Patent Description:
Known leak detection methods for food and/or drink packaging, including food and/or drink containers, typically place each container under a vacuum and detect leaks through pressure change. This can be performed offline on single containers or on-line.

Other methods include water bath testing, where the container is submerged under water and if there is a leak then the operator may see bubbles. This inspection method may be inefficient and/or destructive, meaning the package and its contents must be disposed of.

<CIT> describes a leak detection system for detecting breaches in sealed food containers. The detection system described includes at least one pressing member configured to apply pressure to the sealed food container. <CIT> considers sealed food containers, in particular, modified atmosphere food containers such as trays and packs. <CIT> also considers film-topped trays and sealed bags.

In some circumstances, for example, for rigid containers, testing for a leak by applying a pressure to the rigid container may not be suitable for extracting a sample for further analysis. There is a need for an improved or at least alternative leak detection system, in particular, a system for detecting leaks from different types of containers. <CIT> describes a system for leak rate testing of pressurized containers in a shipping box. The shipping box with the containers is placed in an airtight test chamber that is partially evacuated. A sample stream may be analyzed using an optical spectrometry system. <CIT> describes methods and devices for detecting breaches in sealed containers, and in particular sealed, modified atmosphere food containers. A leak detection head comprises a pressing member, such as a roller, to apply a force to the container.

Aspects of the invention are in accordance with the appended independent claims. The matter for which protection is sought is defined by the appended claims.

A method of testing the structural integrity of a rigid container is described, the method comprising:.

The presence and/or absence and/or amount of the one or more materials may be representative of at least one of: one or more breaches in the surface of the rigid container, the quality of a seal of the rigid container, a gas, liquid or vapour leak from the rigid container.

The sampling process may comprise providing the volume of sample gas to a sample chamber and the light may be detected from the sample chamber.

The sampling process further comprises applying a pressure or force.

The rigid container is provided inside further packaging. The sampling process comprises applying a pressure or force to at least one surface of the further packaging thereby to extract accumulated leaked gas or vapour from said further packaging.

The further packaging is non-rigid. The gas or vapour sample is extracted through one or more holes or gaps in the surface of the packaging. The rigid container may be sealed or closed for at least one of: prevention of tampering, preservation of contents, prevent leakage, hygiene purposes. The further packaging may be closed for holding and/or transporting the container.

The method may allow quick detection of broken or leaking bottles inside a container. The method may further comprise providing a sample head for use in performing the sampling process.

The sample head may comprise a shape that complements at least part of the rigid container.

The method may further comprise selecting a shape of the sample head such that the at least part of the rigid container comes within a distance of <NUM> or less from the sample head during the sampling process.

The at least part of the rigid container may come within a distance of <NUM> or less, optionally within a distance of <NUM> or less, optionally within a distance of <NUM> or less from the sample head during the sampling process.

The method may further comprise passing the rigid container through and/or past the sample head and performing the sampling process as the rigid container passes through and/or past the sample head.

The sample head may define at least part of an aperture to allow the rigid container to pass through and the method may further comprise performing the sampling process as the rigid container passes through the aperture. The aperture may have a profile substantially equal or matched to the shape of rigid container.

The sample head may comprise one or more of a size or a shape such that the container can pass through the aperture.

The method may further comprise aligning at least part of the rigid container with at least part of the sample head.

The method may further comprise sampling the volume of sample gas from a plurality of sample inputs that are distributed about the rigid container during the sampling process such that the sample region at least partially surrounds the rigid container.

The plurality of sample inputs may be distributed such that the sample region surrounds an upper portion of the rigid container.

The plurality of sample inputs may be distributed such that the sample region extends about a length and/or a width of the rigid container.

The method may further comprise providing a plurality of sample inputs that are distributed along a first direction and moving the rigid container through the plurality of sample inputs in a second, different direction.

The first direction may correspond to a first dimension of the rigid container, for example, height, width or length. The first direction and second direction may be substantially orthogonal.

The plurality of sample inputs may comprise a plurality of holes of different sizes to produce an even distribution of suction during the sampling process.

The method may further comprise providing a deformable sample member comprising a plurality of sample inputs distributed along its length and selecting a shape for the deformable sample head thereby to: match a shape of at least part of the rigid container and/or to minimize a gap between the plurality of sample inputs and at least part of a surface of the rigid container during the sampling process.

The sampling process may comprise moving a moveable sample head proximate to at least one surface of the container.

The sampling process may comprise moving of a moveable hand held device by a user.

The moveable sample head and/or moveable hand held device may comprise a sample head comprising a plurality of sample inlet holes.

The sampling process may comprise performing a suction or a blowing process to move the sample of gas or vapour from the sampling region to a sample chamber. The suction or blowing process may be performed continuously.

The method may further comprise performing the sampling process on more than one rigid container and the suction or blowing process comprises providing a continuous air flow as the sampling process is performed on subsequent rigid containers.

The method may further comprise providing a substantially empty rigid container. The method may further comprise providing a rigid container that contains substantially no liquid and/or substantially no solid. The method may further comprise providing a test gas to the container.

The method may further comprise injecting the test gas into the container to force the sample gas from the container.

The method may further comprise providing the test gas to a substantially empty container.

The method may further comprise providing the test gas to the empty rigid container thereby to place the rigid container under pressure before the sampling process is performed.

The test gas may be one of carbon dioxide, CO2, or compressed air.

The one or more materials may comprise at least one of: carbon dioxide (CO2), ethanol, carbon monoxide (CO), nitrous oxide (N2O).

The rigid container may comprise at least one of:
a drink container, an alcoholic or distilled drink container, a pharmaceutical product container, a medicine container, a perfume container, a barrel, a bottle, a dairy product container.

A system for testing the structural integrity of a rigid container is described. The system comprises:.

The system may further comprise a sample chamber configured to receive a volume of sample gas wherein the sampling apparatus is configured to provide the volume of sample gas to the sample chamber.

