The new generation of sub-10µm pixel pitch bolometers are currently arriving on the market for uncooled LWIR detectors. Pixel pitches are now starting to get smaller than the wavelength of light. The effect on the requirements for new lenses is still an open question, which in turn relies on the increased efficiency of this new generation of micro-bolometers. This study looks into the possible improvements expected on the lens side, whether it is needed to compensate the lower performance of the detectors and at what cost.
Infrared cameras could serve automotive applications by delivering breakthrough perception systems for both in-cabin passengers monitoring and car surrounding. However, low-cost and high-throughput manufacturing methods are essential to sustain the growth in thermal imaging markets for automotive applications, and for other close-to-consumer applications which have a fast growth potential. Fast low cost infrared lenses suitable for microbolometers are currently already sold by companies like Umicore, Lightpath, FLIR… They are either made of a single inverse meniscus Chalcogenide glass or of two Silicon optics. In this paper, we explore hybrid systems with a large field of view around 40° combining Chalcogenide and Silicon in order to take advantage of both materials. Both are compatible with wafer-level process. Silicon optics can be manufactured by photolithography process and are expected to be more cost-effective than Chalcogenide ones. However they are constrained in shape and sag height. On the other hand, Chalcogenide optics can be collectively molded and could have more free shapes. They are thus more suitable to reach high-demanding performance. So hybrid designs could be seen as a compromise between cost and performance. In this paper, we show that fast lenses with diameter constraints to few millimeters to make affordable wafer-level process lead to small size detectors. As a consequence, the pixel pitch reduction of microbolometers is a key point to maintain a good resolution. Finally, strategies to improve the production yield of hybrid lenses are explored.
In this paper we present techniques for measuring efficiently the optical properties of chalcogenide glasses. In particular we discuss methods for measuring refractive index and the variation of refractive index with temperature. We then apply these techniques to a new glass composition and demonstrate a high index of 3.26 @10 μm and a large thermo-optic coefficient of 1.99 ⋅ 10−4 K−1. These properties make this glass a good candidate for replacing germanium.
The last twenty years have seen a dramatic improvement in the performance of infrared detectors, especially those with uncooled microbolometer arrays. These make new commercial applications possible, from the Internet of things to drones for crop monitoring. Such emerging markets are constantly pushing the requirements on the existing technology to improve cost, performance, weight and size. In this context, gradient index (GRIN) lenses can offer a new degree of freedom compared to their homogeneous counterparts. For example, recent papers have shown how GRIN lenses could help reduce the number of elements in a system, by helping correct lens chromatism and athermalization. While the interest in using GRIN is obvious, mastering their fabrication with infrared materials remains highly challenging. Encouraging progress has been made in that direction, for instance by stacking different materials or by laser writing. Very recently, it has been demonstrated that partial crystallization of chalcogenide glass allows for tuning the refractive index. In this paper, we introduce a new technique based on the controlled formation of nano-crystallites in chalcogenide glass to fabricate the first macroscopic radial GRIN in the infrared. We also propose a simple way to test the index gradient value by interferometry and demonstrate GRIN with index contrast of ▵n ~ 3⋅10-2 between the center and the edge of the disk. The process is easily repeated and opens the possibility for a rapid transfer to the industry.
Over recent years, the pixel size of uncooled thermal detectors has kept shrinking, going from 50 μm in the last decade to 17 μm today. The latest generation of detectors, with 12 μm pixel pitch and smaller, come with a new set of challenges. In this paper, we investigate the link between pixel size and optics cost and performance by relying on a well-defined framework and concrete examples. First, we briefly clarify the relationship between the reduction in pixel size and requirements on the optics, from both the radiometric and the resolution point of view. Within this framework, we study the effect of decenter corresponding to current state-of-the art manufacturing on performance and price of lenses. Finally we demonstrate that reducing the pixel size indirectly leads to much more demanding lenses. As the new generation of 12 μm pixel pitch arrays are emerging in the long wave infrared, lenses will become more complex and harder to manufacture. Consequently, optics with equivalent levels of performance can become more expensive.
