle of Whether
this resulted in a thin region or a complete discontinuity was not assessed.
] Scan signal 96 of Film No 3 was also within the predetermined
threshold value over a majority of the area inspected, but exhibited one out-of-
threshold signal region 98 (Le, a signal valley) caused by a layer discontinuity
corresponding with a die line in the barrier layer. It is apparent in scan signal 96 that
the signal valley at signal region 98 was large enough to reveal the discontinuity
formed by the die line. The signal valley was larger in scan signal 96 than in scan
signal 92 due to the higher level of indicator component in the barrier layer of Film
No. 3 vs. Film No. 2. Thus, the level of the indicator component in the r layer
affects the ability to detect a signal valley e of the noise level, the valley
indicating a tinuity or thin region of the barrier layer of the film.
That scan signal 90 taken across coated annular tape of Film No. 1
exhibited no apparent discontinuity in the barrier layer was consistent with the fact
that the die used to extrude the g onto the uncoated annular tape of the Film
No. 1 was not modified by the insertion of a blockage that produced a die line in the
barrier layer. The lack of a die line is tent with the lack of any apparent die line
in image 91 of the coated tape of Film No. 1 at the bottom of
Scan signal 92 of the barrier layer of the coated annular tape of Film
No. 2 exhibited signal valley 94 (the phrase “signal valley” refers to a dip in the signal
amplitude in the scan chart) representing a discontinuity in the barrier layer. In fact,
signal valley 93 was present because the die used to extrude the coating onto the
uncoated annular tape of Film No. 2 was modified by insertion of a blockage that
produced die line 97 in image 95 of the coated tape of Film No. 2, as shown in the
bottom middle of
Scan signal 96 of the barrier layer of the coated annular tape of Film
No. 3 exhibited signal valley 98 representing a discontinuity in the barrier layer of the
coated annulartape of Film No. 3. Signal valley 98 was present because the die
used to extrude the coating onto the ed annular tape of Film No. 3 was also
modified by ion of a blockage that produced die line 100 in image 99 of the
coated tape of Film No. 3, as shown in the bottom right image in
Although the scan charts of Film No. 1 and Film No. 2 were of barrier
layers containing 6.25 ppm and 12.5 ppm of the optical brightener detectable
component, the camera settings were not optimized to reveal signal valleys. With
optimization of the camera settings, detectable component levels from 2 to 5 ppm
are believed to be e of clearly revealing signal s indicative of
discontinuities in the barrier layer.
Film No. 7 Film No. 8 and Film No. 9
Film No. 7, Film No. 8, and Film No. 9 were multilayer hrinkable
films made and inspected in accordance with the process illustrated in Figs 1A, 1B,
and 1C, described above. The resulting heat-shrinkable film tubing of each of Film
Nos. 7, 8, and 9 had a layer arrangement, layer composition, layer thickness, and
layer function as follows:
Film No. 7 and Film No. 8
Layer function Seal Bulk Barner Abuse
Layer 60% SSPEl 70% VLDPEl PVDC 85% EVA3
Composition 40% LLDPEl 30% EVAl 15% LLDPE2
wt. % 14 51.4 24.3
Thickness 0.28 mil 1.03 mil .49 mil
[00166] Film No. 7 was made without any optical brightener in the PVDC layer.
Film No. 8 was made with a PVDC layer ning BENETEXTIVI optical brightener a
level of 5.44 ppm. Film No. 9 was made with a PVDC layer containing BENETEXTIVI
optical brightener at a level of 8.38 ppm.
includes scan signal 110 of the coated r tape of Film No.
7, which contained no optical brightener. The annulartape was in its lay-flat
configuration. The inspection of Film No. 7 was carried out as described for Film
Nos. 1, 2, and 3, except that the camera was a monochrome line scan camera rather
than a color line scan camera. OthenNise, the camera specifications were the same
as described above for the evaluation of Film Nos. 1, 2, and 3. As is apparent from
scan signal 110, even with no optical brightener present, the film exhibited a 435 nm
emission ity level of about 60 (a unitless figure on a relative scale). It is
believed that the positive level of emission intensity was due to ambient light
ted into the line scan camera head. Although the scan signal intensity across
Film No. 7 did not indicate any discontinuity in the barrier layer, if there had been a
discontinuity it should not have been revealed by a valley in the scan signal
amplitude because the scan signal amplitude was not generated by the scence
of the optical brightener, as the optical brightener was not present in Film No. 7.
also es scan signal 112 of coated annular tape of Film No.
