Defect and thickness inspection system for cast thin films using machine vision and full-field transmission densitometry

Quick mass production of homogeneous thin film material is required in paper, plastic, fabric, and thin film industries. Due to the high feed rates and small thicknesses, machine vision and other nondestructive evaluation techniques are used to ensure consistent, defect-free material by continuously assessing post-production quality. One of the fastest growing inspection areas is for 0.5-500 micrometer thick thin films, which are used for semiconductor wafers, amorphous photovoltaics, optical films, plastics, and organic and inorganic membranes. As a demonstration application, a prototype roll-feed imaging system has been designed to inspect high-temperature polymer electrolyte membrane (PEM), used for fuel cells, after being die cast onto a moving transparent substrate. The inspection system continuously detects thin film defects and classifies them with a neural network into categories of holes, bubbles, thinning, and gels, with a 1.2% false alarm rate, 7.1% escape rate, and classification accuracy of 96.1%. In slot die casting processes, defect types are indicative of a misbalance in the mass flow rate and web speed; so, based on the classified defects, the inspection system informs the operator of corrective adjustments to these manufacturing parameters. Thickness uniformity is also critical to membrane functionality, so a real-time, full-field transmission densitometer has been created to measure the bi-directional thickness profile of the semi-transparent PEM between 25-400 micrometers. The local thickness of the 75 mm x 100 mm imaged area is determined by converting the optical density of the sample to thickness with the Beer-Lambert law. The PEM extinction coefficient is determined to be 1.4 D/mm and the average thickness error is found to be 4.7%. Finally, the defect inspection and thickness profilometry systems are compiled into a specially-designed graphical user interface for intuitive real-time operation and visualization.M.S.Committee Chair: Tequila Harris; Committee Member: Levent Degertekin; Committee Member: Wayne Dale

Metrology and Characterisation of Defects in Thin-Film Barrier Layers Employed in Flexible Photovoltaic Modules

Flexible thin-film photovoltaic (PV) modules based on copper indium gallium selenide (CIGS) materials are one of the most recent developments in the renewable energy field, and the latest films have efficiencies at or beyond the level of Si-based rigid PV modules. Whilst these films offer significant advantages in terms of mass and the possibility of building-integrated photovoltaic (BIPV) applications, they are at present highly susceptible to long term environmental degradation as a result of water vapour transmission through the protective encapsulation layer to the active (absorber) layer. To maintain the PV module flexibility and to reduce or eliminate the water vapour permeability, the PV encapsulation includes a barrier layer of amorphous aluminium oxide (Al2O3) material of a few nanometres thickness deposited on a planarised polyethylene naphthalate (PEN) substrate. The highly conformal barrier layer of the Al2O3 is produced by atomic layer deposition (ALD) methods using roll-to-roll (R2R) technology. Nevertheless, water vapour permeation is still facilitated by the presence of micro and nano-scale defects generated during the deposition processes of the barrier material, which results in decreased cell efficiency and reduced unit longevity. The state of the art surface metrology technologies including: optical microscopy, white light scanning interferometry (WLSI), atomic force microscopy (AFM) and scanning electron microscopy (SEM) were extensively deployed in this project as offline surface characterisation methods to characterise the water vapour barrier layer defects, which are postulated to be directly responsible for the water vapour ingress. Areal surface texture parameters analysis based on wolf pruning, area pruning and segmentation analysis methods as defined in ISO 25178-2; allow the efficient separation of small insignificant defects from significant defects. The presence of both large and small defects is then correlated with the barrier films functionality as measured on typical sets of Al2O3 ALD films using a standard MOCON® (quantitative gas permeation) test. The investigation results of the initial analysis finishes by drawing conclusions based on the analysis of the water vapour transmission rate (WVTR), defects size, density and distribution, where it is confirmed that small numbers of large defects have more influence on the deterioration of the barrier films functionality than large numbers of small defects. This result was then used to provide the basis for developing a roll-to-roll in process metrology device for quality control of flexible PV barrier films. Furthermore, a theoretical model approach was developed in this thesis based on the water vapour diffusion theory to determine the cut- off level between large significant defects and small insignificant defects. The results of the model would seem to reveal that, in order to build up in process, non-contact optical defect detection system for R2R barrier films, the critical spatial resolution required for defect detection need not be less than 3 μm laterally and 3Sq nm (Sq= root mean square surface roughness deviation of non-defective sample area) per field of view (FOV) vertically. Any defect that has dimensions less than this appears to have a significantly lower effect on the PV barrier properties and functionality. In this study, the surface topography analysis results and the theoretical model approach outcomes, both provide the basis for developing a R2R in process metrology device for PV barrier films defect detection. Eventually, the work in this thesis reports on the deployment of new (novel) in-line interferometric optical sensors based on wavelength scanning interferometry (WSI) designed to measure and catalogue the PV barrier films defects where they are present. The sensors have built-in environmental vibration compensation and are being deployed on a demonstrator system at a R2R production facility in the UK

