Optical Filter Coatings for Low-Cost Precision Measurement
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Solution Overview
Problem
Existing color measuring devices, such as spectrometers and colorimeters, are expensive due to their complex optical designs and require complex and costly sensor filters that account for additional optical component filtering, leading to high production costs.
Innovation Solution
A method for manufacturing optical filters involves applying multiple coatings on a substrate, dividing it into portions, examining for spectral sensitivity, and dicing successful portions to create a stock of filters, which are then assembled into a predefined pattern, using techniques like sputter deposition to reduce complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensor filters are optimized to account for additional optical component filtering, then measurement accuracy is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent divides the filter manufacturing process into separate stages: first applying coatings to create multiple filter types on a single substrate, then dividing the substrate into portions, and finally selecting only the successful filters. This segmentation allows independent optimization of each filter type without requiring complex inter-dependent designs, reducing overall system complexity while maintaining accuracy.
Solution Approach 2:
The patent applies filter coatings to the entire substrate before dividing it into portions and examining each section. This preliminary action allows all filters to be created simultaneously and evaluated together, enabling selection of only the successful filters for final use, thereby avoiding the need to design and manufacture filters that are likely to fail.
2Measurement precision
If sensor filters are optimized to account for additional optical component filtering, then measurement accuracy is improved, but manufacturing cost increases
Solution Approach 1:
The patent segments the substrate into multiple portions after coating, allowing each portion to be independently examined and selected. This enables manufacturing efficiency by processing multiple filters in parallel while only retaining the successful ones, reducing waste and lowering overall manufacturing costs compared to producing and optimizing individual complex filters.
Solution Approach 2:
The patent creates a stock of successful filters by discarding unsuccessful portions after examination. This approach recovers the investment in successful filters while avoiding the cost of manufacturing and optimizing filters that would likely fail, thereby reducing overall manufacturing costs while maintaining measurement accuracy through the use of only verified successful filters.
3Measurement precision
If complex optical designs are used to achieve detailed wavelength information, then measurement precision is improved, but device cost increases
Solution Approach 1:
The patent creates multiple copies of filter designs on a single substrate, each copy representing a different filter type. By dividing the substrate into portions and examining each, the system creates a library of verified successful filters that can be selected and assembled. This copying approach achieves detailed wavelength information through multiple simple filters rather than one complex optical design, reducing overall system complexity and cost.
4Reliability
If multiple filter coatings are applied to achieve specific spectral sensitivity, then filter performance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges multiple filter coating applications onto a single substrate in sequence, creating multiple filter types simultaneously. By dividing the substrate into portions after all coatings are applied, the system combines the complexity of multiple filters into a single manufacturing process, reducing overall manufacturing complexity while maintaining the performance benefits of multiple specialized filters.
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 method reduces production costs by ensuring only successful filters are used, allowing for cost-effective and predictable manufacturing of optical filter systems and devices with improved accuracy and resolution, comparable to high-end spectrometers.
Implementation Method 1
applying a plurality of filter coatings on a substrate to obtain a coated substrate provided with a stack of filter coatings
Data Source
AI summary
The invention is a method for manufacturing filters for an optical filter system, for manufacturing an optical filter system, and for manufacturing an optical measurement device. The system comprises a plurality of filters, and a frame holding the plurality of filters in a predefined pattern. The method comprises, per filter, the steps of:applying a plurality of coatings on a substrate to obtain a coated substrate provided with a stack of filter coatings designed for the specific spectral sensitivity of the filter,dividing the coated substrate into a plurality of portions,determining the good ones of the portions, which meet a predefined design requirement,dicing the coated substrate into the plurality of portions, andpicking a good one of the portions as the filter.