8, which contained the optical brightener in the PVDC barrier layer at a level of 5.44
ppm. The r tape made from Film No. 8, in at configuration, was
inspected with the same equipment, in the same manner, and at the same time Film
No. 7 was inspected, i.e., Film No. 8 was scanned in side-by-side with Film No. 7.
As is apparent from scan signal 112, Film No. 8 exhibited a 435 nm emission
intensity level of about 190 (again, a unitless figure on a relative scale). Scan signal
112 did not t any valley in the signal amplitude, indicating no discontinuity in
the scan across the annular tape in lay-flat configuration. No blockage had been
placed in the barrier layer slot in the coating die, contrary to the blockage placed in
the barrier layer slot of the coating die in the making of Film No. 2 and Film No. 3,
described above.
illustrates scan signal 114 of Film No. 8, and scan signal 116 of
Film No. 9. As can be seen in the scan signal of Film No. 9 had a higher
intensity (about 250 units on the unitless scale, with a majority of the scan signal
reaching saturation of the scale at 255 units) than the scan signal of Film No. 8. The
higher scan signal amplitude of Film No. 9 was due to the higher level of optical
brightener in Film No. 9 compared with Film No. 8, Le, the barrier layer of Film No. 9
contained 8.38 ppm optical ener whereas the barrier layer of Film No. 8
contained only 5.44 ppm l brightener. As with the scan signal 114 of Film No.
8, the scan signal of Film No. 9 did not t any valley in the signal amplitude,
indicating no discontinuity in the scan across the annulartape of Film No. 9, which
annulartape was in its lay-flat configuration. As with Film No. 8, no blockage had
been placed in the barrier layer slot in the coating die used to make Film No. 9,
contrary to the blockage placed in the barrier layer slot of the coating die in the
making of Film No. 2 and Film No. 3, described above.
Film No. 10
Film No. 10 was a multilayer hrinkable film made and inspected
in accordance with the process illustrated in Figs 1A, 1B, and 10, described above.
Moreover, the layer arrangement and layer composition was the same as set forth in
Table 1, above. The barrier layer of Film No. 10 contained 4.41 ppm BENETEXT'VI
optical brightener blended with the PVDC polymer. The barrier layer slot in the
annular coating die was partially blocked with three artificial blockages in order to
cause the coating die to extrude a PVDC oxygen barrier layer having three die lines
therein. Two of the artificial die blockages were placed so that the resulting die lines
would coincide or overlap each other when the tape was in the lay-flat configuration.
The third artificial die blockage was placed to fall in one at side of the lay-flat
annulartape. In this manner, the scan of the annular tape in lay-flat configuration
would show the effects of overlapping and non-overlapping discontinuities in the
barrier layer.
is a scan chart 150 of a scan taken across (i.e., in the
transverse direction) lay-flat coated annular tape 170 of Film No. 10 using the same
4k line-scan monochrome camera used to scan Film Nos. 7-9. is an image
of the d portion of the coated annular tape 170 of Film No. 10, with r
tape 170 being in lay-flat uration. Both the scan chart of and tape
image of were taken while the coated annular tape was in its lay-flat
configuration, with a first lay-flat side up and a second lay-flat side down, with the
image of the coated annular tape in being taken while the coated annular
tape was being illuminated with infrared radiation having a wavelength of 375
nanometers causing the l brightener to fluoresce ion at 435 nanometers.
Figs 5A and 58 were vertically d with respect to each other, in
that the image of left edge 172 of lay-flat tape 170 of is illustrated so that it is
aligned with the negative gradient n left edge amplitude peak 152 and left
edge ude valley 154 of the scan signal of . Moreover, the image of
right edge 174 of lay-flat tape 170 of is aligned with the negative gradient
n right edge amplitude peak 156 and right edge amplitude valley 158 of the
scan signal of . Furthermore, first die line 176 in lay-flat tape 170 of
is aligned with the positive gradient between first die line amplitude valley 160 and
first die line ude peak 162 in scan chart 150. Finally, second die line 178 in
lay-flat tape 170 of is aligned with the positive gradient between second die
line amplitude valley 164 and second die line amplitude peak 166 in scan chart 150.