Physics of the Cosmos (PCOS) Program Technology Development 2018

We present a final report on our program to raise the Technology Readiness Level (TRL) of enhanced chargecoupleddevice (CCD) detectors capable of meeting the requirements of Xray grating spectrometers (XGS) and widefield Xray imaging instruments for small, medium, and large missions. Because they are made of silicon, all Xray CCDs require blocking filters to prevent corruption of the Xray signal by outofband, mainly optical and nearinfrared (nearIR) radiation. Our primary objective is to demonstrate technology that can replace the fragile, extremely thin, freestanding blocking filter that has been standard practice with a much more robust filter deposited directly on the detector surface. Highperformance, backilluminated CCDs have flown with freestanding filters (e.g., one of our detectors on Suzaku), and other relatively lowperformance CCDs with directly deposited filters have flown (e.g., on the Xray Multimirror MissionNewton, XMMNewton Reflection Grating Spectrometer, RGS). At the inception of our program, a highperformance, backilluminated CCD with a directly deposited filter has not been demonstrated. Our effort will be the first to show such a filter can be deposited on an Xray CCD that meets the requirements of a variety of contemplated future instruments. Our principal results are as follows: i) we have demonstrated a process for direct deposition of aluminum optical blocking filters on backilluminated MIT Lincoln Laboratory CCDs. Filters ranging in thickness from 70 nm to 220 nm exhibit expected bulk visibleband and Xray transmission properties except in a small number (affecting 1% of detector area) of isolated detector pixels ("pinholes"), which show higherthanexpected visibleband transmission; ii) these filters produce no measurable degradation in softXray spectral resolution, demonstrating that direct filter deposition is compatible with the MIT Lincoln Laboratory backillumination process; iii) we have shown that under sufficiently intense visible and nearIR illumination, outofband light can enter the detector through its sidewalls and mounting surfaces, compromising detector performance. This 'sidewall leakage' has been observed, for example, by a previous experiment on the International Space Station during its orbitday operations. We have developed effective countermeasures for this sidewall leakage; iv) we developed an exceptionally productive collaboration with the Regolith Xray Imaging Spectrometer (REXIS) team. REXIS is a student instrument now flying on the Origins Spectral Interpretation Resource Identification Security - Regolith Explorer (OSIRISREx) mission. REXIS students participated in our filter development program, adopted our technology for their flight instrument, and raised the TRL of this technology beyond our initial goals. This Strategic Astrophysics Technology (SAT) project, a collaboration between the MKI and MIT Lincoln Laboratory, began July 1, 2012, and ended on June 30, 2018

Development of Microscopy Systems for Super-Resolution, Whole-Slide, Hyperspectral, and Confocal Imaging

Optical microscope is an important tool for researchers to study small objects. In this thesis, we will focus on the improvement of traditional microscope systems from several aspects including resolution, field of view, speed, cost, compactness, multimodality. In particular, we will investigate computational imaging methods that bypass the limitations with traditional microscope systems by combining the optical hardware design and image processing algorithm. Examples will include optimizing illumination strategy for the Fourier ptychography (FP), developing field-portable high-resolution microscope using a cellphone lens, investigating pattern-illuminated FP for fluorescence microscopy, demonstrating multimodal microscopic imaging with the use of liquid crystal display, achieving fast and accurate autofocusing for whole slide imaging system

