US6565686B2 — Infrared imaging to detect components on personal…

Claim 1

Independent Claim 220 words

A method of sensing assembly quality characteristics of a web of personal care article products or personal care article product precursors being fabricated on a fabrication line by processing apparatus, each personal care article product or personal care article product precursor having, as an element thereof, a bodyside liner, an outer cover, and at least one element of the personal care article product or personal care article product precursor disposed between the bodyside liner and the outer cover, the method comprising: (a) sensing infrared properties of product or product precursors being fabricated on the web using infrared sensing apparatus; (b) outputting signals indicative of infrared properties of the product or product precursors being fabricated on the web to visual image processing apparatus; (c) creating a database representative of infrared properties of product standards within selected control tolerance; (d) comparing the sensed infrared properties of product being fabricated with the database, using the image processing apparatus, the image processing apparatus comprising a programmable logic controller capable of comparing image data from the infrared sensing apparatus with preselected stored images of the database, and thereby developing an image comparison result; and (e) outputting processing adjustment signals from the programmable logic controller to processing apparatus of the fabrication line to effect adjustment of absorbent article processing in accord with the image comparison result.

Claim 2

Independent Claim 220 words

A method of sensing assembly quality characteristics of a web of personal care article products or personal care article product precursors being fabricated on a fabrication line by processing apparatus, each personal care article product or personal care article product precursor having, as an element thereof, a bodyside liner, an outer cover, and at least one element of the personal care article product or personal care article product precursor disposed between the bodyside liner and the outer cover, the method comprising: (a) sensing infrared properties of product or product precursors being fabricated on the web using infrared sensing apparatus; (b) outputting signals indicative of infrared properties of the product or product precursors being fabricated on the web to visual image processing apparatus; (c) creating a database representative of infrared properties of product standards within selected control tolerance; (d) comparing the sensed infrared properties of product being fabricated with the database, using the image processing apparatus, the image processing apparatus comprising a programmable logic controller capable of comparing image data from the infrared sensing apparatus with preselected stored images of the database, and thereby developing an image comparison result; and (e) outputting processing adjustment signals from the programmable logic controller to processing apparatus of the fabrication line to effect adjustment of absorbent article processing in accord with the image comparison result.

Claim 3

Dependent Claim 33 words

A method as in claim 1 wherein signals indicative of infrared properties of product being fabricated on the web are outputted in video format acceptable for processing in the visual image processing apparatus.

Claim 4

Dependent Claim 30 words

A method as in claim 1 , including outputting signals indicative of visual images, derived from the infrared signatures, to an operator station display using said visual image processing apparatus.

Claim 5

Dependent Claim 45 words

A method as in claim 3 , including displaying at the operator station respective preselected stored visual image information on said operator station display concurrently with display of the real time images of infrared properties of product or product precursors being fabricated on the web.

Claim 6

Dependent Claim 57 words

A method as in claim 1 , including comparing visual image data for a given personal care article on the web against a predetermined data standard and thereby determining conformance of the respective personal care article to the standard, and outputting cull signals to cull selected ones of such compared personal care articles from said fabrication line.

Claim 7

Dependent Claim 78 words

A method as in claim 1 , including said visual image processing apparatus outputting one or more of the signals selected from the group consisting of: (i) a fabrication line shutdown signal; (ii) a signal which calls attention to characteristics of the personal care articles which are not within preselected control tolerances; and (iii) a signal which activates process adjustments to adjust characteristics of the personal care articles, such characteristics not being within preselected control tolerances before adjustment.

Claim 8

Independent Claim 185 words

A method of fabricating composite personal care articles and sensing assembly quality characteristics of the personal care articles so fabricated, at least one of the components of precursors of the personal care articles so fabricated comprising a continuous web of material, the method comprising: (a) transporting the web along a fabrication line, past a plurality of work stations where work, for fabricating the personal care article precursors according to a predetermined arrangement, is performed on the web, thereby to form an array of precursors of such personal care articles on the web; (b) separating ones of the array of personal care article precursors, from the web, and into individual personal care articles, including severing the web across a transverse dimension thereof; (c) sensing infrared properties of product being fabricated on the web, and outputting signals indicative of infrared signatures of the product; and (d) accepting such outputted signals indicative of infrared signatures of the product being fabricated on the web, and processing such data and thereby determining assembly quality characteristics of respective ones of the composite personal care articles or composite personal care article precursors.