Changes in the position of best focus over temperature are a major source of contrast degradation in the long-wave infrared. The prime sources of this focus shift are the difference between thermal expansion coefficients of lens material and housing material, and the change in refractive index over temperature ∂n/∂T. These parameters, combined with the limited depth of focus when using lenses for uncooled detectors, can rapidly degrade performance with changing temperature. Firstorder paraxial calculations to model these changes are discussed, with a demonstration of its application to single-element imaging systems. The model is then expanded to include two-element systems where both elements are made of the same optical material, or the more general case where different materials are combined. It is shown how a chalcogenide glasses are well suited for athermalization, and how a combination of material choice and optical prescription can lead to an improved passive optical athermalization scheme, i.e. stable performance over temperature with no moving components. The limits of the used model are discussed and examples given for various focal lengths.
For many years, the Thermal Imaging market has been driven by the high volume consumer market. The first signs of
this came with the launch of night vision systems for cars, first by Cadillac and Honda and then, more successfully by
BMW, Daimler and Audi. For the first time, simple thermal imaging systems were being manufactured at the rate of
more than 10,000 units a year. This step change in volumes enabled a step change in system costs, with thermal imaging
moving into the consumer’s price range.
Today we see that the consumer awareness and the consumer market continues to increase with the launch of a number
of consumer focused smart phone add-ons. This has brought a further step change in system costs, with the possibility to
turn your mobile phone into a thermal imager for under $250.
As the detector technology has matured, the pixel pitches have dropped from 50μm in 2002 to 12 μm or even 10μm in
today’s detectors. This dramatic shrinkage in size has had an equally dramatic effect on the optics required to produce
the image on the detector. A moderate field of view that would have required a focal length of 40mm in 2002 now
requires a focal length of 8mm. For wide field of view applications and small detector formats, focal lengths in the range
1mm to 5mm are becoming common.
For lenses, the quantity manufactured, quality and costs will require a new approach to high volume Infra-Red (IR)
manufacturing to meet customer expectations. This, taken with the SwaP-C requirements and the emerging requirement
for very small lenses driven by the new detectors, suggests that wafer scale optics are part of the solution. Umicore can
now present initial results from an intensive research and development program to mold and coat wafer level optics,
using its chalcogenide glass, GASIR®.
Modern thermal imaging lenses for uncooled detectors are high aperture systems. Very often, their aperture based fnumber is faster than 1.2. The impact of this on the depth of field is dramatic, especially for narrow field lenses. The users would like to know how the image quality changes with and without refocusing for objects at different distances from the camera core. The Depth of Field approach presented here is based on the lens specific Through Focus MTF. It will be averaged for the detector area. The lens specific Through Focus MTF will be determined at the detector Nyquist frequency, which is defined by the pixel pitch. In this way, the specific lens and the specific FPA-geometry (pixel pitch, detector area) are considered. The condition, that the Through Focus MTF at full Nyquist must be higher than 0.25, defines a certain symmetrical depth of focus. This criterion provides a good discrimination for reasonable lens/detector combinations. The examples chosen reflect the actual development of uncooled camera cores. The symmetrical depth of focus is transferred to object space using paraxial relations. This defines a typical depth of field diagram containing three functions: Hyperfocal distance, nearest and furthest distance versus sharp distance (best focus). Pictures taken with an IR Camera illustrate the effect in the depth of field and its dependence on focal length. These pictures confirm the methodology. A separate problem is the acceptable drop of resolution in combination with a specific camera core and specific object scenes. We propose to evaluate the MTF-graph at half Nyquist frequency. This quantifies the resolution loss without refocus in accordance with the IR-picture degradation at the limits of the Depth of Field. The approach is applied to different commercially available lenses. Pictures illustrate the Depth of Field for different pixel pitches and pixel counts.