NASA Tech Briefs, February 1996

Topics covered include: Materials; Computer Programs; Mechanics; Machinery/Automation; Manufacturing/Fabrication; Mathematics and Information Sciences; Life Sciences; Books and Reports

Program Annual Technology Report: Physics of the Cosmos Program Office

From ancient times, humans have looked up at the night sky and wondered: Are we alone? How did the universe come to be? How does the universe work? PCOS focuses on that last question. Scientists investigating this broad theme use the universe as their laboratory, investigating its fundamental laws and properties. They test Einsteins General Theory of Relativity to see if our current understanding of space-time is borne out by observations. They examine the behavior of the most extreme environments supermassive black holes, active galactic nuclei, and others and the farthest reaches of the universe, to expand our understanding. With instruments sensitive across the spectrum, from radio, through infrared (IR), visible light, ultraviolet (UV), to X rays and gamma rays, as well as gravitational waves (GWs), they peer across billions of light-years, observing echoes of events that occurred instants after the Big Bang. Last year, the LISA Pathfinder (LPF) mission exceeded expectations in proving the maturity of technologies needed for the Laser Interferometer Space Antenna (LISA) mission, and the Laser Interferometer Gravitational-Wave Observatory (LIGO) recorded the first direct measurements of long-theorized GWs. Another surprising recent discovery is that the universe is expanding at an ever-accelerating rate, the first hint of so-called dark energy, estimated to account for 75% of mass-energy in the universe. Dark matter, so called because we can only observe its effects on regular matter, is thought to account for another20%, leaving only 5% for regular matter and energy. Scientists now also search for special polarization in the cosmic microwave background to support the notion that in the split-second after the Big Bang, the universe inflated faster than the speed of light! The most exciting aspect of this grand enterprise today is the extraordinary rate at which we can harness technologies to enable these key discoveries

Characterization of Flow Dynamics in a Heart Simulator by means of PIV = Charakterisierung der Strömungsdynamik in einem Herzsimulator mittels PIV

Diese Arbeit konzentriert sich auf die strömungsmechanische Charakterisierung von Regurgitationsjets, die durch insuffiziente Mitralklappen entstehen. Die Untersuchungen wurden mit Particle Image Velocimetry (PIV) Messtechnik und eigens entwickelten Post-Processing-Skripten durchgeführt. Die Mitralinsuffizienz ist die häufigste Form der Herzklappenerkrankung und bezeichnet den Rückfluss von Blut in den linken Vorhof aufgrund einer insuffizienten Mitralklappe, was zu verschiedenen gesundheitlichen Komplikationen führt. Eine genaue Diagnose der Mitralinsuffizienz ist für eine erfolgreiche Behandlung von entscheidender Bedeutung. Bei komplexen Regurgitationsjets ist die Aussagekraft herkömmlicher Methoden jedoch limitiert. Diese Studie zielt darauf ab, das Verständnis für die komplexe Strömungssituation von Regurgitationsjets zu verbessern und so zur Verbesserung der Diagnose und damit der Therapie beizutragen. Dazu wurden phasengemittelte und phasenaufgelöste 2D2C-PIV-Experimente für verschiedene Mitralklappengeometrien im Herzsimulator durchgeführt. Der Laserlichtschnitt wurde traversiert, um quasi 3D Geschwindigkeitsdaten zu erhalten. Drei generische Mitralklappengeometrien unterschiedlicher Größe wurden untersucht: eine runde Lochblende, ein spitzes Oval und eine Tropfenform. Zusätzlich wurden eine exzentrische Klappengeometrie und eine patienten-spezifische Klappe untersucht. Die Geschwindigkeitsdaten wurden bezüglich zeitlichem Strömungsverlauf und Form des Jets untersucht. Die Wirbeldynamische Untersuchung basierte auf der Wirbelstärke, sowie dem Q- und $\Gamma_1$-Kriterium. Die Ergebnisse der generischen Mitralklappen zeigten typische Merkmale von pulsierenden Jets. Unterschiede in der radialen Geschwindigkeitsverteilung konnten mit den unterschiedlichen Öffnungsformen in Verbindung gebracht werden. Die Sattel-behafteten radialen Profile der Axialgeschwindigkeit am Auslass können durch die geringe Einlasslänge und die scharfen Öffnungsränder erklärt werden. Zusätzlich zu periodisch wiederkehrenden Anfangswirbeln wurden Kelvin-Helmholtz-Instabilitäten in der Grenzschicht stromaufwärts detektiert. Die exzentrische Klappengeometrie zeigte ähnliche Beobachtungen, jedoch um den Winkel der Exzentrizität gedreht. Die patientenspezifische Mitralklappe ergab, im Vergleich zu den generischen Fällen,eine deutlich instabilere und turbulentere Strömungssituation, was auf die komplexere Öffnungsform, die höhere Reynoldszahl und die größere Flexibilität der Klappenblätter zurückzuführen ist. Form und Richtung des Jets unterlagen starken zeitlichen und räumlichen Schwankungen. Gemittelte PIV-Auswertungen ergaben ein dominantes Anfangswirbelpaar, während Einzelbildpaarauswertungen keine eindeutige Wirbelerkennung zeigten. Für zukünftige Untersuchungen wird empfohlen, das Innere des Atriums mit einer realistischeren Geometrie zu modellieren und Hochgeschwindigkeits-PIV zu verwenden