The system may further comprise a sample cell configured to receive the volume of sample gas.

The sampling apparatus may further comprise a pressure apparatus configured to apply a pressure or force to further packaging containing the rigid container thereby to extract accumulated leaked gas or vapour from said further packaging.

The pressure apparatus may further comprise at least one roller and/or at least one pressing member.

The pressure apparatus may be configured to apply a linear and/or a rotational force.

The further packaging may be non-rigid. The gas sample may be extracted through one or more holes or gaps in the surface of the packaging. The rigid container may be sealed or closed for at least one of: the prevention of tampering, the preservation of contents, to prevent leakage, for hygiene purposes. The further packaging may be closed for holding and/or transporting the container.

The sampling apparatus may further comprise a sample head wherein the sample head comprises a shape that complements at least part of the rigid container.

The shape of the sample head may be such that the at least part of the rigid container comes within a distance of <NUM> from the sample head during the sampling process.

The shape of the sample head may be such that at least part of the rigid container comes within a distance of <NUM>, optionally within a distance of <NUM>, further optionally within a distance of <NUM> from the sample head during the sampling process.

The sample head may define at least part of an aperture for the rigid container to pass through.

The system may further comprise an alignment mechanism for aligning at least part of the rigid container with at least part of the sample head.

The sample head may further comprise a plurality of sample inputs distributed along its length such that, during the sampling process, the sample region at least partially surrounds the rigid container.

The sample head may further comprise a plurality of sample inputs distributed along its length such that the sample region surrounds an upper region of the rigid container.

The sample head may further comprise a plurality of sample inputs distributed along its length such that the sample region extends along a length of the rigid container.

The sample head may further comprise a least one deformable sample member comprising a plurality of sample inputs distributed along its length wherein the deformable member is configured to be deformed into a shape thereby to: match a shape of at least part of the rigid container and/or to minimize a gap between the plurality of sample inputs and at least part of a surface of the rigid container during the sampling process.

The sample head may comprise a shape that corresponds to at least one of:
a rectangular archway, a bottle-shaped archway.

The sample head may comprise a shape that is curved to match the shape of a barrel.

The sampling apparatus may be a hand held sample head, optionally wherein the sampling apparatus comprises a nozzle.

The system may further comprise a source for providing test gas to the rigid container via the sample head.

The system may further comprise a conveyer system for conveying at least a part of the rigid container past the sampling apparatus.

The conveyer system may comprise a linear conveyer belt for conveying the container linearly past the sampling apparatus.

The system may further comprise a mechanism for rotating the rigid container, such that at least part of the rigid container passes the sampling apparatus.

The system may further comprise a controller configured to control the one or more lasers to produce respective laser beams as the container is conveyed past the sampling apparatus.

The system may further comprise an air pump system for moving the sample gas from the sampling region to the sample chamber.

The one or more lasers may comprise at least one of: a semiconductor diode laser, optionally a quantum cascade laser, for example, a pulse, chirped quantum cascade laser.

A method of detecting leaks from an alcoholic drink container is described, the method comprising:
performing a sampling process on the alcoholic drink container comprising:
sampling a volume of sample gas from a sampling region associated with the rigid container; wherein the method further comprises:
performing a detection process comprising:.

The one or more materials may comprise at least one of ethanol and/or carbon dioxide.

The one or more lasers may be configured to produce laser beams comprising at least one of:.

The one or more lasers may be configured to produce a laser beam having a first wavelength in a wavelength range between <NUM> and <NUM>-<NUM> used to detect ethanol in the volume of sample gas.

The one or more lasers may be configured to produce a laser beam having a wavelength about <NUM>-<NUM> used to detect CO2 in the volume of sample gas.

The one or more lasers may be configured to produce a laser beam having a wavelength about <NUM>-<NUM> used to detect N2O in the volume of sample gas.

The alcoholic drink container may be one of: a barrel, a bottle, a can, a flask, a keg.

A laser detection system for testing the structural integrity of a container is described, the system comprising:.

The sampling apparatus may provide a substantially enclosed space about the container.

The sampling apparatus may comprise an adjustable mounting for adjusting the distance between the pressure apparatus and the container.

The sampling apparatus may comprise at least one pressing member or roller and a sample head comprising a plurality of sample inlets, wherein the at least one pressing member is moveable relative to said sample head.

Any feature in one aspect of the invention may be applied to other aspects of the invention, in any appropriate combination. For example, apparatus features may be applied as method features and vice versa.

Embodiments will now be described by way of example only, and with reference to the accompanying drawings, of which:.

The present invention is concerned with the problem of detecting leaks from containers. In particular, a system for detecting leaks from rigid containers are described. In addition, leak detection systems for detecting leaks from non-rigid containers are also described.

<FIG> is a schematic representation of a laser spectroscopy system <NUM> for analysing gas and/or vapour sampled from a sampling region about a container <NUM>. The system <NUM> has a sampling apparatus <NUM> for sampling a volume of sample gas from a sampling region associated with the container <NUM>.

In <FIG>, the container is tested in-line on a conveyer belt system <NUM> and the system is adapted so that gas and/or vapour is collected from a sampling region about the container on the conveyer belt system <NUM>.

Although <FIG> shows laser detection system in use with a conveyer belt system, it will be understood, that in some embodiments, the container can be sampled off-line. In particular, the embodiments described with reference to <FIG> include a portable sampling apparatus capable of being moved about the surface of a container under test.

The laser spectroscopy system <NUM> may also be referred to as a leak detection system. By analysing a collected sample of gas and/or vapour using a laser detection process, the system is capable of determining the presence and/or absence and/or amount of one or more materials in the sample gas that is indicative of one of: a breach in the surface of the container, the state or quality of a seal of the container by detecting a leak of one or more of gas, vapour or liquid, from the container <NUM>.

