U.S. patent application number 14/627820 was filed with the patent office on 2015-06-11 for vacuum insulation panel quality control systems and methods for using same.
The applicant listed for this patent is Caralon Global Limited. Invention is credited to Charles Hewitt, Timothy Wojciechowski.
Application Number | 20150163569 14/627820 |
Document ID | / |
Family ID | 48902404 |
Filed Date | 2015-06-11 |
United States Patent
Application |
20150163569 |
Kind Code |
A1 |
Hewitt; Charles ; et
al. |
June 11, 2015 |
VACUUM INSULATION PANEL QUALITY CONTROL SYSTEMS AND METHODS FOR
USING SAME
Abstract
A system and method for implementing quality control for a panel
is described. For example, the panel may be configured as a vacuum
insulation panel having sensors arranged within the panel and/or on
a surface thereof. A radio frequency identification unit may be in
operable communication with the sensor and may transmit panel
information to an external radio frequency identification receiver.
A data collation element in operable communication with the radio
frequency identification receiver may be configured to receive and
analyze aggregated panel performance data received from the radio
frequency identification receiver.
Inventors: |
Hewitt; Charles; (London,
GB) ; Wojciechowski; Timothy; (Westlake, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Caralon Global Limited |
Milton Keynes |
|
GB |
|
|
Family ID: |
48902404 |
Appl. No.: |
14/627820 |
Filed: |
February 20, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13758659 |
Feb 4, 2013 |
8994555 |
|
|
14627820 |
|
|
|
|
61594819 |
Feb 3, 2012 |
|
|
|
Current U.S.
Class: |
340/870.3 |
Current CPC
Class: |
G08C 17/02 20130101;
G01M 3/40 20130101; H04Q 9/00 20130101; H04Q 2209/47 20130101; G01M
3/16 20130101 |
International
Class: |
H04Q 9/00 20060101
H04Q009/00 |
Claims
1. A quality control system for a panel, the system comprising: at
least one sensor; a radio frequency identification unit in operable
communication with the sensor, the radio frequency identification
unit being configured to receive panel information associated with
the panel; a radio frequency identification receiver configured to
receive panel performance data transmitted from the radio frequency
identification unit, the panel performance data comprising the
panel information; and a data collation element in operable
communication with the radio frequency identification receiver and
configured to analyze aggregated panel performance data received
from the radio frequency identification receiver.
2. The system of claim 1, wherein the sensor comprises a dielectric
film.
3. The system of claim 1, wherein the radio frequency
identification unit is in operative communication with the
dielectric film.
4. The system of claim 1, wherein the panel comprises a vacuum
insulation panel.
5. The system of claim 1, wherein the sensor is positioned within
the panel.
6. The system of claim 1, wherein the at least one sensor comprises
a plurality of sensors positioned in multiple locations within the
panel.
7. The system of claim 1, wherein the dielectric film is coated
with a coating configured to change at least one property
responsive to an event.
8. The system of claim 7, wherein the coating comprises an alumina
coating configured to change an electrical conductance responsive
to exposure to an oxidizing substance.
9. The system of claim 1, wherein the radio frequency
identification unit is arranged within the panel.
10. The system of claim 1, wherein the radio frequency
identification unit is configured to transmit encrypted panel
performance data.
11. The system of claim 1, wherein the quality control system is
configured as a thermal packaging unit.
12. The system of claim 1, wherein the data collation element is
configured to associate the aggregated panel performance data with
production batch information associated with the panel.
13. The system of claim 1, further comprising: a handheld unit
comprising a processor and a non-transitory, computer-readable
storage medium in operable communication with the processor, the
handheld unit having the radio frequency identification receiver
positioned therein, wherein the computer-readable storage medium
contains one or more programming instructions that, when executed,
cause the processor to analyze aggregated panel performance data
via the data collation element.
14. A method of aggregating panel performance data, the method
comprising: detecting panel information using a sensor;
transmitting, by the sensor, the panel information to a radio
frequency identification unit; transmitting, by the radio frequency
identification unit, panel performance data to a radio frequency
identification receiver, the panel performance data comprising the
panel information; aggregating panel performance data at a data
collation element; and analyzing the aggregated panel performance
data by the data collation element.
15. The method of claim 14, wherein the sensor detects panel
information using a dielectric film.
