Porous SiGe Thermoelectric Optical Sensor for Lower NEP

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Solution Overview

Problem

Existing optical sensors, particularly infrared sensors, face challenges in achieving low noise equivalent power (NEP) due to high thermal conductivity of material layers that convert thermal energy into electric energy, which hinders sensitivity improvement.

Innovation Solution

The optical sensor incorporates a thermoelectric conversion material section with alternating p-type and n-type SiGe layers formed into a first phononic structure with numerous pores, reducing thermal conductivity and balancing resistances to enhance sensitivity and reduce NEP.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional thermoelectric conversion material layers are used, then the optical sensor can be manufactured with standard materials, but the thermal conductivity is too high which reduces sensitivity and increases noise equivalent power

Engineering Contradiction:
ImprovesensitivityVSAvoidthermal conductivity
Core Design Contradiction:
Measurement precisionVSLoss of energy

Solution Approach 1:

The patent applies porous materials by forming phononic structures with pores in the thermoelectric conversion material layers. These porous structures reduce thermal conductivity while maintaining electrical conductivity, directly addressing the contradiction between high sensitivity and low thermal conductivity. The pores act as thermal barriers that prevent heat leakage without significantly impeding charge carrier transport.

Inventive Principle:
Principle #31Porous materials

Solution Approach 2:

The patent uses composite materials by combining different materials with complementary properties in the phononic structure. The thermoelectric conversion material is integrated with phononic crystal structures that have specific acoustic and thermal properties, creating a composite system that optimizes both thermal insulation and electrical conduction for improved sensitivity and reduced noise equivalent power.

Inventive Principle:
Principle #40Composite materials

2Measurement precision

If phononic structures with pores are introduced to reduce thermal conductivity, then sensitivity improves, but the manufacturing complexity increases

Engineering Contradiction:
ImprovesensitivityVSAvoidstructure complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent applies segmentation by dividing the thermoelectric conversion material into multiple discrete layers with phononic structures. Each layer can be independently formed and optimized, allowing complex porous structures to be created through sequential deposition processes. This segmentation enables precise control over pore size, distribution, and morphology while maintaining manufacturability.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent replaces traditional mechanical drilling or etching methods for creating pores with vapor-phase deposition techniques. The phononic structures with pores are formed through chemical vapor deposition or atomic layer deposition processes, substituting complex mechanical fabrication with more controllable and scalable vapor-phase methods that reduce manufacturing complexity.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

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 configuration increases sensitivity and reduces noise equivalent power by effectively managing thermal conductance and resistance, thereby improving the sensor's performance.

Implementation Method 1

a light absorbing film configured to convert received light into thermal energy

Methodology Applied
Scientific EffectPhotothermal conversion: Absorption (EM radiation)

Implementation Method 2

Each of the plurality of first material layers... is configured to convert thermal energy into electric energy. Each of the plurality of second material layers... is configured to convert thermal energy into electric energy

Methodology Applied
Scientific EffectSeebeck effect: Seebeck Effect

Implementation Method 3

The plurality of first material layers and the plurality of second material layers are formed of a first phononic structure having a large number of pores

Methodology Applied
Scientific EffectPhonon scattering: Phononic Crystal

Data Source

PatentUS12439822B2Optical sensor
Publication Date: 2025.10.07 SUMITOMO ELECTRIC INDUSTRIES LTD
  • US12439822B2 patent drawing
  • US12439822B2 patent drawing
  • US12439822B2 patent drawing

AI summary

An optical sensor includes a support film having a first main surface and a second main surface located opposite to the first main surface in a thickness direction; a thermoelectric-conversion material section disposed on the first main surface and including a plurality of strip-shaped first material layers formed of SiGe having p-type conductivity and configured to convert thermal energy into electric energy, and a plurality of strip-shaped second material layers formed of SiGe having n-type conductivity and configured to convert thermal energy into electric energy; a heat sink disposed on the second main surface; and a light absorbing film disposed so as to form a temperature difference in each of the first material layers in longitudinal directions and each of the second material layers in longitudinal directions and configured to convert received light into thermal energy.