Claim 9

Independent Claim 185 words

A method of fabricating composite personal care articles and sensing assembly quality characteristics of the personal care articles so fabricated, at least one of the components of precursors of the personal care articles so fabricated comprising a continuous web of material, the method comprising: (a) transporting the web along a fabrication line, past a plurality of work stations where work, for fabricating the personal care article precursors according to a predetermined arrangement, is performed on the web, thereby to form an array of precursors of such personal care articles on the web; (b) separating ones of the array of personal care article precursors, from the web, and into individual personal care articles, including severing the web across a transverse dimension thereof; (c) sensing infrared properties of product being fabricated on the web, and outputting signals indicative of infrared signatures of the product; and (d) accepting such outputted signals indicative of infrared signatures of the product being fabricated on the web, and processing such data and thereby determining assembly quality characteristics of respective ones of the composite personal care articles or composite personal care article precursors.

Claim 10

Dependent Claim 26 words

A method as in claim 7 , including outputting such signals indicative of infrared signatures in video format acceptable for processing in visual image processing apparatus.

Claim 11

Dependent Claim 25 words

A method as in claim 7 , further comprising, using a computer module, comparing image data from the infrared sensing apparatus with preselected stored images.

Claim 12

Dependent Claim 32 words

A method as in claim 7 , further comprising outputting, from visual image processing apparatus, to an operator station display, output signals indicative of visual images and derived from the infrared signatures.

Claim 13

Dependent Claim 22 words

A method as in claim 10 , further comprising concurrently displaying, at the operator station display, respective preselected stored visual image information.

Claim 14

Dependent Claim 57 words

A method as in claim 7 , further comprising comparing image data for a given personal care article on the web against a predetermined data standard and thereby determining conformance of the respective personal care article to the standard, and outputting cull signals to cull selected ones of the compared personal care articles from the fabrication line.

Claim 15

Dependent Claim 76 words

A method as in claim 7 , further comprising outputting, from the visual image processing apparatus, one or more signal from the group consisting of: (i) a fabrication line shutdown signal; (ii) a signal which calls attention to characteristics of personal care articles which are not within preselected control tolerances; and (iii) a signal which activates process adjustments to adjust characteristics of the personal care articles, such characteristics not being within preselected control tolerances before adjustment.

Claim 16

Independent Claim 162 words

A method for fabricating composite personal care articles and sensing assembly quality characteristics of the personal care articles so fabricated, at least one of the components of precursors of the personal care articles so fabricated comprising a continuous web of material, the method comprising: (a) transporting the web along a fabrication line, past a plurality of work stations where work, for fabricating the personal care article precursors according to a predetermined arrangement, is performed on the web thereby to form an array of precursors of such personal care articles on the web; (b) separating ones of the array of personal care article precursors from the web, and into individual personal care articles, including severing the web across a transverse dimension thereof; and (c) sensing infrared signatures of product being fabricated on the web, thereby determining assembly quality characteristics of respective ones of the composite personal care articles or composite personal care article precursors, and outputting a signal representative of the sensed characteristics.

Claim 17

Independent Claim 162 words

A method for fabricating composite personal care articles and sensing assembly quality characteristics of the personal care articles so fabricated, at least one of the components of precursors of the personal care articles so fabricated comprising a continuous web of material, the method comprising: (a) transporting the web along a fabrication line, past a plurality of work stations where work, for fabricating the personal care article precursors according to a predetermined arrangement, is performed on the web thereby to form an array of precursors of such personal care articles on the web; (b) separating ones of the array of personal care article precursors from the web, and into individual personal care articles, including severing the web across a transverse dimension thereof; and (c) sensing infrared signatures of product being fabricated on the web, thereby determining assembly quality characteristics of respective ones of the composite personal care articles or composite personal care article precursors, and outputting a signal representative of the sensed characteristics.

Claim 18

Dependent Claim 44 words

A method as in claim 14 , further comprising receiving and processing such signal in a signal processor and providing a processor output representative of at least one of the personal care articles or personal care article precursors being fabricated on the fabrication line.

Claim 19

Dependent Claim 59 words

A method as in claim 14 , further comprising placing an absorbent core on the web, and bodyside liner material over the absorbent core such that the absorbent core is between the web and the bodyside liner material and, using infrared sensing and signal processing apparatus, viewing and sensing the position of the absorbent core through visually obstructive material.

