Perforated Emitter Layer for Uniform Infrared Spectrum
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Solution Overview
Problem
Existing radiation sources, particularly those used in sensors for gas mixture analysis, exhibit deviations from the ideal blackbody spectrum due to multiple reflections within carrier and cover layers, leading to emission losses and mechanical instability issues, especially with thicker layers.
Innovation Solution
A radiation source with a membrane layer having a surface structure where the emitter layer follows this structure, featuring varying angles and an average amplitude equal to or greater than the emitter layer thickness, and a perforated emitter layer with holes to reduce mechanical stress and enhance emissivity, allowing for a uniform emission spectrum without additional coating steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If multiple reflections occur within carrier and cover layers, then radiation source structure is formed, but emission losses increase and spectrum uniformity deteriorates
Solution Approach 1:
The patent extracts the problematic carrier substrate and thick cover layers from the radiation source structure. By removing the carrier substrate completely and using a thin membrane layer (5-20 μm) as the cover, the design eliminates the multiple reflections that cause emission losses and spectral non-uniformity, while maintaining mechanical stability through the perforated emitter layer structure
Solution Approach 2:
The emitter layer is designed with a perforated structure (porous material) having opening areas of 10-50 μm². This porous configuration reduces the path length for radiation transmission, minimizes multiple reflections, and improves emissivity while maintaining structural integrity. The perforations allow radiation to escape directly without undergoing multiple internal reflections within thick layers
2Stability of the object's composition
If thicker membrane or passivation layers are used, then mechanical stability is improved, but emission spectrum deviations increase due to multiple reflections
Solution Approach 1:
The patent applies local quality by creating a perforated structure in the emitter layer with specific opening areas (10-50 μm²). This localized structural modification allows the membrane layer to maintain overall mechanical stability while the perforations provide direct radiation escape paths that eliminate multiple reflections. The perforations are distributed throughout the emitter layer to locally address the reflection problem without compromising global structural integrity
Solution Approach 2:
The patent uses a thin membrane layer (5-20 μm) instead of thick cover layers. This thin film approach minimizes the path length for radiation transmission and reduces multiple reflections while maintaining adequate mechanical stability through the perforated emitter layer structure and appropriate material selection
3Manufacturing precision
If thin layers are used to minimize reflection errors, then emission spectrum uniformity is improved, but mechanical instability increases
Solution Approach 1:
The emitter layer incorporates a perforated structure with opening areas of 10-50 μm² that provides both mechanical support and optimal radiation transmission. The perforated configuration creates a three-dimensional structure that maintains structural integrity while minimizing the effective path length for radiation, thereby reducing multiple reflections and improving spectral uniformity
Solution Approach 2:
The radiation source uses a composite structure combining a membrane layer (5-20 μm thick) with a perforated emitter layer. This composite design integrates the advantages of thin layers (reduced reflections) with the benefits of a perforated structure (enhanced mechanical stability and controlled radiation transmission), achieving both spectral uniformity and mechanical stability simultaneously
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
The solution achieves a uniform emission spectrum, reduces interference phenomena, and increases radiation output with reduced mechanical stress, while simplifying the manufacturing process and avoiding the need for additional emission layers.
Implementation Method 1
an emitter layer (104) applied to the membrane layer (103), which can be connected to a power supply source via electrical contact areas (106) in order to be heated and thereby emit the electromagnetic radiation
Implementation Method 2
emitter layer... which can be heated and thereby emit the electromagnetic radiation, preferably in the infrared range
Implementation Method 3
The carrier substrate is removed in a membrane area on the side of the membrane layer facing away from the emitter layer, which is necessary in particular for the thermal insulation of the emitter layer
Data Source
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AI summary
The invention relates to a radiation source for generating electromagnetic radiation. The radiation source comprises a carrier substrate (101), a membrane layer (103) which is supported by the carrier substrate (101), and an emitter layer (104) which is applied onto the membrane layer (103) and comprises electric contact regions (106). The carrier substrate (101) is removed in a membrane region on the membrane layer face facing away from the emitter layer (104). The emitter layer (104) is heated upon applying an electric current in order to emit the electromagnetic radiation. According to the invention, the membrane layer (103) has a surface structure (102) in the membrane region, and the emitter layer (104) follows the structure (102). The average amplitude of the structure (102) is greater than or equal to the thickness of the emitter layer (104). The invention also relates to a method for producing such a radiation source.