Transmission is a key parameter in describing an IR-lens, but is also often the subject of controversy. One reason is the misinterpretation of “transmission” in infrared camera practice. If the camera lens is replaced by an alternative one the signal will be affected by two parameters: proportional to the square of the effective aperture based F-number and linearly to the transmission. The measure to collect energy is defined as the Energy Throughput ETP, and the signal level of the IR-camera is proportional to ETP. Most published lens transmission values are based on spectrophotometric measurement of plane-parallel witness pieces obtained from coating processes. Published aperture based F-numbers derive very often from ray tracing values in the on-axis bundle. The following contribution is about transmission measurement. It highlights the bulk absorption and coating issues of infrared lenses. Two different setups are built and tested, an Integrating Sphere (IS)-based setup and a Camera-Based (CB) setup. The comparison of the two principles also clarifies the impact of the F-number. One difficulty in accurately estimating lens transmission lies in measuring the ratio between the signal of ray bundles deviated by the lens under test and the signal of non-deviated ray bundles without lens (100% transmission). There are many sources for errors and deviations in LWIR-region including: background radiation, reflection from “rough” surfaces, and unexpected transmission bands. Care is taken in the set up that measured signals with and without the lens are consistent and reproducible. Reference elements such as uncoated lenses are used for calibration of both setups. When solid angle-based radiometric relationships are included, both setups yield consistent transmission values. Setups and their calibration will be described and test results on commercially available lenses will be published.
In recent years, thermal detectors with a 17 μm pixel pitch have become well-established for use in various applications, such as thermal imaging in cars. This has allowed the civilian infrared market to steadily mature. The main cost for these lens designs comes from the number of lenses used. The development of thermal detectors, which are less sensitive than quantum detectors, has compelled camera manufacturers to demand very fast F-numbers such as f/1.2 or faster. This also minimizes the impact of diffraction in the 8-12 μmm waveband. The freedom afforded by the choice of the stop position in these designs has been used to create high-resolution lenses that operate near the diffraction limit. Based on GASIR®1, a chalcogenide glass, two-lens designs have been developed for all pixel counts and fields of view. Additionally, all these designs have been passively athermalized, either optically or mechanically. Lenses for cooled quantum detectors have a defined stop position called the cold stop (CS) near the FPA-plane. The solid angle defined by the CS fixes not only the F-number (which is less fast than for thermal detectors), but determines also the required resolution. The main cost driver of these designs is the lens diameter. Lenses must be sufficiently large to avoid any vignetting of ray bundles intended to reach the cooled detector. This paper studies the transfer of approved lens design principles for thermal detectors to lenses for cooled quantum detectors with CS for same pixel count at three horizontal fields of view: a 28° medium field lens, an 8° narrow field lens, and a 90° wide field lens. The lens arrangements found for each category have similar lens costs.
In the 8-12 micron waveband Focal Plane Arrays (FPA) are available with a pixel pitch of 12 microns or less. High resolution FPAs with VGA, XGA and SXGA resolution should become available at a reasonable price. These will require new lens designs to give the required fields of view. The challenge for the Optical Designer is to design lenses when the pixel pitch of the detector is the same as the wavelength of the light imaged. The lens specification will need to give more thought to the resolution required by the system. A smaller pixel pitch detector defines a requirement for a shorter focal length to give the same field of view. This will have a number of effects upon the lens design. Geometrical aberrations decrease proportionally with the focal length. Reverse telephoto layouts will become more common, particularly when the system has a shutter. The increase in pixel count will require wide field of view lenses which present particular challenges. The impact of diffraction effects on the lens design is considerably increased. The fast F-number causes an increase in the diffraction limit of the system, but also increases geometric aberrations by a cube law. Therefore the balance between the diffraction limited and the aberration limited performance becomes more difficult. The first approach of the designer is to re-use proven designs originally intended for use with 17micron detectors. Some of these designs will have adequate performance at the Nyquist limit of the 12 micron detectors. Even smaller detector pitches, such as 10 micron, will demand new approaches to Infra Red lens design. The traditional approach will quickly increase the number of elements to 3 or even more. This could lead to the lenses with medium fields of view driving the system cost. A close cooperation between the camera developer and lens designer will become necessary in order to explore alternate approaches, such as wavefront coding, in order to reach the most cost effective solution.