In , the negative gradient of the scan signals representing the tape edges, as
well as the positive gradient of the scan signals representing die lines 176 and 178,
were a product of the data processing thm applied to generate the scan chart.
includes scan chart 180 of a scan taken across lay-flat coated
annulartape 200 of Film No. 10 using the same 4k line-scan monochrome camera
used to produce the scan chart in and the same camera used to take the
image of the tape of . In scan chart 180 is of the same section of
Film No. 10 scanned in and illustrated in , except in annular
tape 200 was flipped end-to-end, i.e., was placed in lay-flat configuration with its
second lay-flat side up and its first lay-flat side down. The image of coated
annular tape 200 in lay-flat uration was taken while the coated annular tape
was being illuminated with infrared radiation having a wavelength of 375
nanometers causing the optical brightener in the oxygen barrier layer to fluoresce
radiation at 435 nanometers.
In scan chart 180 is vertically aligned with r tape 200, in
that the image of left edge 202 of lay-flat tape 200 is illustrated so that it is aligned
with the negative nt between left edge amplitude peak 182 and left edge
ude valley 184 of scan signal 180. Moreover, the image of right edge 204 of
lay-flat tape 200 of is aligned with the negative gradient between right edge
amplitude peak 186 and right edge amplitude valley 188 of scan signal 180.
Furthermore, first die line 206 in lay-flat tape 200 is aligned with the positive gradient
between first die line amplitude valley 190 and first die line amplitude peak 192 in
scan chart 180. Finally, second die line 208 in lay-flat tape 200 is aligned with the
positive gradient between second die line amplitude valley 194 and second die line
ude peak 196 in scan chart 180. As with , in the negative
gradient of the scan signals representing the tape edges 202 and 204, and the
positive gradient of the scan signals representing die lines 206 and 208, were a
product of the data processing algorithm applied to generate scan chart 180.
A comparison of the images of coated annular tape 170 of
having first lay-flat side up, and coated annular tape 200 of having second
lay-flat side up, i.e., the same section of annulartape butwith reversed lay-flat sides
up, s that (i) the scan signal amplitude of valley 164 and peak 166 of the scan
signal corresponding with second die line 178 in are of greater amplitude
than (ii) the scan signal amplitude of valley 194 and peak 196 of the scan signal
corresponding with second die line 208 of The higher amplitude of scan
signal valley 164 and peak 166 in vs. the ponding scan signal valley
194 and peak 196 of second die line 208 of is believed to be due to second
die line 178 being in the first at side of the coated annular tape, where in second die line 178 was viewed directly by the camera without being partially
masked by the second lay-flat side of the tape, as was second die line 208 in
It is believed that even though second die line 178 in was the same die line
as die line 208 in ishing that the machine vision scan was able to
detect the presence of the die lines in both lay-flat side of the annular tape,
less of which lay-flat side the die line was in.
As to the first die line 176 in and the first die line 206 in
a comparison of the darkness intensity of die lines 176 and 206 shows that they are
relatively similar in darkness intensity. It is believed that the images of die lines 176
and 206 and their associated scans ented the two overlapping/coinciding die
lines produced by two of the artificially placed die blockages in the barrier layer die
slot. The similarity of appearance of the pping/coinciding die lines 176 in tapes
170 and 200 shows that discontinuities that are superimposed over each other in the
lay-flat sides of the annular tape will have a darker appearance when viewed from
both sides, unlike the marked difference in appearance and signal intensity of
second die line 178 (and signal valley 164 and signal peak 166) of Figs 5A and 5B,
versus second die line 208 (and signal valley 194 and signal peak 196) of
Scan signal 180 in also exhibited a negative nt between
scan signal amplitude peak 198 and scan signal amplitude valley 199. This peak
and valley appeared to correspond with a portion of the barrier layer containing a
higher level of the optical brightener, believed to be due to a thickened region of the
barrier layer. Based on the machine direction orientation of the thickened region of
the barrier layer in it is believed that this thickened region may also be based
on an anomaly in the barrier layer slot of the extrusion die.
is a scan chart 220 of a scan taken across (i.e., in the
transverse direction) a portion of the lay-flat heat-shrinkable rfilm tubing
section 240 rated in , which annular film tubing section 210 was made
from the annular tape illustrated in Figs 5B and 6, which tape was made from Film
No. 10. The heat-shrinkable annular film tubing section 240 in lay-flat configuration
was the result of further processing the lay-flat annular tape 170 via the process of
, to produce lay-flat heat-shrinkable annular film tubing 240.