Different species of materials can be detected thereby to determine breaches in different types of containers. For example, CO2 may be sensed for food containers, ethanol may be sensed for alcoholic drink containers (e.g. bottles, barrels or boxes) and N2O may be sensed for dairy products as an alternative to CO2. Carbon monoxide can be used in meat packaging and may therefore be used to detect breaches in meat containers.

Detecting different species of material requires using laser light having different wavelengths. To detect ethanol, a laser beam having a first wavelength in a wavelength range between <NUM> to <NUM>-<NUM> is used. To detect CO2 a laser beam having a wavelength at about <NUM>-<NUM> is used. To detect N2O a laser beam having a wavelength about <NUM>-<NUM> is used.

As shown in <FIG>, in addition to the sampling apparatus <NUM>, the leak detection system <NUM> has a sensor module <NUM>, a controller <NUM> and an air pump system <NUM>. In some embodiments, the sampling apparatus <NUM> may be referred to as a sample head.

The system <NUM> has an air circuit <NUM> for moving gas and/or vapour from the sampling region to the sample cell <NUM> of the sampling apparatus <NUM>. The sample cell is provided inside an at least partially enclosed sample chamber. The air circuit <NUM> is illustrated in <FIG> as a dashed line. The air circuit <NUM> connects the sampling apparatus <NUM> to the air pump system <NUM>. The sampling apparatus <NUM> has one or more sample inlets that provide an entrance for a sample to the air circuit <NUM>.

The air circuit of the system <NUM> is shown in further detail in <FIG>. As part of the circuit, the sensor module <NUM> has a sample cell <NUM> that is in fluid communication with the sampling apparatus <NUM>. The piping of air circuit <NUM> may be considered to form part of the air pump system <NUM>.

As shown in <FIG>, in the present embodiment, the sensor module <NUM>, the controller <NUM> and the air pump system <NUM> are provided in the same housing. In other embodiments, one or more of these components is provided separately.

The system <NUM> is operable to move extracted gas and/or vapour from the sample region to the sample cell <NUM>, via the air circuit <NUM>, to be analysed. The sample cell <NUM> is optically coupled to a laser module <NUM> and to a detector module <NUM>. Together, the sample cell <NUM>, laser module <NUM> and detector module <NUM> are operable as a gas sensor capable of detecting the presence, absence or amount of one or more materials in the sample gas provided to the sample cell. The detector module <NUM> may also be referred to as a detector apparatus.

The sensor module <NUM> also includes steering optical components (not shown) for steering laser light from the lasers of the laser module <NUM> to the detector module <NUM> via the sample cell <NUM>. The detector apparatus has one or more detectors that are configured to detect light from the sample cell. The light may be infra-red or visible light or light of any other suitable wavelength or from any suitable part of the electromagnetic spectrum.

The lasers are semiconductor diode lasers. A quantum cascade laser, for example, a pulse, chirped quantum cascade laser can be used. Different types of laser may be suitable for use in the system <NUM> for detecting different materials. As a first example, to detect CO2 from packaged foods, a quantum cascade laser may be suitable. As a second example, to detect ethanol from, for example, whisky barrels and/or bottles, a tuneable diode laser and/or an inter-band cascade laser may be suitable.

The controller <NUM> is electronically coupled to the sensor module <NUM>. The controller <NUM> has a control module <NUM> for providing control signal to the sensor module <NUM>. The control module <NUM> is configured to provide control signals to the laser module <NUM> to control operation of the laser.

The controller <NUM> also has an air circuit control module <NUM> configured for controlling the pump system <NUM> thereby to provide air flow through the air circuit. The air circuit control module <NUM> controls the pump system <NUM> by providing electronic control signals to the pump system <NUM>.

The air circuit module also comprises an air preparation module, which is configured to clean and remove moisture from the compressed air supply of pump system <NUM>. The air circuit module <NUM> is configured to control the pump system to perform a cell purge process, which includes the step of removing debris from the sample cell.

The cell purge is a maintenance task, carried out at times when the system requires it. An alarm may be triggered based on one or more operating conditions, where the alarm is indicative that maintenance tasks, including a cell purge, should be carried out. For example, the alarm may be triggered if the pulse amplitude drops below a threshold value. Other maintenance tasks to be performed include, cleaning the mirrors and steering optics of the laser. The frequency of foreign objects reaching the cell and causing contamination varies from site to site, depending on the general cleanliness. As a non-limiting example, a pharmaceutical site may never need the cell purged or mirrors cleaned.

In the present embodiment, the sampling apparatus is mechanically coupled to the sensor module via piping of flow circuit <NUM>. In the present embodiment, the sampling apparatus is set up to be mounted on the conveyer belt.

In some embodiments, the controller <NUM> may also be electronically coupled to the sampling apparatus <NUM> to control operation of the sampling apparatus. As described with reference to further embodiments, the sampling apparatus <NUM> may have a pressure apparatus that is controlled by control module <NUM>.

In some embodiments, that have a pressure apparatus, control of the pressure applied by the pressure apparatus is performed using a precise height adjustment mechanism. In some embodiments where the sampling apparatus has a roller and the roller is made of compliant silicone which deforms around the package, application of a greater pressure may be achievable by adjusting the height of the roller such that the roller is closer to the conveyer belt. Application of less pressure may be achievable by adjusting the roller to be at a greater height so that the roller only briefly touches the container as it passed the roller. In some embodiments, the height adjustment mechanism is adjusted by a user and/or control signals via an actuator or suitable electro-mechanical device.

The controller <NUM> also has a signal processor <NUM> that is electronically coupled to the detector apparatus <NUM>. The signal processor is configured to process signals obtained from the detector apparatus <NUM>. The controller <NUM> may be, for example, in the form of a suitably programmed PC or other computer, or may comprise dedicated circuitry or other hardware, for example one or more ASICs or FPGAs or any suitable mixture of hardware and software. The control module <NUM> and signal processor <NUM> may be provided as separate, distinct components in some embodiments, for example separate processing resources, rather than being provided within the same controller component as shown in <FIG>.