16. The method of claim 15, further comprising detecting a
conductance of the panel via the dielectric film.
17. The method of claim 14, further comprising transmitting
identification information associated with the sensor to the radio
frequency identification receiver via the radio frequency
identification unit.
18. The method of claim 14, wherein analyzing the aggregated panel
performance data comprises determining a likelihood of failure of
the panel based on panel performance data.
19. The method of claim 14, wherein the radio frequency
identification receiver is configured to receive panel information
from a plurality of radio frequency identification units associated
with a plurality of panels.
20. The method of claim 14, wherein the panel information comprises
manufacturer information and production batch information
associated with the panel.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 13/758,659, filed on Feb. 4, 2013, which
claims the benefit of U.S. Provisional Application No. 61/594,819,
filed on Feb. 3, 2012, the contents of which are incorporated by
reference in its entirety as if fully set forth herein.
BACKGROUND
[0002] Significant product reliability problems exist for vacuum
insulation panels (VIPs). In addition, it is difficult to identify
panels in VIP systems that have marginal failures. A marginal
failure occurs when a VIP has not fully inflated or has a
micro-leak resulting from, for example, handling or materials. Any
of these failures can cause a reduction in performance due to a
loss of vacuum.
[0003] In some cases, conventional VIP systems do not verify the
panel performance and, as such, cannot detect leaks in the systems.
Alternatively, conventional VIP quality control systems require
direct contact with a VIP in order to identify a leak because the
quality control systems detect leaks by performing thermal testing
of the panel. In such a case, the amount of time and effort
required to fully test a VIP system can be significant.
SUMMARY
[0004] This disclosure is not limited to the particular systems,
devices and methods described, as these may vary. The terminology
used in the description is for the purpose of describing the
particular versions or embodiments only, and is not intended to
limit the scope.
[0005] As used in this document, the singular forms "a," "an," and
"the" include plural references unless the context clearly dictates
otherwise. Unless defined otherwise, all technical and scientific
terms used herein have the same meanings as commonly understood by
one of ordinary skill in the art. Nothing in this disclosure is to
be construed as an admission that the embodiments described in this
disclosure are not entitled to antedate such disclosure by virtue
of prior invention. As used in this document, the term "comprising"
means "including, but not limited to."
[0006] In an embodiment, a quality control system may include a
sensor having a dielectric film, an RFID unit in operable
communication with the dielectric film that receives panel
information, a RFID receiver configured to receive panel
performance data, including the panel information, transmitted from
the RFID unit, and a data collation system in operable
communication with the RFID receiver and configured to analyze
aggregated panel performance data received from the RFID
receiver.
[0007] In an embodiment, a method of aggregating panel performance
data may include detecting panel information using a sensor and/or
a dielectric film, transmitting the panel information to an RFID
unit, transmitting panel performance data, including the panel
information, to an RFID receiver, aggregating panel performance
data at a data collation system, and analyzing the aggregated panel
performance data by the data collation system.
[0008] In an embodiment, a quality control system for a panel may
comprise at least one sensor; a radio frequency identification unit
in operable communication with the sensor, the radio frequency
identification unit being configured to receive panel information
associated with the panel; a radio frequency identification
receiver configured to receive panel performance data transmitted
from the radio frequency identification unit, the panel performance
data comprising the panel information; and a data collation element
in operable communication with the radio frequency identification
receiver and configured to analyze aggregated panel performance
data received from the radio frequency identification receiver.
[0009] In an embodiment, a method of aggregating panel performance
data may comprise detecting panel information using a sensor;
transmitting, by the sensor, the panel information to a radio
frequency identification unit; transmitting, by the radio frequency
identification unit, panel performance data to an radio frequency
identification receiver, the panel performance data comprising the
panel information; aggregating panel performance data at a data
collation system; and analyzing the aggregated panel performance
data by the data collation system.
BRIEF DESCRIPTION OF DRAWINGS
[0010] FIG. 1 depicts an illustrative block diagram of a VIP
quality control system according to an embodiment.
[0011] FIG. 2 depicts a flow diagram of an illustrative method of
aggregating panel performance data according to an embodiment.
[0012] FIG. 3 depicts a block diagram of illustrative internal
hardware that may be used to contain or implement program
instructions according to an embodiment.