Cumulative index to NASA Tech Briefs, 1986-1990, volumes 10-14

Tech Briefs are short announcements of new technology derived from the R&D activities of the National Aeronautics and Space Administration. These briefs emphasize information considered likely to be transferrable across industrial, regional, or disciplinary lines and are issued to encourage commercial application. This cumulative index of Tech Briefs contains abstracts and four indexes (subject, personal author, originating center, and Tech Brief number) and covers the period 1986 to 1990. The abstract section is organized by the following subject categories: electronic components and circuits, electronic systems, physical sciences, materials, computer programs, life sciences, mechanics, machinery, fabrication technology, and mathematics and information sciences

Tactile and Touchless Sensors Printed on Flexible Textile Substrates for Gesture Recognition

Tesis por compendio[EN] The main objective of this thesis is the development of new sensors and actuators using Printed Electronics technology. For this, conductive, semiconductor and dielectric polymeric materials are used on flexible and/or elastic substrates. By means of suitable designs and application processes, it is possible to manufacture sensors capable of interacting with the environment. In this way, specific sensing functionalities can be incorporated into the substrates, such as textile fabrics. Additionally, it is necessary to include electronic systems capable of processing the data obtained, as well as its registration. In the development of these sensors and actuators, the physical properties of the different materials are precisely combined. For this, multilayer structures are designed where the properties of some materials interact with those of others. The result is a sensor capable of capturing physical variations of the environment, and convert them into signals that can be processed, and finally transformed into data. On the one hand, a tactile sensor printed on textile substrate for 2D gesture recognition was developed. This sensor consists of a matrix composed of small capacitive sensors based on a capacitor type structure. These sensors were designed in such a way that, if a finger or other object with capacitive properties, gets close enough, its behaviour varies, and it can be measured. The small sensors are arranged in this matrix as in a grid. Each sensor has a position that is determined by a row and a column. The capacity of each small sensor is periodically measured in order to assess whether significant variations have been produced. For this, it is necessary to convert the sensor capacity into a value that is subsequently digitally processed. On the other hand, to improve the effectiveness in the use of the developed 2D touch sensors, the way of incorporating an actuator system was studied. Thereby, the user receives feedback that the order or action was recognized. To achieve this, the capacitive sensor grid was complemented with an electroluminescent screen printed as well. The final prototype offers a solution that combines a 2D tactile sensor with an electroluminescent actuator on a printed textile substrate. Next, the development of a 3D gesture sensor was carried out using a combination of sensors also printed on textile substrate. In this type of 3D sensor, a signal is sent generating an electric field on the sensors. This is done using a transmission electrode located very close to them. The generated field is received by the reception sensors and converted to electrical signals. For this, the sensors are based on electrodes that act as receivers. If a person places their hands within the emission area, a disturbance of the electric field lines is created. This is due to the deviation of the lines to ground using the intrinsic conductivity of the human body. This disturbance affects the signals received by the electrodes. Variations captured by all electrodes are processed together and can determine the position and movement of the hand on the sensor surface. Finally, the development of an improved 3D gesture sensor was carried out. As in the previous development, the sensor allows contactless gesture detection, but increasing the detection range. In addition to printed electronic technology, two other textile manufacturing technologies were evaluated.