Passive athermalization has become a key-technology for automotive and other outdoor applications using modern
uncooled 25 and 17 micron bolometer arrays. For high volume applications, passive athermalized optical designs
with only two lenses reduce costs. A two lens solution requires a careful choice of lens and housing materials.
A first order approach to thermal drift uses the RAYLEIGH criteria for depth of focus. It can be seen that narrow
field of view lenses are the most sensitive to defocus with temperature. The different methods used to achieve stable
performance over the required Temperature Range can be compared, namely passive optical athermalization and
passive mechanical athermalization. GASIR® possesses inherent properties enabling optical passive athermalization.
High resolution, two element designs for different field angles are presented. Each lens category is present: Super
Wide Angle, Wide Angle, Standard, Tele and Super Tele. All examples are designed for 17micron VGA-detectors.
These designs use aspheres and diffractive structures.
The impact of temperature on all these parameters can only be determined by ray tracing. The proposed metric is the
average of the tangential and sagittal MTF versus image height at Nyquist frequency. A very nonlinear impact of
temperature on MTFA at different image heights is clearly visible. Examples are shown.
An MTF based criteria for judging athermalization is proposed. It contains two values: the admissible MTF-drop
▵MTF in % and the resulting Temperature Range ▵T in Kelvin. The procedure to get these values is demonstrated.
Values of 9 lens assemblies are listed. A comparison with results of first order approach shows limitations of this
approach.
A general quantification of athermalization is proposed. The pair of values (▵MTF, ▵T) is independent of other lens
indexes. The limitations of this method are discussed.
In the 8-12 micron waveband Focal Plane Arrays (FPA) are available with a 17 micron pixel pitch in different arrays sizes
(e.g. 512 x 480 pixels and 320 x 240 pixels) and with excellent electrical properties. Many applications become possible
using this new type of IR-detector which will become the future standard in uncooled technology.
Lenses with an f-number faster than f/1.5 minimize the diffraction impact on the spatial resolution and guarantee a high
thermal resolution for uncooled cameras. Both effects will be quantified. The distinction between Traditional f-number (TF)
and Radiometric f-number (RF) is discussed.
Lenses with different focal lengths are required for applications in a variety of markets. They are classified by their
Horizontal field of view (HFOV). Respecting the requirements for high volume markets, several two lens solutions will be
discussed.
A commonly accepted parameter of spatial resolution is the Modulation Transfer Function (MTF)-value at the Nyquist
frequency of the detector (here 30cy/mm). This parameter of resolution will be presented versus field of view. Wide Angle
and Super Wide Angle lenses are susceptible to low relative illumination in the corner of the detector. Measures to reduce
this drop to an acceptable value are presented.
The next generation of automotive Night Vision Enhancement systems offers automatic pedestrian recognition with a
performance beyond current Night Vision systems at a lower cost. This will allow high market penetration, covering the
luxury as well as compact car segments.
Improved performance can be achieved by fusing a Far Infrared (FIR) sensor with a Near Infrared (NIR) sensor.
However, fusing with today's FIR systems will be too costly to get a high market penetration. The main cost drivers of
the FIR system are its resolution and its sensitivity. Sensor cost is largely determined by sensor die size. Fewer and
smaller pixels will reduce die size but also resolution and sensitivity. Sensitivity limits are mainly determined by
inclement weather performance. Sensitivity requirements should be matched to the possibilities of low cost FIR optics,
especially implications of molding of highly complex optical surfaces. As a FIR sensor specified for fusion can have
lower resolution as well as lower sensitivity, fusing FIR and NIR can solve performance and cost problems.
To allow compensation of FIR-sensor degradation on the pedestrian detection capabilities, a fusion approach called
MultiSensorBoosting is presented that produces a classifier holding highly discriminative sub-pixel features from both
sensors at once. The algorithm is applied on data with different resolution and on data obtained from cameras with
varying optics to incorporate various sensor sensitivities. As it is not feasible to record representative data with all
different sensor configurations, transformation routines on existing high resolution data recorded with high sensitivity
cameras are investigated in order to determine the effects of lower resolution and lower sensitivity to the overall
detection performance. This paper also gives an overview of the first results showing that a reduction of FIR sensor
resolution can be compensated using fusion techniques and a reduction of sensitivity can be compensated.
