Integrated Optical Element for Downhole Fluid Analysis
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Solution Overview
Problem
Current formation fluid analysis tools face challenges in maintaining accuracy and sensitivity due to the complexity of aligning separate integrated computational elements (ICEs) and optical filters in downhole environments, leading to potential manufacturing errors and decreased yields.
Innovation Solution
Fabricating both the ICE and band pass filter on the same substrate to create an integrated optical element, allowing for increased accuracy, sensitivity, and reliability, as well as enabling precise data collection for specific fluid characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If separate ICE and optical filter components are used, then device complexity increases requiring complex alignment procedures, but manufacturing precision and reliability decrease due to potential alignment errors in downhole environments
Solution Approach 1:
The patent combines the ICE and optical filter into a single integrated optical element fabricated on one substrate. This merging eliminates the need for separate alignment procedures between discrete components, thereby reducing device complexity while simultaneously improving measurement reliability by eliminating alignment errors in downhole environments.
Solution Approach 2:
The integrated optical element is segmented into distinct functional regions: the ICE portion with its computational layers and the optical filter portion with its wavelength-selective layers. This segmentation allows each component to maintain its specific function while being fabricated together as a unified structure, avoiding alignment issues between separate parts.
2Ease of manufacture
If separate ICE and optical filter components are used, then ease of manufacture decreases due to additional handling time and operator error potential, but manufacturing precision may be compromised
Solution Approach 1:
By fabricating both the ICE and optical filter on the same substrate in an integrated manner, the manufacturing process eliminates multiple handling steps and alignment operations. This single-substrate approach simplifies manufacturing while ensuring precise spatial relationships between components are maintained throughout the fabrication process.
Solution Approach 2:
The substrate serves as a pre-established platform where both the ICE and optical filter are fabricated in sequence or simultaneously. This preliminary preparation of the substrate with integrated fabrication capabilities ensures that alignment precision is built into the manufacturing process itself, rather than requiring post-fabrication alignment adjustments.
3Manufacturing precision
If integrated optical element with ICE and filter on same substrate is used, then manufacturing precision and reliability increase, but device complexity decreases
Solution Approach 1:
The integration of ICE and optical filter into a single optical element reduces the number of discrete components and assembly steps. This merging simplifies the overall device structure while maintaining high manufacturing precision through unified fabrication processes on a single substrate.
Solution Approach 2:
The single substrate serves multiple functions: it supports the ICE computational layers, holds the optical filter layers, and provides the structural foundation for the entire optical element. This multi-functionality reduces device complexity by eliminating the need for separate mounting structures and alignment mechanisms.
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 enhances the reliability and precision of formation fluid analysis by eliminating the need for separate components, allowing for more accurate and sensitive data collection across various wellbore types and drilling operations.
Implementation Method 1
an optical filter fabricated on a second side of the substrate opposite the first side
Implementation Method 2
measure responses from the formation fluid as a function of the wavelength of the optical source
Data Source
AI summary
An example formation fluid analysis tool includes an optical element and a detector configured to receive light passed through the optical element. The optical element is configured to receive light from a fluid sample and comprises a substrate, an integrated computational element (ICE) fabricated on a first side of the substrate, and an optical filter fabricated on a second side of the substrate opposite the first side.