[ES] La presente tesis doctoral tiene como objetivo fundamental el desarrollo de nuevos sensores y actuadores empleando la tecnología electrónica impresa, también conocida como Printed Electronics. Para ello, se emplean materiales poliméricos conductores, semiconductores y dieléctricos sobre sustratos flexibles y/o elásticos. Por medio de diseños y procesos de aplicación adecuados, es posible fabricar sensores capaces de interactuar con el entorno. De este modo, se pueden incorporar a los sustratos, como puedan ser tejidos textiles, funcionalidades específicas de medición del entorno y de respuesta ante cambios de este. Adicionalmente, es necesario incluir sistemas electrónicos, capaces de realizar el procesado de los datos obtenidos, así como de su registro. En el desarrollo de estos sensores y actuadores se combinan las propiedades físicas de los diferentes materiales de forma precisa. Para ello, se diseñan estructuras multicapa donde las propiedades de unos materiales interaccionan con las de los demás. El resultado es un sensor capaz de captar variaciones físicas del entorno, y convertirlas en señales que pueden ser procesadas y transformadas finalmente en datos. Por una parte, se ha desarrollado un sensor táctil impreso sobre sustrato textil para reconocimiento de gestos en 2D. Este sensor se compone de una matriz formada por pequeños sensores capacitivos basados en estructura de tipo condensador. Estos se han diseñado de forma que, si un dedo u otro objeto con propiedades capacitivas se aproxima suficientemente, su comportamiento varía, pudiendo ser medido. Los pequeños sensores están ordenados en dicha matriz como en una cuadrícula. Cada sensor tiene una posición que viene determinada por una fila y por una columna. Periódicamente se mide la capacidad de cada pequeño sensor con el fin de evaluar si ha sufrido variaciones significativas. Para ello es necesario convertir la capacidad del sensor en un valor que posteriormente es procesado digitalmente. Por otro lado, con el fin de mejorar la efectividad en el uso de los sensores táctiles 2D desarrollados, se ha estudiado el modo de incorporar un sistema actuador. De esta forma, el usuario recibe una retroalimentación indicando que la orden o acción ha sido reconocida. Para ello, se ha complementado la matriz de sensores capacitivos con una pantalla electroluminiscente también impresa. El resultado final ofrece una solución que combina un sensor táctil 2D con un actuador electroluminiscente realizado mediante impresión electrónica sobre sustrato textil. Posteriormente, se ha llevado a cabo el desarrollo de un sensor de gestos 3D empleando una combinación de sensores impresos también sobre sustrato textil. En este tipo de sensor 3D, se envía una señal que genera un campo eléctrico sobre los sensores impresos. Esto se lleva a cabo mediante un electrodo de transmisión situado muy cerca de ellos. El campo generado es recibido por los sensores y convertido a señales eléctricas. Para ello, los sensores se basan en electrodos que actúan de receptores. Si una persona coloca su mano dentro del área de emisión, se crea una perturbación de las líneas de los campos eléctricos. Esto es debido a la desviación de las líneas de campo a tierra utilizando la conductividad intrínseca del cuerpo humano. Esta perturbación cambia/afecta a las señales recibidas por los electrodos. Las variaciones captadas por todos los electrodos son procesadas de forma conjunta pudiendo determinar la posición y el movimiento de la mano sobre la superficie del sensor. Finalmente, se ha llevado a cabo el desarrollo de un sensor de gestos 3D mejorado. Al igual que el desarrollo anterior, permite la detección de gestos sin necesidad de contacto, pero incrementando la distancia de alcance. Además de la tecnología de impresión electrónica, se ha evaluado el empleo de otras dos tecnologías de fabricación textil.