Small size and low weight are among the main drivers in modern military hand-held applications. Consequently, design-ers of such systems strive for combining multiple optical and electronic functions into the same piece of hardware. Present paper deals with the partial integration of an eye safe laser rangefinder into an optical channel for uncooled thermal imager using UMICORE's GASIR® optics. GASIR® is a chalcogenide glass with a transmission window from 0.8-15 µm, making it an effective material for use in near infrared, mid-wave infrared and far infrared applications.
Due to the fact that uncooled sensors in the LWIR spectral band require optics with low f/numbers and that laser range-finders typically need a larger receiver aperture - in order to comply with the maximum range requirement - this ap-proach at first sight promises favorable synergies. However, it soon turns out that such a dual band approach makes life for the rangefinder part of the job difficult - by imposing special surface types required for achieving optical specifica-tions of the thermal channel, which may deteriorate the beam quality of the laser light as well as by introducing special coatings with potentially insufficient transmission at the specific laser wavelength. Several design versions have been developed and evaluated with the purpose of finding optimal balance between image quality of the thermal channel and the laser rangefinder performance.
In this paper various optical and coating design aspects will be addressed together with the limitations of such a multi-spectral approach.
The interest in new infrared materials has grown rapidly during the last decade, one reason being the increasing cost of traditional Germanium, with in the meantime, a decrease of the cost of infrared detectors.
In response to this Umicore has developed the GASIR® range of optical materials. A key strength of the new material is that it can be molded, leading to particularly cost effective solutions for high volume requirements. This paper reviews the GASIR®1 material relative to some of the existing materials and presents a case study of an optical design using GASIR®. In particular the effect of thermal cycling on survivability and performance are examined.
The case study includes Umicore's recently developed iDLC(tm) coating. This coating complies with the specifications for "Diamond Like Carbon" coatings and can thus suit a broad range of applications such as thermography, fire fighting, etc.
A new low-cost long-wavelength infrared bolometer camera system is under development. It is designed for use with an
automatic vision algorithm system as a sensor to detect vulnerable road users in traffic. Looking 15 m in front of the
vehicle it can in case of an unavoidable impact activate a brake assist system or other deployable protection system. To
achieve our cost target below €100 for the sensor system we evaluate the required performance and can reduce the
sensitivity to 150 mK and pixel resolution to 80 x 30. We address all the main cost drivers as sensor size and production
yield along with vacuum packaging, optical components and large volume manufacturing technologies.
The detector array is based on a new type of high performance thermistor material. Very thin Si/SiGe single crystal
multi-layers are grown epitaxially. Due to the resulting valence barriers a high temperature coefficient of resistance is
achieved (3.3%/K). Simultaneously, the high quality crystalline material provides very low 1/f-noise characteristics and
uniform material properties. The thermistor material is transferred from the original substrate wafer to the read-out
circuit using adhesive wafer bonding and subsequent thinning. Bolometer arrays can then be fabricated using industry
standard MEMS process and materials. The inherently good detector performance allows us to reduce the vacuum
requirement and we can implement wafer level vacuum packaging technology used in established automotive sensor
fabrication. The optical design is reduced to a single lens camera. We develop a low cost molding process using a novel
chalcogenide glass (GASIR®3) and integrate anti-reflective and anti-erosion properties using diamond like carbon
coating.