] is an image of the d portion of lay-flat heat-shrinkable
annular film tubing 240 of Film No. 10, in lay-flat uration. Both the scan chart
of and tape image of were taken while the portion of the coated
annular tape was in its lay-flat configuration, with a first lay-flat side up and a second
lay-flat side down. The image of the hrinkable annular film tubing 240 of was taken while the heat-shrinkable annular film tubing was illuminated with
infrared ion having a wavelength of 375 nanometers, causing the optical
brightener to fluoresce radiation at 435 nanometers.
Scan chart 220 of the at heat-shrinkable annular film tubing 240
was produced using the same 4k line-scan monochrome camera used to scan and
photograph Film No. 10 in Figs 5A and 6. Moreover, the same camera used to take
the images of lay-flat annular tapes 170 and 200 of Figs 5B and 6 was used to take
the image of heat-shrinkable annular film tubing section 240 of .
Although heat-shrinkable annular film tubing 240 of was the
same heat-shrinkable annular film tubing the scan of which ed in scan chart
220 of , the lay-flat film tubing edges represented by left edge peak 222 and
right edge peak 224 of scan chart 220 do not line up with the left edge 242 or the
right edge 244 of film tubing section 240 of , because the image illustrated in
does not show the entire width of the heat-shrinkable annular film tubing
produced. However, scan chart 220 of contains first signal valleys 226 and
228 which are believed to correspond with die lines 246 and 248, respectively, of
. Furthermore, signal valley 226 has a shoulder that may correspond with
the apparent double (overlapping) die lines designated as die line 226 in ,
which may be in opposite lay-flat sides of heat-shrinkable annular film tubing section
240. Thus, the s can locate die lines in both the annular tape 170 of
as well as in the heat-shrinkable annular film tubing 240 of .
Although it may be surmised that the die lines 246 and 248 in heat-
able r film tubing 240 should correspond with the die lines in r
tape 170 and 200 (because film tubing 240 was made from the same annular tape
represented by annular tapes 170 and 200), it is believed that the orientation of the
tape in the process illustrated in (described above) may interfere with the
ability to correlate the die lines in the annular tape with the die lines in the resulting
heat-shrinkable annular film tubing.
Film No. 11 and Film No. 12
The evaluation of the degree of uity in the barrier layer in each of
Film No. 1 through Film No. 10 was conducted in a laboratory setting, using pre-
made film samples. These film samples were moved at a speed of only 1 foot per
minute relative to the fixed position of the machine vision system.
] In contrast, Film No. 11 and Film No. 12 were prepared and evaluated
in-Iine on a production process for the making of the film, with the film moving at a
speed in excess of 150 feet per minute relative to the fixed position of the e
vision system, with the run being carried out for a period of 2 hours for each film.
The single-point UV sensor (SMART RGB Digital Sensor Reflective, UV-head, model
CZ-H52, and SMART RGB Digital Sensor Amplifier Main Unit PNP, model CZ-
V21AP, obtained from Keyence Corporation of a) was mounted underneath
the vision system (Industrial Rack Mount PC with Windows 10 OS, PC enclosure,
ISRA “SMASH” Web Processing Board, 320MHz 4096 Pixel Camera, Camera
Cable, rd, Monitor, Camera Lens 50 mm f 1.2, LED light |ine (UV) 10 inch,
Rotary r with Cable and Mounting Bracket, ISRA “CENTRAL” Web Inspection
Software and e, obtained from ISRA Surface Vision) to monitor the UV level
fluctuation. The uv level fluctuation was not high enough to generate false positives.
Software benchmarks were composed for high dose (Film No. 11 had approximately
45 ppm indicator based on barrier layer ) and low dose (Film No. 12 had
approximately 15 ppm based on barrier layer weight). All other parameters were the
same with high dose and low dose except for the exposure time.
