Optical Sensor Film Layer Optimization for Integrated Computational Elements
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Solution Overview
Problem
Existing optical sensors with Integrated Computational Elements (ICEs) require a large number of film layers for performance adjustability, leading to high computational costs and quality control challenges, and often suffer from performance degradation during fabrication and manufacturing.
Innovation Solution
The design optimizes the number of film layers in ICEs to 2-5 layers, using regression techniques and neural networks to select optimal layer thicknesses and materials, reducing manufacturing complexity and costs while maintaining performance through a combination of ICEs and post-fabrication calibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a large number of film layers are used in ICE design, then performance adjustability is improved, but computational cost and manufacturing complexity increase
Solution Approach 1:
The patent segments the ICE structure into a minimal number of essential film layers (2-5 layers) while maintaining performance adjustability through optimized material selection and thickness control. This segmentation reduces the complex multi-layer structure into manageable layers that can be precisely controlled during manufacturing.
Solution Approach 2:
The patent changes the parameters of the film layers, specifically optimizing the thickness and material composition of each layer to achieve the desired performance with fewer layers. By adjusting these parameters, the system maintains adaptability while reducing the total number of layers from traditional designs.
2Adaptability or versatility
If a large number of film layers are used in ICE design, then performance adjustability is improved, but manufacturing precision and quality control deteriorate
Solution Approach 1:
By segmenting the ICE into fewer, well-defined film layers, the patent simplifies the manufacturing process and improves quality control. Each layer can be deposited and measured independently, reducing cumulative errors and improving overall manufacturing precision.
Solution Approach 2:
The patent replaces complex mechanical layering with optimized optical material properties and thickness control. This substitution reduces reliance on precise mechanical deposition of multiple thin layers, thereby improving manufacturing precision and quality control.
3Adaptability or versatility
If a large number of film layers are used in ICE design, then performance adjustability is improved, but fabrication cost increases
Solution Approach 1:
The patent segments the ICE structure into a minimal number of film layers (2-5 layers), which directly reduces fabrication cost by decreasing material usage, deposition time, and manufacturing steps while preserving performance adjustability through optimized layer design.
Solution Approach 2:
By optimizing the parameters of each film layer (thickness, material composition), the patent achieves cost-effective fabrication with fewer layers. This parameter optimization reduces material costs and manufacturing complexity while maintaining the necessary performance adjustability.
4Adaptability or versatility
If a large number of film layers are used in ICE design, then performance adjustability is improved, but sensitivity to manufacturing errors increases
Solution Approach 1:
The patent segments the ICE into fewer, robust film layers, reducing the cumulative sensitivity to manufacturing errors. With fewer layers, there are fewer potential sources of error, and each layer can be more easily controlled and verified during manufacturing.
Solution Approach 2:
The patent incorporates design features that cushion against manufacturing errors by optimizing the film layer parameters to be less sensitive to variations. This beforehand cushioning ensures that minor manufacturing deviations do not significantly impact the overall performance of the ICE.
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 results in cost-effective, high-performance ICEs with reduced sensitivity to manufacturing errors, enabling efficient fluid analysis in hydrocarbon wellbores with improved quality control and calibration capabilities.
Implementation Method 1
ICEs typically have multiple high and low refractive index film layers deposited on a substrate material, which function as multi-band filters
Data Source
AI summary
This disclosure includes methods for designing a simplified Integrated Computational Element (ICE) and for optimizing a selection of a combination of ICE designs. A method for fabricating a simplified ICE having one or more film layers includes predicting an optimal thickness of each of the one or more film layers of the simplified ICE using a neural network. A method for recalibrating the fabricated ICE elements for system implementation is also disclosed. The disclosure also includes the simplified ICE designed by and the ICE combination selected by the disclosed methods. The disclosure also includes an information handling system with machine-readable instructions to perform the methods disclosed herein.