DETAILED DESCRIPTION
[0013] The following terms shall have, for the purposes of this
application, the respective meanings set forth below:
[0014] The present disclosure pertains to vacuum insulation panel
(VIP) quality control systems and methods for using such systems.
The use of such quality control systems may increase confidence in
the reliability of VIPs. In addition, such quality control systems
may enable long-term incremental performance of the production
process by using data from the total life cycle of VIP products to
increase reliability and other metrics.
[0015] In an embodiment, a quality control system 100 may include
an in-panel sensor 105 including a dielectric film 110. In an
embodiment, the dielectric film 110 may be disc-shaped. In an
embodiment, the dielectric film 110 may be coated in a coating,
such as alumina, that changes its electrical conductance when
exposed to an oxidizing substance, such as water vapor.
[0016] The dielectric film 110 may be in operable communication
with a radio frequency identification (RFID) unit 115. In an
embodiment, the RFID unit 115 may be located within or on the
panel, although other locations are also possible within the scope
of this disclosure. The RFID unit 115 may transmit information
pertaining to the conductance of the dielectric film during a
testing operation. In an embodiment, the RFID unit 115 may transmit
the conductance to an RFID receiver 120. In an embodiment, the RFID
unit 115 may transmit an encrypted signal. As a result, only an
RFID receiver 120 having valid decryption keys may be able to
decrypt a transmission from the RFID unit 115.
[0017] The RFID receiver 120 may enable the transmission from the
RFID unit 115 to be received and processed. The RFID receiver 120
may be installed, for example and without limitation, in a
production line, at a location within a distribution chain, or at a
customer location. In an embodiment, the RFID receiver 120 may be
installed as part of a final application for the panel. For
example, the RFID receiver 120 may be installed in a thermal
packaging unit that includes a sensor monitoring package used to
measure the package thermal history. Accordingly, handlers of a VIP
product may receive early notification of package failure before it
occurs or may otherwise be detected.
[0018] A data collation system (or data collation element) 125 may
aggregate panel performance data, including the conductance of the
panel, that is received from the RFID unit 115 via the RFID
receiver 120. The data collation system 125 may enable production
engineers and/or customers to learn how to minimize or avoid future
panel failures. In an embodiment, the data collation system 125 may
not only aggregate and collate panel performance data throughout
the life of the panel, but may also associate the production batch
of each item used in the production of a VIP product and the actual
production metrics, such as the pressure and date of seal, the
pressure and heat of the sealing bar, and the like. Analysis of
this data may provide valuable feedback information to improve
future production performance. According to embodiments, the data
collation system (or data collation element) may be implemented in
software (for example, a software application, module, or the
like), hardware, or a combination thereof.
[0019] The embodiments disclosed herein identify a quality control
system that has a number of advantages over conventional systems.
For example, panels may be tested in real time. Testing should take
on the order of 2 seconds or less to perform. Indeed, it is likely
that testing can be performed in approximately 0.5 seconds.
[0020] Moreover, testing may be performed without human interaction
with the panel. Testing may be performed from a remote distance
from an inch to a few feet away depending upon the signal strength
of the RFID unit and the sensitivity of the RFID receiver.
[0021] In addition, the in-panel sensor does not detract from the
panel performance because it is statically placed. As such,
numerous sensors may be placed in panels allowing easy access for
measurement throughout a VIP product if, for example, the VIP
product contains relatively large panels.
[0022] Panel production information and test history data may be
aggregated and collated in an online system that allows
manufacturing systems to be improved and performance lifespan to be
monitored.
[0023] A handheld test unit incorporating the modules described
above may be used to perform the quality control test. The handheld
test unit may be relatively inexpensive, yet reliable in the
retrieval of test data. Moreover, handheld units could be replaced
by continuous onsite external monitoring devices for critical
applications.
[0024] Finally, the quality control system may be capable of
reading panels that do not have a flat surface because making
direct contact with the surface of a VIP product is not required
for quality control checks.
[0025] Although the above-disclosed embodiments are described in
reference to a quality control system for a vacuum insulation
panel, the above-described embodiments may be used in other devices
that require a vacuum to be maintained. As such, numerous
applications may benefit from the devices and systems described in
this disclosure.