The sample cell defines a volume into which a sample of gas is introduced and collected. The gas can comprise one or more different compounds of interest. An indication of the presence of these compounds in the gas collected in the sample cell can be determined by passing light from the laser module <NUM> through the sample cell <NUM> and by detecting the laser light using the detector module <NUM>. If the light is in a wavelength range that corresponds to the absorption spectrum or absorption lines of the compound of interest, then any absorption of light as it passes through the cell may be due to the presence of the compound of interest in the sample. The level of absorption, once determined, can be used to determine a physical property of the compound of interest in the sample, for example, concentration. As different compounds have absorption spectra at different wavelength, in some embodiments, it may be desirable to provide different wavelengths of light to the sample cell <NUM>.

The determined level of absorption may be determined relative to a background measurement. In some embodiments, the background measurement is an average background measurement. In the present embodiment, the average background measurement is updated with each container that is tested to provide an up-to-date background measurement. The background measurement is a measurement of the ambient air that is sampled through the system.

Following the indicated path of air flow around the air circuit <NUM> shown in <FIG>, the sampling apparatus <NUM> is connected, via piping, to the sample cell <NUM>. At a point in the piping between the sampling apparatus <NUM> and the sample cell <NUM> a filter (not shown) is provided. The filter provides a protective barrier to prevent the passing of objects that have entered the air circuit that may damage equipment further on in the air circuit. The sample cell <NUM> provides an enclosed volume in which air or gas or vapour can be analysed using the gas sensor.

Continuing on the indicated path of air flow around the air circuit <NUM>, the sample cell <NUM> is connected to the pump <NUM> by further piping. The pump <NUM> draws air through the air circuit <NUM> and into the sample cell <NUM> of the sensor thereby creating an air flow in the air circuit <NUM>. The terminating point of the air circuit <NUM> is an exhaust <NUM>.

In some embodiments, the system <NUM> has one or more air pump(s) that are provided as part of the air pump system <NUM> for moving air from the sampling region through the sample cell which are provided at other locations on the air circuit <NUM>. In some embodiments, a further pump is provided, as part of the air pump system <NUM>, in the sampling apparatus <NUM> that can be controlled by controller <NUM>. In such an embodiment, the controller, for example, the air circuit control module <NUM>, is electronically connected to the further pump of the sampling apparatus.

In the present embodiment, the air pump system <NUM> has an air pump configured to suck air through air circuit <NUM> therefore to allow gas and/or vapour at the sampling region to be collected by the sampling apparatus <NUM>. The air pump is configured to draw air through air circuit <NUM>. It will be understood that other pneumatic systems for providing suction at the sampling apparatus can be used.

In use, container <NUM> is provided at the sample point and the system performs a sampling process on the container which includes collecting gas by the sampling apparatus <NUM> from the sample region about the container. The sampled gas is then drawn, via air circuit <NUM>, from the sample region to the sample cell <NUM>. One or more laser beams are produced by laser module <NUM> and introduced into sample cell <NUM>. The laser beams pass through the sample cell and the sample contained within the sample cell and are detected by the detector module <NUM>. A detection signal is sent to signal processor <NUM> for processing. By processing the detection signal, the presence, absence or amount of one or more materials in the sample of gas can be determined.

In the case that the container <NUM> is leaking gas, vapour or liquid, for example, through one or more breaches in the outer surfaces of the collected gas and/or vapour may include one or more materials of interest, the presence of which can be determined by sensor module <NUM> and controller <NUM>.

Following the sensing process, the sample of gas is drawn, via the air circuit, to the terminating point of the air circuit (the exhaust <NUM>).

The drawing of samples from sample region to the exhaust via the sample cell is a continuous process. Following the exhaust of the sample from the sample cell, the system is then ready to receive and perform the sample process on a further container on the conveyer belt of conveyer belt system <NUM>.

<FIG> are further schematic diagrams showing the system <NUM>. <FIG> show further detail of the sensor module <NUM>. In the present embodiment, the sample cell <NUM> is a Herriot cell or modified Herriot cell. <FIG> also shows further detail of circuit providing airflow through system <NUM>. As discussed above, the air circuit is provided by piping between the sampling apparatus and the sample cell and further piping between the sample cell <NUM> and a pump <NUM> and further piping between the pump <NUM> and an exhaust.

As shown in <FIG>, the sample cell, controller and pneumatic system are enclosed in a housing. In the present embodiment, the measurement cell is provided in an upper enclosure of the housing and the electronics and pneumatics are provided in a lower enclosure.

In the following, different aspects of sampling apparatus <NUM> are discussed. It will be understood that the following described sampling apparatuses are configured to be used with the system described with reference to <FIG> and <FIG>, in place of sampling apparatus <NUM>. In some embodiments, the sampling apparatus <NUM> is a contact apparatus, such that, in use, the sampling apparatus <NUM> or part thereof applies pressure thereby to extract a sample of gas for testing. These may be referred to as contact sensors. In other embodiments, the sampling apparatus <NUM> is a non-contact apparatus such that, in use, the sampling apparatus <NUM> does not contact and/or does not apply pressure. These embodiments are referred to as non-contact sensors. <FIG>, <FIG> and <FIG> illustrate embodiments of non-contact sampling apparatuses, in particular, a first and a second non-contact apparatus. <FIG> show contact sampling apparatuses, in accordance with embodiments. In particular, <FIG> shows a contact sampling apparatus configured to apply pressure directly to the container and <FIG> shows a contact sampling apparatus configured to apply pressure to further packaging containing the container.

Turning to the first non-contact sampling apparatus, <FIG> shows a sampling apparatus <NUM> in an assembled configuration. <FIG> shows the same sampling apparatus <NUM> in a dis-assembled configuration. It will be understood that sampling apparatus <NUM> is configured to be used as part of the detection system <NUM> described with reference to <FIG> and <FIG>, in particular, in place of sampling apparatus <NUM>.