Pedestrian fatalities are around 15% of the traffic fatalities in Europe. A proposed EU regulation requires the automotive industry to develop technologies that will substantially decrease the risk for Vulnerable Road Users when hit by a vehicle. Automatic Brake Assist systems, activated by a suitable sensor, will reduce the speed of the vehicle before the impact, independent of any driver interaction. Long Wavelength Infrared technology is an ideal candidate for such sensors, but requires a significant cost reduction. The target necessary for automotive serial applications are well below the cost of systems available today. Uncooled bolometer arrays are the most mature technology for Long Wave Infrared with low-cost potential. Analyses show that sensor size and production yield along with vacuum packaging and the optical components are the main cost drivers. A project has been started to design a new Long Wave Infrared system with a ten times cost reduction potential, optimized for the pedestrian protection requirement. It will take advantage of the progress in Micro Electro-Mechanical Systems and Long Wave Infrared optics to keep the cost down. Deployable and pre-impact braking systems can become effective alternatives to passive impact protection systems solutions fulfilling the EU pedestrian protection regulation. Low-cost Long Wave Infrared sensors will be an important enabler to make such systems cost competitive, allowing high market penetration.
During many years high volume commercial applications of infrared optics have been slowed down by several cost factors. The development of focal plan arrays and uncooled detectors has allowed to greatly reduce the cost of infrared detectors. In the meantime, Umicore IR Glass has developed an industrial process to manufacture low cost chalcogenide glasses with well controlled properties. These glasses called GASIR 1 and GASIR 2 are transparent in the NEAR and FAR infrared atmospheric windows and are mouldable into high quality finished spherical, aspherical and diffractive lenses. The moulding process allows high volume production of cost effective infrared optics. After the development of several optics in GASIR for medium volume series, Umicore is opening the first high volume factory entirely dedicated to GASIR optics for driving vision enhancement (DVE). This new facility will have a capacity of several tens of thousands of optics per year.
Umicore IR Glass has developed an industrial process to manufacture low cost chalcogenide glasses with well controlled properties. These materials called GASIR® 1 and GASIR® 2 are transparent in the 3-5 and 8-12 μm atmospheric windows allowing a great range of applications in thermal imaging.
In the past two years, several optics based on Germanium existing optics (60 mm and 100 mm) have been redesigned for GASIR® glass and are now produced as standards in medium volume series.
This year Umicore is passing another step in the production of infrared moulded optics by opening the first high volume factory entirely dedicated to GASIR® optics for driving vision enhancement (DVE). This new facility will have a capacity of several tens of thousands of optics per year.
In this article, the first results of performance of the corresponding optics will also be presented.
KEYWORDS: Lenses, Germanium, Thermography, Coating, Infrared radiation, Optics manufacturing, Glasses, Modulation transfer functions, Night vision, Single point diamond turning
Sustainable mobility is a major public concern, making increased safety one of the major challenges for the car of the future. About half of all serious traffic accidents occur at night, while only a minority of journeys is at night. Reduced visibility is one of the main reasons for these striking statistics and this explains the interest of the automobile industry in Enhanced Night Vision Systems.
As an answer to the need for high volume, low cost optics for these applications, Umicore has developed GASIR. This material is transparent in the NEAR and FAR infrared, and is mouldable into high quality finished spherical, aspherical and diffractive lenses. Umicore's GASIR moulded lenses are an ideal solution for thermal imaging for cars (Night Vision) and for sensing systems like pedestrian detection, collision avoidance, occupation detection, intelligent airbag systems etc.
Umicore IR Glass has developed an industrial process to manufacture low cost chalcogenide glasses with well controlled properties. These materials called GASIR 1 and GASIR 2 are transparent in the 3-5 and 8-12 μm atmospheric windows allowing a great range of applications in thermal imaging. A high precision industrial moulding process has been developed and set up allowing to mould GASIR material directly into high quality finished spherical, aspherical and diffractive lenses. This process is especially attractive for medium and high volume applications. Specific antireflection coatings have also been developed offering a maximum transmission of 98% when coated with high efficiency coating. Several optics from 17.5 mm F/1 to 100 mm F/1.25 focal length based on existing germanium optics have been redesigned especially for GASIR 1 and GASIR 2 glasses. The lenses have been manufactured using Umicore’s moulding technology. These chalcogenide moulded optics are used in various applications like imaging, process control, military applications and their performances (modulation transfer function has been measured) are reviewed and compared to the existing solutions made of traditional IR optics.
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