The layer arrangement, layer composition, layer function, and layer
thickness for Film No. 11 were as follows:
Film No. 11
Layer Film Tubing of Film No 11
function
Composition 80% PVDC-2 80%
SSPEl containing SSPEZ
% 45 ppm 19%
LLDPEl OB LLDPEZ
1% NIB-2
wt % 1916 411 217 812
Thickness 0143 mi] 009 mil 0106 mi] 0118 mi]
The layer arrangement, layer composition, layer function, and layer
thickness forthe film tubing of Film No. 12 were as s:
Film No. 12
Film Tubing of Film No_ 12
Composition 80% 80% PVDC-2 80%
SSPEI VLDPEl 100% 100% containing SSPEZ
% 19% EVAI EVAZ 15 ppm 19%
LLDPEI SSPE3 OB LLDPEZ
1% MB-l 1% MB-Z
The barrier layer ations for each of Film No. 11 and Film No. 12
were provided with an indicator which was BENETEX OB PLUS® benzoxazole-2,5-
enediylbis(5-tert-buty|-1,3-benzoxazole. Although this material has been used
as a brightening agent to reduce the appearance of the browning of PVDC during
film extrusion, benzoxazole-2,5-thiophenediylbis(5-tert—butyl-1,3-benzoxazole also
acts as a fluorescent agent when subject to incident radiation at 375 nm. Upon
excitement by exposure to radiation having at peak wavelength of 375 nm, the
indicatorfluoresced at peak wavelength of 435 nm. Film No. 11 had a barrier layer
with an OB level of 45 ppm. Film No. 12 had a barrier layer with an OB level of 15
ppm.
In the evaluation of Film No. 11 and Film No. 12, the e vision
evaluation was carried out on a line moving in excess of 150 feet per minute.
Although the machine vision system was able to detect a discontinuity down to below
0.1 mm, the minimum discontinuity level reported was 0.1 mm.
In order to provide barrier layer discontinuities in the films for the test
runs, the extrusion of Film No. 11 and Film No. 12 included blocking four locations
on the PVDC extrusion coating die, in order to generate discontinuities in the PVDC
layerthat simulated a solid particle ng lodged in the die gap. The PVDC layer
portion of the die stack allowed a molten stream of PVDC/indicator blend to emerge
from the die. The four ges caused four discontinuities in the PVDC layer. The
four tinuities ran uously in the machine direction in the PVDC layer. The
four discontinuities appeared as continuous streaks running in the machine direction
in the PVDC layer of the film produced using the die.
A schematic of single section 258 of an annular multilayer coating die
with four blockages installed therein is illustrated in The four die blockages
illustrated in include first blockage 260 which had a width of 0.5 inch, second
blockage 262 which had a width of 0.0625 inch, third blockage 264 which had a
width of 0.125 inch, and fourth blockage 266 which had width of width of 0.25 inch.
The four discontinuities were confined to the PVDC layer of the extrusion coating die.
Microscopy of the final film revealed that the four streaks had widths of about 4.1 mil
(about 0.1 mm), 18.9 mil (about 0.5 mm), 19.5 mil (about 0.5 mm), and 27.7 mil
(about 0.7 mm).
is a plot of film width position across the lay-flat web (x-axis) as
a function of signal intensity (y-axis) for Film No. 12, bed above. Upper and
lower horizontal dashed lines 270 and 272 represented the software limits that had
to be exceeded to establish the presence of a discontinuity. ln 0, the highest
signal peaks 274 and 276 (together with the unlabeled signal s paired
therewith) occurred at the edges of the web, i.e., where the machine vision was
looking outside of the width of the at film tubing. Centrally-located signal
intensity peaks 280 and 282 (together with the unlabeled signal valleys paired
therewith) occurred at tinuity locations that exhibited a signal intensity outside
of the pre-set limits, and corresponded with the streaks from the 0.0625 inch and
0.125 inch die blockages. ediately-Iocated signal intensity peaks 284 and 286
her with the unlabeled signal s paired therewith) represented
tinuity locations that exhibited a signal intensity outside of the pre-set limits,
and corresponded with the streaks from the 0.25 inch and 0.50 inch die blockages.
