Infrared Sensor Calibration Substrate for Thermal Stability
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Solution Overview
Problem
Conventional infrared device calibration processes are time-consuming and challenging due to difficulties in stabilizing the temperature of the camera core and blackbody, leading to increased manufacturing costs and limited manufacturing capability.
Innovation Solution
The proposed solution involves performing sensor-level calibration outside of the camera core using a low-emissivity or high-emissivity calibration target within an environmental chamber, with active temperature control to improve temperature stability and reduce calibration cycle time, allowing for the generation and storage of calibration information before integration into the camera core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional calibration process is performed on infrared camera core viewing uniform-flux scene from high-emissivity uniform blackbody within environmental chamber over range of temperatures, then calibration data can be obtained, but the time necessary to obtain calibration data is excessive and manufacturing costs increase
Solution Approach 1:
The patent applies preliminary action by performing calibration of the infrared sensor array before it is integrated into the camera core assembly. The sensor array is calibrated independently on a sensor calibration substrate, allowing calibration to be completed prior to assembly with other camera components. This eliminates the need to wait for thermal stabilization of the entire camera core and blackbody assembly during calibration, significantly reducing the calibration cycle time while maintaining calibration accuracy.
2Measurement precision
If conventional calibration process is performed with infrared camera core and blackbody at same temperature during calibration data acquisition, then accurate calibration can be achieved, but it is difficult to adequately stabilize the temperatures and calibration time increases
Solution Approach 1:
The patent applies segmentation by separating the calibration process from the camera core assembly. The infrared sensor array is calibrated independently on a dedicated sensor calibration substrate rather than as part of the complete camera core assembly. This segmentation allows the calibration process to be decoupled from the thermal management requirements of the camera core, enabling faster calibration without compromising accuracy.
Solution Approach 2:
The patent introduces an intermediary calibration substrate that facilitates calibration of the sensor array without requiring the presence of the camera core assembly. This intermediary substrate provides a controlled environment for calibration and enables thermal coupling between the sensor array and the blackbody reference without requiring stabilization of the entire camera core system, thereby reducing calibration time while maintaining accuracy.
3Productivity
If sensor-level calibration is performed prior to incorporation within camera core, then calibration cycle time is reduced and manufacturing costs are lowered, but additional calibration equipment and process steps are required
Solution Approach 1:
The patent applies universality by designing a sensor calibration substrate that can be used for calibrating sensor arrays from multiple different camera core assemblies. The calibration substrate provides a universal interface and thermal coupling mechanism that works with various sensor array configurations, allowing a single calibration setup to serve multiple production lines and camera models, thereby reducing the overall complexity burden of the additional calibration capability.
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 significantly reduces the calibration cycle time, enhances temperature stability, and lowers manufacturing costs by enabling faster and more efficient production of calibrated infrared sensors, while allowing for earlier detection of calibration errors and improved image accuracy across varying temperatures.
Implementation Method 1
an infrared detector (within a vacuum package assembly) along with associated electronic components
Implementation Method 2
performing a calibration operation on an infrared sensor to obtain calibration information... within an environmental chamber
Data Source
AI summary
Systems and methods directed to calibration techniques for infrared cameras are disclosed for some embodiments. For example, a method of determining infrared sensor calibration information, in accordance with an embodiment, includes performing a calibration operation on an infrared sensor to obtain calibration information, wherein the infrared sensor is not within an infrared camera core, and storing the calibration information.