Multispectral Thickness Mapping for Roll-to-Roll Membranes
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Solution Overview
Problem
Existing roll-to-roll systems for manufacturing thin materials like membranes struggle with efficient, high-resolution, real-time thickness mapping, especially when materials are in motion, as they can only inspect along a single line or in a limited pattern, lacking the capability for full-area, two-dimensional inspection.
Innovation Solution
The system employs multispectral imaging and spectral interference fringe analysis using a push-broom multispectral camera to simultaneously inspect hundreds or thousands of points along the material's width, allowing for continuous, high-resolution two-dimensional thickness mapping, even for multilayer structures, by capturing light intensity across multiple wavelengths and processing it in real-time or near-real-time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single-line inspection method is used, then the device complexity is low, but the measurement precision and inspection coverage are insufficient
Solution Approach 1:
The patent transitions from single-line (1D) inspection to two-dimensional (2D) full-area inspection by adding the across-web dimension. The push-broom multispectral camera captures spectral data across multiple wavelengths simultaneously at numerous points across the material width, enabling comprehensive thickness mapping while maintaining real-time processing capability.
Solution Approach 2:
The inspection system divides the material surface into multiple discrete measurement points arranged in a grid pattern. Each point captures spectral interference fringe data independently, and the processing system reconstructs the complete thickness map from these segmented measurements, achieving high-resolution 2D inspection.
2Measurement precision
If full-area two-dimensional inspection is implemented, then the measurement precision improves, but the productivity decreases due to inspection time
Solution Approach 1:
The push-broom multispectral camera continuously captures spectral data as the material moves through the inspection zone, maintaining uninterrupted inspection throughout the material web. The system processes data in real-time or near-real-time, ensuring continuous thickness mapping without stopping production, thus maintaining high productivity while achieving comprehensive 2D inspection.
Solution Approach 2:
The system performs preliminary spectral data capture and processing while the material is in motion, rather than stopping production for inspection. By preparing and analyzing data during the material transport process, the system eliminates downtime and maintains continuous production flow.
3Productivity
If real-time thickness mapping is performed, then the productivity is maintained, but the measurement precision may be compromised due to processing speed constraints
Solution Approach 1:
The patent replaces mechanical scanning methods with optical spectral interference fringe analysis. By measuring the interference pattern of light reflected from or transmitted through the material at multiple wavelengths, the system extracts thickness information through computational analysis of the spectral data, achieving real-time processing without compromising precision.
Solution Approach 2:
The system transforms the measurement approach by changing from direct spatial profiling to spectral domain analysis. By capturing data across multiple wavelengths and converting to the frequency domain through Fourier transforms, the system extracts precise thickness information rapidly, enabling real-time processing while maintaining high measurement accuracy.
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 thickness mapping of materials in motion, providing comprehensive quality control by generating a two-dimensional thickness map, which can detect thickness variations and alert for deviations from specified thresholds, enhancing production efficiency and product quality.
Implementation Method 1
spectral interference fringe analysis using a push-broom multispectral camera to simultaneously inspect hundreds or thousands of points along the material's width
Implementation Method 2
capturing light intensity across multiple wavelengths and processing it in real-time or near-real-time
Data Source
AI summary
An example system includes a material transport system configured to transport a substantially planar material through a monitoring zone, an illumination source configured to illuminate at least a portion of the material that is within the monitoring zone with light, and a sensor configured to obtain a plurality of consecutive datasets. Datasets indicate, for locations of the material and for a specific wavelength of light, a respective intensity of the light that is of the wavelength and that is received from the location. The system also includes a processing system configured to receive the dataset, determine, based on the dataset and for each of at least two locations in the plurality of locations, a respective value of a thickness of the material, and execute, based on the respective value of the thickness of the material for at least one of the at least two locations, an action.