is a plot of film discontinuity data points obtained overtime as
a function of brightness emanating from an excited indicator present in the barrier
layer of Film No. 12. Each data point 290 represents “barrier streak average
brightness,” i.e., the decreased average brightness level emanating from a portion of
the film having a discontinuity which appears as a streak in the barrier layer. Each
data point 290 is generated based on data meeting a pre-set threshold of a
designated number of consecutive dark pixels (e.g., a continuous string of 100 dark
pixels in the machine direction, each pixel being from a ent line scan, with the
100 pixels being from 100 consecutive line scans, each pixel being in the same
place along each line scan) resulting from each machine direction streak generated
by a particular die blockage intentionally placed in the die during the production of
Film No. 12. In this manner, each data point represents a discontinuity in the barrier
layer corresponding with meeting a pre-set threshold of a designated number of
consecutive dark pixels resulting from each machine direction streak ponding
with a particular blockage in the die used to make Film 12. Line 292 represents the
mean of barrier streak e brightness.
is a plot of film anomaly data points ed overtime as a
on of brightness for Film No. 11. Data points 296 in the grouping of data points
between average brightness level of from 115 to 170 represent the average
brightness in a barrier streak in Film No. 11, in the same manner that data points 290
of represent barrier streak e brightness in a streak in the indicator-
containing barrier layer of Film No. 12 rated in , described above. Line
298 represents the mean of barrier streak average brightness for data points 296.
As with data points 290 in , each data point 296 represents a discontinuity in
the barrier layer corresponding with meeting a pre-set old of a designated
number of consecutive dark pixels resulting from each machine direction streak
corresponding with a particular die blockage of Film No. 11. Each of the data points
290 of corresponds with a string of 100 consecutive dark pixels located in
approximately the same position across the web in 100 consecutive line scans from
the . In this manner, each data point 296 corresponds with a portion of a
streak in the film, which streak was caused by the blockage intentionally placed in
the die. The blockage interrupted the continuity of the melt flow, or reduced the
thickness of the barrier layer in the region of the film affected by the blockage to an
extent that the amount of indicator per unit area is not high enough to meet a
minimum level of brightness associated with a minimum acceptable barrier layer
ess.
] A comparison of the e Brightness units of with the
Average Brightness level of cannot be made because in the generation of
this data, the light ity and exposure time settings were different between Film
No. 11 and Film No. 12. Also, the concentration of indicator in the barrier layers was
different between Film No. 11 and Film No. 12.
FIG 12 further illustrates film data points 300 for “bright defects,” Le, a
plurality of bright spots in the film resulting from the presence of gels, water droplets,
and dust present in the film or on the film. Usually, these bright spots are not the
result of gels, water droplets, or dust in the barrier layer. Rather, the bright spots
emanate from other films layers (seal layer, abuse layer, tie layers, etc). They can
emanate from contamination on the surface of the film, i.e., not within the volume
ed by the film. They can also emanate from anomalies n film layers.
] FIG 12 further illustrates film data points 302 for “dark defects,” i.e., a
plurality of dark spots in the film resulting from the presence of carbon particles and
creases present in, on, or of the film. Usually, these dark spots do no emanate from
the barrier layer. Rather, they emanate from other films layers (seal layer, abuse
layer, tie , etc), orfrom anomalies present on the film outer surface or between
film layers.
Claims (21)
- Claim 1: A process for assessing continuity of a functional layer of a web, comprising: A. forming the web by extruding a thermoplastic material through an annular die 5 to form an annular tape, ing the tape, and collapsing the tape into layflat configuration, which is thereafter converted to a plurality of bags; B. forwarding the web at a speed of at least 5 meters per minute; C. detecting the presence of the functional layer and a discontinuity in the functional layer, by inspecting the web with a machine vision system capable 10 of detecting the presence or absence of a detectable component in the functional layer; and D. generating a signal in response to the discontinuity in the functional layer, wherein the functional layer comprises a blend of a thermoplastic composition and a detectable component, the detectable component being 15 t at a detectable level in the functional layer, the r tape is ed to its softening point and oriented while in the solid state after quenching, and ting the web is carried out as an inspection of the web in its lay-flat characterization by scanning the annular tape while the tape is in motion, wherein the scanning is carried out by a camera positioned 20 downstream of a point at which the tape is ed and collapsed into the lay-flat configuration.
- Claim 2: The process according to claim 1, wherein the web is a monolayer web.
- Claim 3: The process ing to claim 1, wherein the web is a multilayer web comprising the functional layer and at least one onal layer.