The sampling apparatus <NUM> has a first sampling member <NUM>, a second sampling member <NUM> and a sample bar <NUM>. In the present embodiment, the sample bar <NUM> is substantially horizontal. The first and second members <NUM>, <NUM> are attachable to the sample bar <NUM> such that, when attached, they hang suspended from the sample bar.

The first and second members <NUM>, <NUM> each comprise a hollow conduit. The conduits extend along the length of the sampling members <NUM>, <NUM>. Each of the first and second members <NUM>, <NUM> comprise a plurality of inlets on their surface to allow air or other gas to enter its hollow conduit (the air-flow into the inlets is indicated by the inward facing arrows in <FIG>). The inlets may be referred to as sample inlets. The sample bar <NUM> comprises a manifold providing a hollow chamber with a first and a second inlet <NUM>, <NUM> and an outlet <NUM>. The first and second members <NUM>, <NUM> are attachable to the sample bar <NUM> at the first and second inlet thereby placing the conduits of the sample members and the manifold in fluid communication. The outlet <NUM> of the manifold allows the sampling apparatus to be connected to the detection system, via piping, a described with reference to <FIG> and <FIG>. When sampling apparatus <NUM> is connected to the detection system, the air conduits of the sampling members <NUM>, <NUM> provide entrance points to the air circuit <NUM>.

First and second connectors <NUM>, <NUM> (shown in <FIG>) are provided to connect and secure the sampling members <NUM>, <NUM> to the sample bar at first and second inlets <NUM>, <NUM>. A third connector <NUM> is provided to connect the sample bar, at the outlet <NUM>, to further piping of detection system. As shown in <FIG>, in the present embodiment, the first and second sample members do not fully extend to the conveyer belt, however, it will be understood that these sample members may, in other embodiments, extend to the conveyer belt.

The sample bar <NUM> can be connected to the first and second members <NUM>, <NUM>, using connectors <NUM>, <NUM> at the first and second inlet <NUM>, <NUM>, so that, when connected, the conduits of the first member are in fluid communication with the manifold and the conduit of the second member is in fluid communication with the manifold. The upper sample bar can be connected at the outlet <NUM>, to the air circuit <NUM> using connector <NUM>.

Sampling apparatus <NUM> also has a mounting assembly <NUM> for mounting onto either side of the conveyer belt. When assembled and mounted to the conveyer belt, the sampling apparatus sits above the conveyer belt. When mounted to the conveyer belt, the first and second member <NUM>, <NUM>, part of the sample bar <NUM> and the conveyer belt form a gap through which a container, carried by the conveyer belt, can pass through.

In some embodiments, a height adjustment mechanism is provided allowing the height of the sampling apparatus <NUM>, in particular the sample bar <NUM>, when mounted on the conveyer belt, to be adjusted.

In some embodiments, a width adjustment mechanism is provided allowing the width of the sampling apparatus, in particular, the width between sampling members <NUM> and <NUM>, when mounted to the conveyer belt, to be adjusted. In the present embodiment, a width between sampling members <NUM>, <NUM> can be adjusted by bending the sampling members <NUM>, <NUM>. In other embodiments, a width adjusting mechanism is provided that is controllable by control signals.

The mounting assembly comprises securing means for securing the mounting assembly to the conveyer belt. The mounting assembly further comprises two support bars for supporting the sample bar <NUM> at a height above the conveyer belt.

The first and second members <NUM>, <NUM> are shaped or contoured to correspond to the shape of the container that to be tested. The first and second members extend along the height of the bottle. In this embodiment, the shape of the first and second members <NUM>, <NUM> are configured to correspond to the shape of a bottle. This is shown in <FIG>, where bottle <NUM> is shown.

In the present embodiment, each sample member has many inlets, however it will be understood that more inlets may be provided. In some embodiments, a plurality of inlets are distributed along the length of the sampling members <NUM>, <NUM>. In some embodiments, the distribution of inlets is uniform, in other embodiments, the distribution is such that inlets are more concentrated at certain points of the bottle, for example, at the neck and/or at a sealed part and/or at a part that is more likely to break. In some embodiments, sample inlets are also provided on the sample bar.

In the present embodiment, <NUM> inlet holes are provided on each sample bar, therefore <NUM> inlet holes in total. It will be understood that the number of inlet holes on each sample bar can be varied.

In the present embodiment, the inlet hole sizes are different. The inlet hole sizes of the plurality of sample inlets are staggered along the length of the sampling member <NUM> to produce even suction along the length of the sampling members <NUM>, <NUM>. The inlet hole sizes are selected to provide an even distribution of suction along the length of the container.

<FIG> shows the sampling apparatus <NUM> in use with a bottle <NUM>. As illustrated in <FIG>, the first sampling member <NUM> and the second sampling member <NUM> both have a shape that complemented the shape of the bottle. The two members <NUM>, <NUM>, together with the sample bar <NUM> and the upper surface of conveyer belt of conveyer belt system <NUM>, form an aperture that has a profile that substantially corresponds to the shape of the bottle <NUM> under test. The formed aperture is shaped and has a size such that, in use, the bottle can pass along the conveyer and through the aperture without making substantial contact with the members. In the present embodiment, the formed aperture is such that the bottle <NUM> can pass under the sampling apparatus, on the conveyer belt, without touching the sampling members or any other part of the sampling apparatus.

In the present embodiment, the sampling apparatus is shaped such that, during the sampling process, as the bottle passes underneath the sampling apparatus, the bottle comes within a distance of <NUM> of the sample inlets of the sampling members <NUM>, <NUM>. As the bottle passes the sampling apparatus on the conveyer belt the surface of the bottle passes within <NUM> of the sampling members.

