Statistical approach to choosing a strategy of monochromatic monitoring of optical coating production

Noble Infrared Optical Thickness Monitoring System Based on the Algorithm of Phase-Locked Output Current–Reflectivity Coefficient

With the rapid development of modern science and technology, the application of infrared (IR) optical thin films is increasingly widespread, including in aerospace, autonomous driving, military development, and the fight against Coronavirus Disease 2019 (COVID-19), in which thin film devices play an important role. Similarly, with the improvement of user requirements, the precision requirements for the preparation of optical films are also developing and improving. In this paper, the IR optical thickness monitoring system is studied with the noble algorithm introducing the phase-locked amplifier current and single film reflectivity coefficient. An optical control system is developed to monitor the IR thin film accurately, which aids the IR narrow-band filter film research.

Automated optical monitoring wavelength selection for thin-film filters

In this paper we study the wavelength selection process for optical monitoring of thin film filters. We first discuss the technical limitations of monitoring systems as well as the criteria defining the sensitivity of different wavelengths to thickness errors. We then present an approach that considers the best monitoring wavelength for each individual layer with a monitoring strategy selection process that can be fully automated. We finally validate experimentally the proposed approach on several optical filters of increasing complexity. Optical interference filters with close to theoretical performances are demonstrated.

Fabrication of short-wavelength infrared dual-band-pass filter based on combination of Fabry-Perot filters

Dual-band-pass filters are key optical components in dual-spectral detection applications; it is imperative to fabricate them in a relatively simple way for practical use. In this paper, a dual-band-pass filter working in short-wavelength infrared is developed by the combination of two Fabry-Perot (F-P) filters, each having a transparent band. These two filters are designed separately, and deposited at different sides of a substrate. The total layers' number of the dual-band-pass filter is limited to 34; these layers are monitored by the method of direct transmittance level cut monitoring with a single monitor wavelength. The percent of optical extrema monitoring strategy is adopted in the deposition. The spectra of the F-P filters and the dual-band-pass filter are tested. The shorter pass-band's average transmittance is above 84%, the longer one is above 88%, and four of the pass-bands' edge steepness values are 1.4%,2.8%,1.9%, and 1.7%.

Advantages and challenges of optical coating production with indirect monochromatic monitoring

In this paper, we present our recent studies on raising the quality of optical coating production with an indirect monochromatic monitoring system. Preproduction error analysis and computational manufacturing are used to estimate potential advantages of application of indirect optical monitoring. It is then demonstrated that a key issue for realization of this advantage is accurate specification of tooling factors for layer thicknesses on test glasses. The tooling factors are precalibrated using single layer depositions and then are corrected using results of reverse engineering for the first production run. It is found that a gradual variation of tooling factors of low index layers is the main error factor in the first deposition run. Finally, we redeposit our coating with a modified monitoring strategy, taking into account this factor. The new experimental results show excellent correspondence with the theoretical spectral performance.

Automated construction of monochromatic monitoring strategies

We focus our efforts on development of an advanced monochromatic monitoring strategy to assist the optical coating engineer in finding a single wavelength or a sequence of monitoring wavelengths that meet simultaneously several practical demands, namely, specified input and output swing values, specified amplitude of a monitoring signal variation, and the distance between trigger point and the last signal extremum. Additionally, the most important demand is that the number of different monitoring wavelengths must be as small as possible. Manual construction of such a monitoring strategy is almost impossible because of a large number of conditions to be satisfied. We propose an algorithm that automatically generates a monitoring spreadsheet so that all demands can be satisfied as closely as possible. We consider six typical design problems and obtain a series of solutions for each of them. Then, we provide computational simulations of deposition processes assuming that they are controlled by monochromatic monitoring with the monitoring strategy generated by our algorithm, and we demonstrate how an optical coating engineer can select design solutions that exhibit the highest production yields.

Application of image spectrometer to in situ infrared broadband optical monitoring for thin film deposition

A path-folded infrared image spectrometer with five sub-gratings and five linear-array detectors was applied to a broadband optical monitoring (BOM) system for thin film deposition. Through in situ BOM, we can simultaneously acquire the thickness and refractive index of each layer in real time by fitting the measured spectra, and modify the deposition parameters during deposition process according to the fitting results. An effective data processing method was proposed and applied in the BOM process, and it shortened the data processing time and improved the monitoring efficiency greatly. For demonstration, a narrow band-pass filter (NBF) at 1540 nm with ~10 nm full width at half-maximum (FWHM) had been manufactured using the developed BOM system, and the results showed that this BOM method was satisfying for monitoring deposition of thin film devices.

Estimations of production yields for selection of a practical optimal optical coating design

Modern design approaches enable one to construct a series of theoretical designs with excellent spectral properties for almost all optical coating design problems. Selection of a practical optimal design among a variety of possible theoretical designs becomes a key issue. We demonstrate how preproduction estimations of expected production yields can be used for selection of a practical optimal design. The question of reliability of such estimations is also addressed.

Investigation of the error self-compensation effect associated with broadband optical monitoring

A rigorous definition of the error self-compensation effect is provided. An existence of this effect in the case of coating production with broadband optical monitoring of layer thicknesses is investigated for several widely used types of optical coatings.

Dual wavelengths monitoring for optical coatings

A new monitoring method based on the use of dual wavelengths monitoring is proposed. Firstly, the sensitivity of each layer in an optical coating for the monitoring wavelength is calculated by admittance equations. Then two appropriate monitoring wavelengths are chosen to make sure that every layer has a sensitive terminal point. The thickness error of the layer can be compensated. For quarter-wave multilayer and nonquarter-wave multilayer optical coatings, the advantage of this new monitoring method has been demonstrated by both the theoretical analyses and experimental results.

In situ optical characterization and reengineering of interference coatings

A new optical monitoring system has been developed that allows recording of transmission spectra in the wavelength range between 400 and 920 nm of a growing optical coating during deposition. Several kinds of thin film sample have been prepared by use of a hybrid monitoring strategy that is essentially based on a combination of quartz monitoring and in situ transmission spectra measurements. We demonstrate and discuss the applicability of our system for reengineering procedures of high-low stacks and measurements of small vacuum or thermal shifts of optical coatings.

Computational experiments on optical coating production using monochromatic monitoring strategy aimed at eliminating a cumulative effect of thickness errors

We present an algorithm for the automatic generation of a monitoring spreadsheet that enables the most effective application of the termination level correction algorithm proposed in our previous publication. On a whole the presented monochromatic monitoring strategy entirely eliminates a cumulative effect of thickness errors in optical coating production using direct optical monitoring. The effectiveness of the new monitoring strategy is demonstrated by computational manufacturing experiments in which such error factors as instability of deposition rates, errors in measured transmittance data, shutter delays, and variations of layer refractive indices from their theoretical values are simulated.