Removable Imaging Cartridge for Stable Surface Topography Capture
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Solution Overview
Problem
Existing surface topography measurement systems using clear elastomers with reflective coatings face issues with delamination and replacement challenges, making it difficult for end users to change elastomers quickly and conveniently.
Innovation Solution
A removable imaging cartridge with a rigid optical element and clear elastomeric sensing surface, featuring a mechanical key for precise positioning and light shaping features, allows for easy replacement and ensures stable, high-resolution topographical data capture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a clear elastomer with reflective coating is used for surface topography measurement, then high-resolution surface measurements can be achieved, but the elastomer can delaminate and become damaged over multiple uses
Solution Approach 1:
The system divides the elastomer into separate, replaceable cartridges that can be independently exchanged. Each cartridge contains a fresh elastomer layer bonded to an optical element, allowing the elastomer to be replaced without replacing the entire optical system. This segmentation resolves the contradiction by maintaining measurement precision through consistent optical elements while improving reliability through replaceable elastomers that prevent delamination issues.
Solution Approach 2:
The patent changes the physical state and bonding parameters of the elastomer by using optimized adhesive layers and bonding processes. The elastomer is bonded to the optical element with controlled adhesive properties that prevent delamination during use. This parameter change allows the elastomer to maintain its structural integrity over multiple uses while preserving the high-resolution measurement capability.
2Ease of repair
If the elastomer is replaced manually, then damaged elastomers can be exchanged, but the process is error prone and challenging for end users
Solution Approach 1:
The elastomer is segmented into pre-assembled cartridges that include the optical element and elastomer layer as an integrated unit. This segmentation allows end users to simply replace the entire cartridge rather than manually handling and bonding elastomer layers, eliminating errors and simplifying the replacement process to a straightforward cartridge exchange operation.
Solution Approach 2:
The system employs disposable or limited-life elastomer cartridges that are replaced rather than repaired. These cartridges are designed as single-use or limited-use units that maintain consistent performance throughout their service life and are then replaced, eliminating the complexity of elastomer replacement while ensuring consistent measurement quality.
3Reliability
If the elastomer is replaced frequently, then damaged elastomers can be exchanged, but time is lost and productivity decreases
Solution Approach 1:
The elastomer is segmented into pre-assembled cartridges that can be rapidly exchanged without disassembling the optical system. This segmentation enables quick cartridge replacement that minimizes downtime and maintains measurement consistency by ensuring each cartridge contains a fresh, undamaged elastomer layer ready for immediate use.
Solution Approach 2:
The elastomer cartridges are pre-assembled and prepared in advance with the optical element and elastomer layer already bonded together. This preliminary action eliminates the time-consuming steps of manual elastomer installation and bonding during replacement, allowing users to simply exchange pre-prepared cartridges and maintain high productivity while ensuring measurement reliability.
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 provides a robust and user-friendly system for rapid elastomer changes, ensuring reliable and repeatable imaging performance by maintaining the integrity of the elastomer and reducing the risk of contamination or air bubbles.
Implementation Method 1
a first side of the layer adjacent to the second surface of the optical element having a second index of refraction matched to a first index of refraction of the second surface
Implementation Method 2
a second side of the layer opposing the second surface of the optical element having an optical coating with a predetermined reflectance
Implementation Method 3
the sidewall including one or more light shaping features configured to control an illumination of the second surface through the sidewall
Data Source
AI summary
A topographical measurement system uses an imaging cartridge formed of a rigid optical element and a clear, elastomeric sensing surface configured to capture high-resolution topographical data from a measurement surface. The imaging cartridge may be configured as a removable cartridge for the system so that the imaging cartridge, including the rigid optical element and elastomeric sensing surface can be removed and replaced as a single, integral component that is robust/stable over multiple uses, and easily user-replaceable as frequently as necessary or desired. The cartridge may also usefully incorporate a number of light shaping and other features to support optimal illumination and image capture.