While a specific distance is described between container and sample inlets, it will be understood that the distance may be varied, by adjusting the sampling members, to provide good sensitivity. In some embodiments, the sample head is positioned such that the container comes within <NUM> of the sample head. In some embodiments, the sample head is positioned such that the container comes within <NUM> of the sample head.

In some embodiments, one or more guiding elements are provided on the conveyer belt to align the bottle with the sampling apparatus.

In the present embodiment, the distance between subsequent containers being tested on the conveyer belt is sufficient to allow each container to be tested and counted individually. In the present embodiment this distance is greater than <NUM>, however, it will be understood that the distances used may vary for different containers, and, for example, different speeds of conveyer belt.

Each sample member has a plurality of air inlets to allow air or other gas or vapour into the air circuit of the detection system that has been described with reference to <FIG> and <FIG>. The air inlet may also be referred to as sample inlets. The plurality of inlets are distributed along the length of each sampling member <NUM>, <NUM> and are inward-facing so that the inlets are proximate to the surface of the bottle as it passes underneath the sampling apparatus. The sample inlets are distributed about the bottle so that, during the sampling process, the sample region, from which the sample is collected, surrounds substantially all of the exposed portion of the bottle. In some embodiments, the sample region surrounds an upper portion of the rigid container, for example, the bottle neck. In some embodiment, the sample region extends along a length and/or width of the bottle.

In the present embodiment, the members are formed from deformable piping that allows the members to be deformed to the shape of the container to be sampled. When secured, the deformed members retain their shape, in particular, the members retain their shape during the sampling process. While deformable members are described above, in other embodiments the members may be rigid and/or non-flexible and/or non-deformable.

In the present embodiment, the sample bars are deformable. The deformable member can be deformed into the desired shape in order to match a shape of at least part of the rigid container, in this case, the bottle, and/or to minimize a gap between the plurality of sample inputs and at least part of a surface of the bottle during the sampling process.

In use, a bottle is conveyed by conveyer belt of conveyer belt system <NUM> and passes underneath the sampling members <NUM>, <NUM>, and through the aperture. As the bottle passes underneath the sampling members, a sampling process is performed, such that air from a sampling region is drawn, via the air inlets of the sampling members <NUM>, <NUM>, to the sample cell <NUM>. The collected sample of gas or vapour is then tested for the presence of one or more materials, as described with reference to <FIG> and <FIG>.

In the present embodiment, the sampling members <NUM>, <NUM> extend in the direction of the height of the bottle under test, and the sample inlets are distributed along this direction. The conveyer belt acts to move the sample inlets in a different direction, that is, in a direction orthogonal to the height of the bottle. By distributing sample inlets along the height of the bottle under test and moving the bottle in an orthogonal direction, the sampling apparatus performs a scan at least part of the surface of the bottle when it is conveyed past the sample head. Scanning over the surface may be useful for detecting leaked liquid present on the surface of the bottle. Considered together, first sample member <NUM> scans a first side of the bottle and second sample bar <NUM> scans the other side of the bottle simultaneously.

<FIG> show further views of the sampling apparatus <NUM>.

Although in the above described embodiments, first sampling apparatus <NUM> is described as being bottle-shaped, it will be understood that other shapes are possible. For example, an archway or a rectangular sampling apparatus may be provided.

Different shapes for different containers are used. The shapes can be sized and matched to the container. For testing boxes that contain bottles of whisky, a large, box-shaped archway that is sized to fit over box may be used.

In <FIG>, a further sampling apparatus <NUM> in accordance with further embodiments, is shown. Further sampling apparatus <NUM> is hand operated and suitable for use with detection system <NUM>. The hand operated sampling apparatus <NUM> may be used for sampling air and/or vapour on larger objects, or objects with non-uniform or irregular shapes. In this embodiment, the sampling apparatus <NUM> is a manually operated sampling apparatus <NUM> that is connected to the sensor module by flexible hosing. The sampling apparatus is operable by hand, such that a user can move the sampling apparatus over the surface of the container.

The further sampling apparatus <NUM> has a nozzle allowing the user to control the position of the sampling region where gas or vapour is collected from. The further sampling apparatus <NUM> also has a further gas source for providing, for example, a dopant gas and gas source piping for allowing a user to provide the further gas to a container.

In the present embodiment, the container is a barrel <NUM>. The barrel <NUM> has an opening <NUM>. A modified bung is provided that is sized to fit into opening <NUM> such that the modified bung seals the barrel <NUM>. The modified bung also has pipework that is connectable to gas source piping allowing the reference gas source to be provided to the inside of the barrel <NUM> when the modified bung is in place. In the present embodiment, the pipework is a small diameter pipe.

In use, a user positions the modified bung at barrel opening <NUM>. When positioned at the opening <NUM>, the user can provide reference gas to the inside of the barrel via the reference gas piping and modified bung, thereby filling the barrel with the reference gas. By filling the barrel with reference gas the barrel can be pressurised.

The user can then test for structural defects of the barrel <NUM> by moving the hand held sampling apparatus <NUM> over the surface of the barrel <NUM>. The pump of the laser detection system continuously sucks air from the end of the nozzle and thus the sample chamber receives sample gas from different sample points on the outer surface of the barrel. The gas is then tested for one or more components by the gas sensor, as described above.

By moving the hand-held sampling apparatus over the barrel, a user can control the sample region from which a sample is collected.

In some embodiments, the hand-held sampling apparatus comprises a sample bar with a plurality of inlet holes, as substantially described with reference to sampling member <NUM>, as described with reference to <FIG>. In particular, the sampling member may be shaped and have a plurality of inlet holes distributed along its length.

Empty barrels can be tested for leaks prior to being filled with liquid. This may prevent wastage from defective barrels. For example, some distilled spirits are stored for long periods of time (for example, whisky which is aged for at least three years). Therefore any defects in barrels may be wasteful. The reference gas can be any suitable gas. Compressed air or CO2 may be used. For new or dry barrels, CO2 is used as the reference gas.

