Optical Integrated Computational Element Annealing Control
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Solution Overview
Problem
Optical integrated computational elements (ICEs) used in the oil and gas industry exhibit variability in their optical spectrum both between elements and relative to the desired target spectrum, and undergo unpredictable spectral drift when heated to elevated temperatures, making them unsuitable for downhole applications.
Innovation Solution
The method involves characterizing these variabilities and using annealing processes to shift the operational transmission spectrum of ICEs to an acceptable range, employing a transfer function to design a pre-annealed red-shifted ICE that corrects for the blue shift caused by annealing, ensuring stability and accuracy at high temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batch fabrication process is used to produce ICEs, then productivity is improved, but manufacturing precision deteriorates due to spectral variability between elements
Solution Approach 1:
The patent applies preliminary action by measuring the as-fabricated spectrum of each ICE element before annealing and using this measurement to determine individualized annealing parameters. This pre-characterization step allows the system to predict and correct spectral deviations before final processing, enabling batch fabrication while maintaining spectral precision through element-specific correction protocols.
2Adaptability or versatility
If ICEs are heated to elevated operating temperatures, then adaptability to downhole conditions is improved, but reliability deteriorates due to unpredictable spectral drift and hysteresis
Solution Approach 1:
The patent performs preliminary annealing treatment on ICE elements before deployment to downhole environments. By measuring each element's as-fabricated spectrum and applying tailored annealing protocols, the system pre-stabilizes the spectral response to high temperatures. This preliminary stabilization eliminates unpredictable spectral drift and hysteresis that would otherwise occur during actual elevated temperature operation, ensuring reliable performance in downhole applications.
Solution Approach 2:
The patent implements feedback by measuring the as-fabricated spectrum of each ICE element and using this measurement to determine the specific annealing parameters required for that element. The measured spectral characteristics provide feedback that drives the customization of thermal processing parameters, creating a closed-loop system that compensates for fabrication variations and ensures each element achieves optimal spectral stability for high-temperature operation.
3Manufacturing precision
If individualized annealing treatment is applied to correct spectral variability, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent applies parameter changes by adjusting annealing temperature and duration based on the measured as-fabricated spectrum of each ICE element. Instead of using fixed annealing parameters for all elements, the system modifies thermal processing parameters to match the specific spectral characteristics of each element, thereby correcting spectral deviations and achieving high manufacturing precision through parameter customization rather than physical modification of the elements themselves.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach stabilizes the ICE's transmission spectrum, eliminating unpredictable shifts and ensuring accurate quantitative measurements, even under varying temperature conditions, thereby enhancing their reliability for downhole use.
Implementation Method 1
heating of such elements to elevated operating temperatures may result in variable hysteresis
Implementation Method 2
The elements may exhibit some variability in their optical spectrum both between elements and relative to a desired target spectrum. In addition, heating of such elements to elevated operating temperatures may result in variable hysteresis.
Implementation Method 3
An ICE may comprise a multilayered optical interference filter that is designed to transmit a predetermined target spectrum.
Data Source
AI summary
A method controls fabrication of a multi-layered integrated computational element designed to have a target optical spectrum. A transfer function is generated relating a blue wavelength, shift between an as-annealed optical spectrum and an as-fabricated optical spectrum of a first integrated computational element at a standard temperature. Using the transfer function, an initial compensating red shift is incorporated into a second integrated computational element such that the as-annealed optical spectrum of the second integrated computational element matches the target optical spectrum.