Integrated Computational Element Deposition Control
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Solution Overview
Problem
Multivariate optical computing (MOC) components require precise manufacturing processes for thin film deposition, which are time-intensive, expensive, and difficult to monitor and manage, limiting their effectiveness in real-time, in-situ analysis of test samples, especially in harsh environments.
Innovation Solution
The development of a system and method for controlling the deposition of integrated computational elements (ICE) Cores using ion-assisted electron beam deposition, with real-time monitoring and control of optical functions, allowing for non-destructive, non-invasive, and in-situ analysis of test samples through a system that includes sensors and thermal source translation, enabling accurate detection of properties in various phases and environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional predictive spectroscopic techniques are used to analyze test samples, then comprehensive spectral data can be collected, but the process requires time-intensive post-processing with computers and complex instrumentation
Solution Approach 1:
The patent replaces traditional mechanical/computational spectroscopic systems with an optical computing system that performs spectral analysis through optical interference and diffraction. The ICE core with its specific layer structure enables direct optical calculation of analyte concentration without requiring computer-based post-processing of spectral data
Solution Approach 2:
The patent extracts the computational function from the spectroscopic system and embeds it directly into the optical filter structure. The ICE core contains embedded computational elements that perform the analytical calculation optically, removing the need for separate computational processing steps
2Reliability
If MOC components are manufactured with exact manufacturing compositions and depositions, then the optical computing elements function properly, but the manufacturing process becomes very time intensive and expensive
Solution Approach 1:
The patent performs preliminary computational design to determine the exact layer thicknesses and material compositions required for the ICE core. By calculating the optimal structure beforehand, the manufacturing process can proceed directly to deposition without iterative adjustments, reducing both time and cost while ensuring functional performance
Solution Approach 2:
The patent uses computational optimization to determine specific parameter values for layer thicknesses and material properties that achieve the desired spectral weighting. These predetermined parameters guide the manufacturing process, ensuring functional performance while minimizing manufacturing time
3Reliability
If MOC components are manufactured with exact manufacturing compositions and depositions, then the optical computing elements function properly, but the manufacturing process becomes expensive and difficult to monitor and manage
Solution Approach 1:
The patent implements feedback control during the deposition process by monitoring the actual layer thickness and composition in real-time and adjusting the deposition parameters accordingly. This ensures that the manufactured ICE cores meet the exact specifications required for proper function while making the manufacturing process easier to monitor and manage
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 enables accurate, real-time analysis of test samples without the need for costly spectroscopic instruments, providing reliable and rugged optical analysis devices capable of withstanding extreme conditions, and allowing for simultaneous monitoring of multiple properties in diverse locations.
Implementation Method 1
ion-assisted electron beam deposition
Implementation Method 2
ion-assisted electron beam deposition
Implementation Method 3
controlling the generation or manufacturing of integrated computational elements (ICE) Cores
Data Source
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Figure 3
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AI summary
The disclosed embodiments include a system and method for manufacturing an integrated computational element (ICE) core. In one embodiment, the method comprises thermally evaporating a material to deposit the material on a substrate, wherein the material is deposited to establish a shape of the ICE core. The shape of the ICE core defines transmission, reflection, and absorptive electromagnetic intensity as a function of wavelength of the ICE core. In one embodiment, the method includes varying e-beam or ion-beam intensities and strengths to control the shape of the ICE core.