[CA] La present tesi doctoral té com a objectiu fonamental el desenvolupament de nous sensors i actuadors fent servir la tecnologia de electrònica impresa, també coneguda com Printed Electronics. Es va fer us de materials polimèrics conductors, semiconductors i dielèctrics sobre substrats flexibles i/o elàstics. Per mitjà de dissenys i processos d'aplicació adequats, és possible fabricar sensors capaços d'interactuar amb l'entorn. D'aquesta manera, es poden incorporar als substrats, com ara teixits tèxtils, funcionalitats específiques de mesurament de l'entorn i de resposta davant canvis d'aquest. Addicionalment, és necessari incloure sistemes electrònics, capaços de realitzar el processament de les dades obtingudes, així com del seu registre. En el desenvolupament d'aquests sensors i actuadors es combinen les propietats físiques dels diferents materials de forma precisa. Cal dissenyar estructures multicapa on les propietats d'uns materials interaccionen amb les de la resta. manera El resultat es un sensor capaç de captar variacions físiques de l'entorn, i convertirles en senyals que poden ser processades i convertides en dades. D'una banda, s'ha desenvolupat un sensor tàctil imprès sobre substrat tèxtil per a reconeixement de gestos en 2D. Aquest sensor es compon d'una matriu formada amb petits sensors capacitius basats en una estructura de tipus condensador. Aquests s'han dissenyat de manera que, si un dit o un altre objecte amb propietats capacitives s'aproxima prou, el seu comportament varia, podent ser mesurat. Els petits sensors estan ordenats en aquesta matriu com en una quadrícula. Cada sensor té una posició que ve determinada per una fila i per una columna. Periòdicament es mesura la capacitat de cada petit sensor per tal d'avaluar si ha sofert variacions significatives. Per a això cal convertir la capacitat del sensor a un valor que posteriorment és processat digitalment. D'altra banda, per tal de millorar l'efectivitat en l'ús dels sensors tàctils 2D desenvolupats, s'ha estudiat la manera d'incorporar un sistema actuador. D'aquesta forma, l'usuari rep una retroalimentació indicant que l'ordre o acció ha estat reconeguda. Per a això, s'ha complementat la matriu de sensors capacitius amb una pantalla electroluminescent també impresa. El resultat final ofereix una solució que combina un sensor tàctil 2D amb un actuador electroluminescent realitzat mitjançant impressió electrònica sobre substrat tèxtil. Posteriorment, s'ha dut a terme el desenvolupament d'un sensor de gestos 3D emprant una combinació d'un mínim de sensors impresos també sobre substrat tèxtil. En aquest tipus de sensor 3D, s'envia un senyal que genera un camp elèctric sobre els sensors impresos. Això es porta a terme mitjançant un elèctrode de transmissió situat molt a proper a ells. El camp generat és rebut pels sensors i convertit a senyals elèctrics. Per això, els sensors es basen en elèctrodes que actuen de receptors. Si una persona col·loca la seva mà dins de l'àrea d'emissió, es crea una pertorbació de les línies dels camps elèctrics. Això és a causa de la desviació de les línies de camp a terra utilitzant la conductivitat intrínseca de el cos humà. Aquesta pertorbació afecta als senyals rebudes pels elèctrodes. Les variacions captades per tots els elèctrodes són processades de manera conjunta per determinar la posició i el moviment de la mà sobre la superfície del sensor. Finalment, s'ha dut a terme el desenvolupament d'un sensor de gestos 3D millorat. A l'igual que el desenvolupament anterior, permet la detecció de gestos sense necessitat de contacte, però incrementant la distància d'abast. A més a més de la tecnologia d'impressió electrònica, s'ha avaluat emprar altres dues tecnologies de fabricació tèxtil.Ferri Pascual, J. (2020). Tactile and Touchless Sensors Printed on Flexible Textile Substrates for Gesture Recognition [Tesis doctoral no publicada]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/153075TESISCompendi