- Claim 4: The process according to any of claims 1-3, wherein the machine vision system 30 is capable of generating a signal in response to a layer discontinuity having a size down to at least as small as 7 mm in the machine ion and 3.5 mm in the transverse direction.
- Claim 5: The process according to any of claims 1-3, wherein the machine vision system 5 is capable of generating a signal in response to a layer discontinuity having a size down to at least as small as 3.5 mm in the machine direction and 1.8 mm in the transverse direction.
- Claim 6: The process according to any of claims 1-3, wherein the machine vision system 10 is capable of generating a signal in response to a layer discontinuity having a size down to at least as small as 0.7 mm in the machine direction and 0.35 mm in the transverse direction.
- Claim 7: The process according to any of claims 1-6, further sing detecting an amount 15 of the detectable component in the functional layer, wherein the amount of the detectable component is proportional to a thickness of the functional layer.
- Claim 8: The process according to claim 1, wherein the functional layer is a member selected from the group consisting of an oxygen barrier layer, an organoleptic barrier 20 layer, and a moisture barrier layer, ous chemical barrier layer, microbial barrier layer, acid layer, acid salt layer, bacteriocin layer, bacteriophage layer, metal layer, metal salt layer, natural oil layer, l extract layer, layer containing polyhexamethylene biguanide hloride, layer containing paraben, layer containing d silanequaternary amine, layer containing triclosan, layer containing zeolite of silver, copper, 25 and/or zinc.
- Claim 9: The process according to claim 8, wherein the functional layer is an oxygen barrier layer comprising at least one member selected from the group consisting of vinylidene chloride copolymer, saponified ne/vinyl acetate copolymer, 30 polyamide, ter, oriented polypropylene, and ne homopolymer.
- Claim 10: The process according to any of claims 1-7, wherein the inspecting of the web is carried out over at least 10% of the web.
- Claim 11: The process according to any of claims 1-8, wherein the inspecting of the 5 tape is carried out by scanning the annular tape while the tape is in motion and in a layflat configuration, the scanning being carried out by a camera positioned downstream of a point at which the tape is quenched and collapsed into the lay-flat configuration.
- Claim 12: The process according to Claim 11, n the scanning is carried out by 10 a camera positioned downstream of a point at which the annular tape is subjected to solid state orientation to form an annular film tubing, the camera being positioned am of a point at which the r film is wound up or slit.
- Claim 13: The process according to any of claims 1-12, wherein the detectable 15 component comprises at least one member selected from the group consisting of ultraviolet- indicator, infrared-indicator, dye, pigment, l ener, scent whitening agent, and 2,5-thiophenediylbis(5-tert-butyl-1,3-benzoxazole).
- Claim 14: The process according to any of claims 1-13, wherein the able 20 component is present in the layer at a level of at least 1 part per million.
- Claim 15: The process according to any of claims 1-14, n the detectable component is of a type which, if exposed to radiation at a first peak wavelength, 25 emits radiation at a second peak wavelength.
- Claim 16: The process according to claim 15, wherein the detecting of the presence of the functional layer is carried out by exposing the detectable component to ion at the first peak wavelength to generate an excited detectable component, and thereafter 30 detecting the presence of the functional layer and a discontinuity in the functional layer by inspecting the web with the machine vision system while the detectable component emits radiation at the second peak wavelength.
- Claim 17: The process according to any of claims 1-16, wherein the signal generated in response to the discontinuity is used to activate at least one member selected from the group consisting of an alarm, film flagging, displaying an image of a tinuity, 5 displaying data pertaining to one or more discontinuities, and generating a report of the discontinuity data.