Barrels that are not empty may also be tested. For barrels filled with distilled spirits, the system can be configured to detect for ethanol. Barrels that have been used but are wet may also be tested for ethanol that has soaked into the wood of the barrel.

Detection results can be collected and later analysed. In the present embodiment, an alarm or other indicator is activated on detection of the reference gas so that a user can locate the source of any structural defects. Leaking containers may be rejected, for example, by providing means to physically remove them from the conveyer belt line. Such means can be a jet of compressed air or another device for moving the container off the conveyer belt.

While barrel testing is described with reference to a hand-held sampling apparatus, it will be understood that in further embodiments, barrel testing can also be performed in-line, for example, on a conveyer belt system.

In such further embodiments, a non-contact sampling apparatus suitable for use with barrels and similar to the sampling apparatus <NUM> is provided. The barrel sampling apparatus has one or more sample members curved to match the curve of the outside of the barrel.

In the embodiments described with reference to <FIG>, the user operates the sampling apparatus <NUM> by hand. In further embodiments, the barrel is placed on a rotating conveyer belt such that at least part of the barrel passes by the sample head as it rotates. The sample head is curved to match the shape of the barrel. The sample head thus scans over the surface of the barrel as the barrel rotates.

In <FIG>, a further sampling apparatus <NUM> suitable for use with detection system <NUM> in accordance with further embodiments is illustrated. In contrast to other embodiments, in particular to the non-contact sampling apparatus of <FIG>, the further sampling apparatus <NUM> is referred to as a contact sampling apparatus <NUM>.

<FIG> is a first view of the contact sampling apparatus <NUM> from a first perspective and <FIG> is a second view of the contact sampling apparatus <NUM> from a second perspective. <FIG> shows a perspective drawing of the contact sampling apparatus <NUM> in a dis-assembled configuration. <FIG> shows the contact sampling apparatus mounted on a conveyer belt. <FIG> shows a side view of the contact sensor in an assembled configuration from a first and second viewpoint.

It will be understood that the contact sampling apparatus <NUM> is configured to be used with detection system <NUM>, in particular, in place of sampling apparatus <NUM>. In contrast to the non-contact sensors described above, contact sampling apparatus <NUM> has pressure apparatus for applying a pressure to the container. In this embodiment, the pressure apparatus comprises a roller <NUM>. The roller <NUM> provides a rotational force to the container, as the container is conveyed past the roller. In other embodiments, other pressure apparatuses are used, for example, a pressing member for applying a linear force to the container.

When mounted and secured to the conveyer belt, the roller <NUM> sits in an elevated position above the conveyer belt such that the container can pass, on the conveyer belt, beneath the roller. The height of the roller can be adjusted up or down thereby to change the distance between the roller <NUM> and the conveyer belt. The roller <NUM> is positioned such that, as the container passes beneath the roller <NUM>, the roller makes contact with the upper surface of the container. As the container moves beneath the roller <NUM> , the roller will rotate thereby applying pressure to different points across the upper surface of container. By making contact, the roller <NUM> applies a pressure to the container, so that, if there are any structural defects in the container, for example, holes or breaches, gas or vapour from inside the container is expelled out from the container.

On either side of the roller there is provided first and second sampling members 318a, 318b. The first and second sampling members may be referred to as first and second sampling heads. The first and second sampling members are configured to collect gas from a sample region about the container. When contact sampling apparatus <NUM> is mounted on the conveyer belt, the sampling members 318a, 318b are provided at an elevated position above the conveyer belt. The height of the sampling members above the conveyer belt is sufficient to allow the container to be tested to pass under the sample members without making contact.

The sampling members are provided parallel to each other, the first sampling member 318a at a first sampling position and the second sampling member 318b at a second sampling position, such that the roller <NUM> is provided between the first sampling position and the second sampling position. The contact sampling apparatus <NUM> has piping such that the sampling members can be connected to the system <NUM>, such that the sample members are in fluid communication with the air circuit <NUM>.

In use, the system is configured to take two samples per container that pass through the sampling apparatus. A first gas sample is collected using the first sampling member at the first sampling position (before pressure is applied) and a second sample using the second sampling member (after pressure is applied).

By sampling at more than one sampling position, fuller coverage of the container under test may be provided. By sampling at more than one sampling positions, the possibility of missing leaks from leading or trailing edges of packages may be reduced.

In the present embodiment, the roller <NUM> and sampling members 318a, 318b are provided as part of a roller carriage <NUM>, as illustrated in <FIG> shows a perspective drawing of the contact sampling apparatus <NUM> in a dis-assembled configuration. The roller carriage <NUM> is held in place by a first and second adjustable mounts <NUM>, <NUM>. A user can adjust the height of the roller carriage <NUM>, and thus the height of roller <NUM> and sampling heads 318a, 318b using adjustable mounts. The roller carriage <NUM> also has a structure that partially surrounds the roller and sample head. In particular, the roller carriage has a first and second screen 334a, 334b provided on either side of the roller.

By partially surrounding the container during the sampling process, background gas in the sample may be reduced, which may improve the sensitivity of the system.

An outer housing <NUM> is also provided that fits over the roller carriage <NUM>. The outer housing <NUM> and first and second screen of the roller carriage <NUM> co-operate to provide an enclosure for the roller carriage <NUM>. When mounted on the conveyer, as shown in <FIG>, the outer housing <NUM>, the first and second screen 334a, 334b of the roller carriage <NUM> and the conveyer belt provide a volume with an entrance on the conveyer belt for receiving the container and an exit for that container. The volume is partially enclosed by the combination of outer housing <NUM>, roller carriage <NUM> and conveyer belt.

The outer housing <NUM> also provides guiding members for receiving the adjustable mounts <NUM>, <NUM>. The roller carriage <NUM> can be raised or lowered by moving the adjustable mounts up and down the guiding members and securing them at the desired height. It will be understood that in other embodiments, other suitable adjustment mechanisms may be used to raise or lower the height of the roller and/or sample members.