[0026] FIG. 2 depicts a flow diagram of an illustrative method of
aggregating panel performance data according to an embodiment. As
shown in FIG. 2, a panel sensor disposed on a panel may detect 205
panel information. In an embodiment, the panel sensor may detect
205 panel information using a dielectric film. For example, the
panel sensor may detect 205 a conductance of the panel using the
dielectric film. Other panel information may also be detected 205
within the scope of this disclosure.
[0027] The panel information may be transmitted 210 to an RFID
unit. In an embodiment, the RFID unit may be in operable
communication with the panel sensor and/or the dielectric film. In
an embodiment, the RFID unit may be located in or on the panel.
Additional information, such as an identification of the panel
sensor from which the panel information was transmitted, may also
be transmitted 210 to the RFID unit within the scope of this
disclosure.
[0028] The RFID unit may transmit 215 the panel information and
other panel performance data to an RFID receiver that is located
remote from the RFID unit. In an embodiment, the panel performance
data may include information regarding the sensor and/or the RFID
unit from which the panel information is received. Additional
information may also be transmitted 215 as part of the panel
performance data within the scope of this disclosure.
[0029] Panel performance data may be aggregated 220 at a data
collation system. The aggregated panel performance data may
include, for example and without limitation, panel performance data
received over time from a particular RFID unit and/or panel
performance data from a plurality of RFID units.
[0030] The panel performance may be analyzed 225 based on the
aggregated panel performance data. In an embodiment, the panel
performance data 225 may be analyzed by a data collation system
used to determine the performance of the panel over time. In
particular, the data collation system may analyze 225 an expected
time to failure or a likelihood of failure for a particular panel
based on the panel performance data. In an embodiment, the data
collation system may analyze 225 the performance of a plurality of
panels made in a batch to determine the mean time to failure for
the batch. In an additional embodiment, the data collation system
may analyze 225 a performance of panels from a particular
manufacturer or set of manufacturers to identify failure data for
panels of a particular type. Additional and/or alternate analysis
may also be performed within the scope of this disclosure.
[0031] FIG. 3 depicts a block diagram of illustrative internal
hardware that may be used to contain or implement program
instructions, such as the process steps discussed above in
reference to FIG. 2, according to embodiments. A bus 300 serves as
the main information highway interconnecting the other illustrated
components of the hardware. CPU 305 is the central processing unit
of the system, performing calculations and logic operations
required to execute a program. CPU 305, alone or in conjunction
with one or more of the other elements disclosed in FIG. 3, is an
illustrative processing device, computing device or processor as
such terms are used within this disclosure. Read only memory (ROM)
310 and random access memory (RAM) 315 constitute illustrative
memory devices (i.e., processor-readable non-transitory storage
media).
[0032] A controller 320 interfaces with one or more optional memory
devices 325 to the system bus 300. These memory devices 325 may
include, for example, an external or internal DVD drive, a CD ROM
drive, a hard drive, flash memory, a USB drive or the like. As
indicated previously, these various drives and controllers are
optional devices.
[0033] Program instructions, software or interactive modules for
providing the interface and performing any querying or analysis
associated with one or more data sets may be stored in the ROM 310
and/or the RAM 315. Optionally, the program instructions may be
stored on a tangible computer readable medium such as a compact
disk, a digital disk, flash memory, a memory card, a USB drive, an
optical disc storage medium, such as a Blu-ray.TM. disc, and/or
other non-transitory storage media.
[0034] An optional display interface 330 may permit information
from the bus 300 to be displayed on the display 335 in audio,
visual, graphic or alphanumeric format. Communication with external
devices, such as a print device, may occur using various
communication ports 340. An illustrative communication port 340 may
be attached to a communications network, such as the Internet or an
intranet.
[0035] The hardware may also include an interface 345 which allows
for receipt of data from input devices such as a keyboard 350 or
other input device 355 such as a mouse, a joystick, a touch screen,
a remote control, a pointing device, a video input device and/or an
audio input device.
[0036] Various of the above-disclosed and other features and
functions, or alternatives thereof, may be combined into many other
different systems or applications. Various presently unforeseen or
unanticipated alternatives, modifications, variations or
improvements therein may be subsequently made by those skilled in
the art each of which is also intended to be encompassed by the
disclosed embodiments.
* * * * *