- Claim 18: The process according to any of claims 1-17, wherein: A) the web is forwarded at a speed of at least 30 meters per minute; 10 B) the able component is present in the thermoplastic composition at a level of from 0.5 to 150 ppm, C) the detecting of the presence the functional layer and the discontinuity in the functional layer are d out by inspecting the web with a machine vision system e of generating a signal indicating the presence or absence 15 of the detectable component in the functional layer, by scanning ersely across the web and generating a signal in response to the presence, absence, and amount of the detectable component present in a functional layer of the web, wherein: 20 (c)(i) the machine vision system comprises a line-scan camera scanning at a speed of from 50 to 1000 rtz and at an exposure time of from 2 x 10 -3 second to 1 x 10-5 second; (c)(ii) the machine vision system is capable of generating a signal in response to a layer discontinuity having a size down to at least as small as 7 mm in the 25 machine direction and at least as small as 3.5 mm in the transverse direction; (c)(iii) the machine vision system scans with a pixel count of from 500 to 50,000 per scan. 30
- Claim 19: The process according to any of claims 1-17, wherein: A) the web is forwarded at a speed of at least 50 meters per minute; B) the able ent is present in the plastic composition at a level of from 1 to 20 ppm, C) the detecting of the presence the functional layer and the discontinuity in the functional layer are carried out by ting the web with a machine vision 5 system capable of generating a signal indicating the presence or e of the detectable component in the functional layer, by scanning transversely across the web and generating a signal in response to the presence, absence, and amount of the detectable component present in a functional layer of the web, wherein: 10 (c)(i) the machine vision system comprises a line-scan camera scanning at a speed of from 100 to 750 megahertz and at an re time of from 7 x 10-3 second to 3 x 10-5 second; (c)(ii) the machine vision system is capable of generating a signal in response to a layer discontinuity having a size down to at least as small as 3.5 mm in the 15 machine direction and at least as small as 1.8 mm in the transverse direction; and (c)(iii) the machine vision system scans with a pixel count of from 1,000 to 15,000 per scan.
- Claim 20: The process according to any of claims 1-17, wherein: 20 A) the web is forwarded at a speed of from 60 to 150 meters per minute; B) the detectable component is present in the thermoplastic composition at a level of from 2 to 10 ppm, C) the detecting of the presence the functional layer and the discontinuity in the onal layer are carried out by inspecting the web with a machine vision 25 system capable of generating a signal indicating the presence or absence of the detectable component in the functional layer, by scanning transversely across the web and generating a signal in response to the ce, absence, and amount of the detectable component present in a functional layer of the web, wherein: (c)(i) the machine vision system comprises a line-scan camera scanning at a 30 speed of from 200 to 500 megahertz and at an re time of from 2 x 10-4 second to 5 x 10-5 second; (c)(ii) in an unoriented annular tape the machine vision system is capable of generating a signal in se to a layer discontinuity having a size down to at least as small as 0.2 mm in the machine direction and having a size down to at least 0.1 mm in the transverse direction, or in an oriented heat- 5 shrinkable film tubing the machine vision system iscapable of generating a signal in response to a layer discontinuity having a size down to at least as small as 0.7 mm in the machine direction and at least as small as 0.35 mm in the transverse direction; and (c)(iii) the machine vision system scans with a pixel count of from 3,000 to 9,000 10 per scan.
- Claim 21: A system for assessing layer continuity in a moving web in accordance with a process of any one of claims 1-20, the system comprising: 15 A) a web forwarding device forwarding the web at a speed of from at least 5 meters per minute, the web having a functional layer sing a thermoplastic composition having a detectable component therein and being formed in a process comprising extruding a thermoplastic material through an annular die to form an r tape, ing the 20 tape, and collapsing the tape into a lay-flat configuration, B) an image generator for generating image data of the detectable component in the functional layer of the moving web as the web is being ded by the web forwarding device, wherein the image generator is a camera positioned downstream of a point at which the tape is quenched into the lay-flat 25 configuration to inspect the oriented annular tape, C) a data acquisition system for acquiring the image data of the web from the image tor; and a vision inspection engine for receiving and analyzing the image data to identify and classify the ce and absence of defects in the web using the image data received from the 30 data acquisition system, the vision inspection system ting an alert identifying the presence or absence of a defect in the web.
Applications Claiming Priority (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201762456321P | 2017-02-08 | 2017-02-08 | |
US201762456357P | 2017-02-08 | 2017-02-08 | |
US62/456,321 | 2017-02-08 | ||
US62/456,357 | 2017-02-08 | ||
PCT/US2018/017369 WO2018148371A1 (en) | 2017-02-08 | 2018-02-08 | Processes and systems for in-line inspection of functional film layer containing detectable component |
Publications (2)
Publication Number | Publication Date |
---|---|
NZ754152A NZ754152A (en) | 2021-06-25 |
NZ754152B2 true NZ754152B2 (en) | 2021-09-28 |
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