Micro-Core Thermal Calibration Without Shutter
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Solution Overview
Problem
The challenge lies in calibrating and testing ultra-small thermal imaging cores for integration into consumer devices like smartphones, where traditional thermal imaging systems' design features, such as shutters for non-uniformity correction, are impractical due to size and cost constraints, necessitating innovative test and calibration techniques for high-volume, low-cost production.
Innovation Solution
The development of test procedures and fixtures that allow for full temperature calibration of each micro-core, providing data for uniformity correction and enabling high-throughput testing, including the use of temperature-controlled black-bodies and ambient temperature sensors to generate calibration data for accurate thermography, even without a shutter, and efficient test setups that can calibrate multiple cores simultaneously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional thermal imaging systems with shutters are used for non-uniformity correction, then uniformity correction accuracy is improved, but device size and cost increase
Solution Approach 1:
The patent removes the mechanical shutter component from the thermal imaging system, extracting only the essential function of non-uniformity correction. Instead of using a physical shutter to block thermal radiation, the system employs computational methods and alternative calibration techniques to achieve uniformity correction without the bulky mechanical component, thereby reducing device size while maintaining correction accuracy
Solution Approach 2:
The patent replaces the mechanical shutter system with non-mechanical alternatives including software-based correction algorithms and simplified calibration procedures. This substitution eliminates moving parts and mechanical complexity while achieving the same uniformity correction function through computational methods, directly addressing the contradiction between correction accuracy and device size
2Measurement precision
If traditional thermal imaging systems with shutters are used for non-uniformity correction, then uniformity correction accuracy is improved, but manufacturing cost increases
Solution Approach 1:
The patent extracts and eliminates the expensive mechanical shutter assembly from the thermal imaging system. By removing this high-cost component, the overall manufacturing cost is reduced while the essential uniformity correction function is maintained through alternative, lower-cost methods such as software algorithms and simplified calibration procedures
Solution Approach 2:
The patent employs cost-effective, non-mechanical solutions replacing expensive durable mechanical components. The software-based correction and simplified calibration approaches use inexpensive computational resources instead of costly mechanical shutters, achieving uniformity correction at a fraction of the original manufacturing cost
3Measurement precision
If conventional test procedures are used for thermal imaging cores, then comprehensive calibration is achieved, but calibration time and throughput are insufficient for high-volume production
Solution Approach 1:
The patent implements preliminary characterization of the thermal imaging core during the manufacturing process itself. By performing initial calibration measurements and storing correction data before the products reach the customer, the system eliminates the need for time-consuming field calibration procedures. This preliminary action enables high-volume production while maintaining calibration accuracy through pre-computed correction algorithms
Solution Approach 2:
The patent changes the calibration approach from time-intensive mechanical adjustment procedures to rapid computational parameter optimization. By using algorithmic methods to determine correction parameters and storing these in lookup tables, the system achieves comprehensive calibration accuracy with dramatically reduced calibration time, enabling high-volume production throughput
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 comprehensive and efficient calibration of small thermal imaging cores, compensating for design limitations and ensuring accurate thermographic performance in consumer devices, achieving unprecedented calibration speed and volume production capabilities.
Implementation Method 1
temperature-controlled black-bodies to generate calibration data for accurate thermography
Implementation Method 2
providing data useful for uniformity correction during operation
Data Source
AI summary
Test procedures and equipment for the test and calibration of ultra-small thermal imaging cores, or micro-cores are disclosed. Test fixtures for calibration and adjustment that allow for operation and image acquisition of multiple cores at a time may also be provided. Test procedures and fixtures that allow for full temperature calibration of each individual core, as well as providing data useful for uniformity correction during operation, may also be provided as part of the test and manufacture of the core.