Claim 20

Dependent Claim 101 words

A method as in claim 14 , further comprising placing an absorbent core on the web, and bodyside liner material over the absorbent core such that the absorbent core is between the web and the bodyside liner material, one of the bodyside liner and material of the web having a first surface facing infrared sensing and signal processing apparatus, the first surface having a visual printed image thereon, the method further comprising, using infrared sensing and signal processing apparatus, sensing an assembly quality characteristic under the respective one of the bodyside liner material and the web, through the visual printed image.

Claim 21

Dependent Claim 64 words

A method as in claim 14 , further comprising applying adhesive for securing at least first portions of first respective components to second portions of second respective ones of the components and, using infrared sensing and signal processing apparatus, sensing one or both of the position of such adhesive in the personal care articles, and quantities of such adhesive in the personal care articles.

Claim 22

Dependent Claim 58 words

A method as in claim 14 , further comprising placing absorbent cores over the web as elements of the personal care article precursors, the absorbent cores having zones comprising relative concentrations of superabsorbent and, using infrared sensing and signal processing apparatus, sensing the zones of relative concentration of superabsorbent as distinct from the remainders of the absorbent cores.

Claim 23

Dependent Claim 53 words

A method as in claim 14 further comprising, using an ultrasonic horn and cooperating anvil, providing ultrasonic energy to create bonds bonding, in the personal care article precursors, at least one component of such personal care article precursors and, using infrared sensing and signal processing apparatus, sensing the positions of such ultrasonic bonds.

Claim 24

Dependent Claim 43 words

A method as in claim 20 , further comprising providing output from the infrared sensing and signal processing apparatus to an operator station as an indication when the infrared sensing and signal processing apparatus does not detect the presence of the ultrasonic bonds.

Claim 25

Dependent Claim 23 words

A method as in claim 14 further comprising, using infrared sensing and signal processing apparatus, sensing registration of predetermined ones of the components.

Claim 26

Dependent Claim 43 words

A method as in claim 14 , further comprising sending an alarm signal as an output of an infrared sensing and signal processing apparatus to an operator station, and thereby identifying existence of an improper condition for at least one of the components.

Claim 27

Dependent Claim 36 words

A method as in claim 14 , further comprising outputting a cull signal from the infrared sensing and signal processing apparatus, to cull selected one or more of the personal care articles from the fabrication line.

Claim 28

Dependent Claim 79 words

A method as in claim 14 , further comprising outputting, from the infrared sensing and signal processing apparatus, one or more signal selected from the group consisting of: (i) a fabrication line shutdown signal; (ii) a signal which calls attention to characteristics of personal care articles which are not within preselected control tolerances; and (iii) a signal which activates process adjustments to adjust characteristics of the personal care articles, such characteristics not being within preselected control tolerances before adjustment.

Claim 29

Dependent Claim 46 words

A method as in claim 14 further comprising, using infrared sensing and signal processing apparatus, sensing assembly quality characteristics common to personal care articles being fabricated on the fabrication line, the assembly quality characteristics, in combination, comprising a signature for the personal care articles being fabricated.

Claim 30

Dependent Claim 44 words

A method as in claim 14 further comprising, using infrared sensing and signal processing apparatus, sensing portions of personal care articles being fabricated on the fabrication line and having temperatures as low as about 20 degrees Celsius and up to about 200 degrees Celsius.

Claim 31

Dependent Claim 32 words

A method as in claim 14 further comprising, using a passive infrared sensor, sensing temperature differences across an overall projected surface defined by an area of one of the personal care articles.

Claim 32

Dependent Claim 20 words

A method as in claim 14 further comprising, using an infrared camera, collecting infrared images from the personal care articles.

Claim 33

Dependent Claim 35 words

A method as in claim 14 further comprising, using infrared sensing and signal processing apparatus, outputting a composite visual image representative of at least one of the personal care articles or personal care article precursors.

Claim 34

Dependent Claim 29 words

A method as in claim 30 , further comprising collecting, for each visual image, an array of infrared signals from discrete areas of the personal care articles being assessed.

Claim 35

Dependent Claim 43 words

A method as in claim 14 , further comprising outputting, from infrared sensing and signal processing apparatus, a signal representing an out-of-tolerance condition in the personal care article or personal care article precursor sensed, and sending the out-of-tolerance signal to an operator station.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	2006-05-19	2006-11-18	2007-05-20	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2010-05-19	2010-11-18	2011-05-20	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2014-05-19	2014-11-18	2015-05-20	$7700.00	Window Closed / Lapsed

Infrared imaging to detect components on personal care articles

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