<FIG> shows a selection of perspective and cross-sectional views of the roller head carriage. In the above described embodiment, the roller carriage <NUM> is described as moveable and therefore the roller and sample heads are also moveable together. In the present embodiment, the sampling members 318a, 318b are mounted to the roller carriage <NUM> via further adjustable mounts so that the position of the sample heads may be adjustable separately from the roller. This is shown in <FIG>, where the roller <NUM> is maintained in the same position and the sampling heads 318a, 318b are adjusted relative to the roller. In some embodiments, the first sampling head 318a is adjusted to be at a first height, the second sampling head 318b is adjusted to be at a second height and the roller <NUM> is adjusted to be at a third height.

In the above described contact sample head embodiments, the pressure apparatus, for example, the roller <NUM>, applies pressure directly to the container being tested. In other embodiments, the sampling apparatus is configured to apply pressure indirectly to the container.

In some embodiments, the roller is manufactured out of food grade silicone or urethane.

Applying pressure or contact directly to a container <NUM> as part of a sampling process may not be desirable for certain types of containers, for example, rigid containers.

<FIG> is a schematic diagram of a sampling apparatus <NUM> in which pressure is applied indirectly to a rigid container to obtain a sample of gas or vapour from a container. It will be understood that sampling apparatus <NUM> can used with the system described with reference to <FIG> and <FIG>, in particular in place of sampling apparatus <NUM>. The sampling apparatus <NUM> is provided that is in fluid communication with the air circuit, as described with reference to <FIG>.

The sampling apparatus <NUM> has a pressure applying member <NUM>. Pressure applying member <NUM> may be referred to as a pressure apparatus. In contrast to embodiments described above, the container under test is provided in further packaging <NUM>. In the present embodiment, a plurality of containers to be tested are provided in the further packaging <NUM>. The plurality of containers are indicated by reference numerals 412a, 412b, 412c. The further packaging is provided on conveyer belt of conveyer belt system <NUM>. The further packaging <NUM> is non-rigid and has one or more breaches, for example holes or gaps, that allows air or gas to escape the packaging in response to the application of a force to the further packaging. The further packaging may be a cardboard box.

In the present embodiment, the plurality of containers 412a, 412b, 412c are sealed bottles holding alcoholic drinks and the further packaging is a box for holding and transporting said bottles. In the present embodiment, the rigid container is sealed or closed to for at least one of: prevention of tampering, preservation of contents, prevent leakage or for hygiene purposes.

While it is described for use with rigid containers, it will be understood that the embodiment shown in <FIG> can be used for other non-rigid containers that are provided in further packaging.

In use, a pressure or force is applied by pressure applying member <NUM>, for example, to the upper surface of the further packaging <NUM> and a sample of gas is extracted from the further packaging <NUM> via one or more gaps or holes. If the container is leaking, then any leaked gas or vapour that has previously accumulated inside the packaging is extracted by application of the pressure. The extracted gas or vapour is then moved to the sample cell to be tested, as described above.

As described with reference to previous embodiments, the sampling apparatus <NUM> may be used together with a conveyer belt of conveyer belt system <NUM> for conveying the further packaging <NUM>.

The present embodiment may be useful for detecting leaking or broken bottles in a box, for example, before the further packaging is stored. In the case of a cardboard box, a leaking or broken bottle will wet the cardboard and may cause the cardboard box to collapse.

It will be understood that the pressing member, can be any member that can apply pressure or force to the packaging. In one embodiment, one or more pressing members are provided on the conveyer belt to squeeze the further packaging as it passes the sampling apparatus. In other embodiments, one or more rollers are provided to apply pressure. In particular, although the sampling apparatus <NUM> with a roller, substantially as described with reference to <FIG>, is described for applying pressure directly to a container, the system can be adapted for applying pressure to further packaging including containers, as described with reference to <FIG>.

It will be understood that in further embodiments, a pressing member may be used together with the archway or contoured type sample head. As an example, the pressing member may apply pressure to a box and the sample is collected using a contoured sample head.

The above described embodiments are suitable for detecting leaks from a number of different types of containers, for example, bottles of distilled spirits, for example, whisky, processed meats, salad trays, frozen meats, beer kegs and fruit punnets. In particular, the roller system may be suitable for detecting leaks from, for example, fruit punnets, salad trays, frozen and processed meats. The non-contact archway may be suitable for detecting leaks from beer kegs and bottles.

While in the above embodiment, a pressure apparatus is described as forcing out the sample gas from the container, in further embodiments, gas or air, for example, a pressurised gas or pressurised air is injected into the container to force out a sample of gas from the container for testing.

In the above described embodiments, a sampling region remote from the sample chamber is described. In further embodiments, in place of the sample chamber, an open laser path may be used to detect the one or more materials, for example to monitor ethanol levels in a whisky storage warehouse. In some embodiments, a sample cell may be provided without a sample chamber.

Claim 1:
A method of testing the structural integrity of a rigid container, the method comprising:
performing a sampling process on the rigid container provided inside non-rigid further packaging, wherein the non-rigid further packaging comprises one or more holes or gaps in a surface, wherein the sampling process further comprises:
applying a force to at least one surface of the non-rigid further packaging by contacting the at least one surface of the non-rigid further packaging with at least one pressing member and/or at least one roller thereby to extract accumulated leaked gas or vapour from said further packaging, wherein the gas or vapour is extracted through one or more holes or gaps in the surface of said further packaging; and
sampling a volume of sample gas from a sampling region associated with the rigid container;
wherein the method further comprises:
performing a detection process comprising:
producing one or more laser beams for excitation of one or more materials that may be in the volume of sample gas, wherein the one or more materials are representative of a gas and/or vapour and/or a liquid leak from the rigid container; and
detecting light that has passed through the volume of sample gas and determining the presence and/or absence and/or amount of said one or more materials in the volume of sample gas based on detected light, .