Ultrasonic Imaging of Micro-Leaks and Seal Contamination in Flexible Food Packages by the Pulse-Echo Technique

Air-Coupled Ultrasound Sealing Integrity Inspection Using Leaky Lamb Waves in a Simplified Model of a Lithium-Ion Pouch Battery: Feasibility Study

Inspecting the sealing integrity of lead tabs is an important means of ensuring the reliability and safety of pouch-type lithium-ion (Li-ion) batteries with a thin multi-layered aluminum (Al) laminated film. This paper presents a new air-coupled ultrasonic non-destructive testing (NDT) inspection method based on leaky Lamb wave transmission; and reception for evaluating the sealing integrity between the lead tab and the Al pouch film. The proposed method uses the critical incidence angle between the air and the layer with the fastest Lamb wave velocity to maximize the signal-to-noise ratio in the through-transmission mode. To determine the critical incidence angle, phantom experiments with two test pieces (i.e., an Al tab and an Al tab sealed with an Al pouch film) are conducted. In addition, 2D scans are performed at various incidence angles for an inhouse pouch-type Li-ion battery with a 1-mm-wide foreign material inserted as a defect. At the critical incidence angle (i.e., 22°), the proposed air-coupled ultrasonic NDT method in through-transmission mode successfully identifies the shape and location of the defect through c-scan image reconstruction. These preliminary results indicate that the proposed air-coupled ultrasonic NDT method with leaky Lamb waves can be used to inspect the sealing integrity of Li-ion pouch batteries in dry test conditions.

A real-time inspection system using a terahertz technique to detect microleak defects in the seal of flexible plastic packages

A method to detect production faults in flexible plastic packages with the use of terahertz radiation is presented. Relying on the large difference between the absorption coefficients of plastic and water (for water-filled channel defects) and on the refraction index difference between plastic and air (for air-filled channel defects), our technique consists of focusing and scanning a terahertz beam on the sealed area of the package, followed by detection of the transmitted signal. Compared with previous methods, such as visual and ultrasound inspection, our technique can be applied to optically opaque packages and does not require immersion in a matching liquid. We tested our system on defects that we fabricated as water-filled and air-filled channels imbedded in polyethylene films, with diameters in the range of 10 to 100 microm. The detection limit (the minimum size of a detectable defect) depends on the conveying speed; this relationship was determined and analyzed. The results show that our system has the potential for application in an actual production line for real-time inspection.

A real-time approach to detect seal defects in food packages using ultrasonic imaging

The microbial integrity of many types of flexible food packages depends on a zero defect level in the fused seam seal. Human inspection for defects in these seals is marginal at best, and secondary incubation protocols are often used to spot packages with compromised integrity before releasing product for sale. A new type of inspection method has been developed and is being evaluated for robustness. The purpose of the study was to evaluate a new raster scanning geometry to simulate continuous motion, online ultrasonic inspection of the seal region in flexible food package seals. A principal engineering tradeoff of scanning inspection systems is between increased line speed that results from decreased spatial sampling (less acquired data to process) and decreased image quality. The previously developed pulse-echo Backscattered Amplitude Integral (BAI) mode imaging technique is used to form ultrasound images using the new scanning geometry. At an ultrasonic frequency of 22.9 MHz, 38- and 50-microm-diameter air-filled channel defects in all-plastic transparent trilaminate are evaluated. The contrast-to-noise ratio (CNR) of the processed BAI-mode image is used to quantify image quality as a function of spatial sampling. Results show seal defects (38- and 50-microm diameter) are still detectable for undersampled conditions, although image quality degrades as spatial sampling decreases. Further, it is concluded that the raster scanning geometry is feasible for online inspection.

High contrast ultrasound images of defects in food package seals

Previous work to detect defects in food packaging seals using pulse-echo ultrasound inspired the backscattered amplitude integral (BAI) imaging technique, which could reliably identify channels with diameters 38 microm or larger at a center frequency of 17.3 MHz (lambda=86 microm). The current study presents two new processing techniques that more reliably reveal smaller channels ( approximately 6 microm in diameter). The RF sampling technique (RFS) displays a single, time-gated, pressure value from the received (not envelope-detected) RF waveform at each transducer position. The RF correlation technique (RFC) calculates the correlation coefficients of the RF signals with a reference signal that does not pass through a channel. The correlation coefficient can be calculated for the entire RF signal (RFCE) or over a short segment of the RF signal (RFCS). The performance of these imaging methods for detecting channel defects is investigated for plastic and aluminum foil trilaminate films with 6, 10, 15, 38, and 50 microm channels filled with water or air. Data are collected with a focused ultrasound transducer (17.3 MHz, 6.35 mm in diameter, f/2, 173 microm -6 dB pulse-echo lateral beamwidth at the focus) scanned over a rectangular grid, keeping the package in the focus. Performance is measured using detection rates, image contrast, and contrast-to-noise ratio (CNR). Both RFS and RFCS have improved detection rates relative to BAI for channels 15 microm or smaller. The RFCS technique is the most effective at smoothing the background, leading to the greatest CNR improvements.