1.0 SUBSTRATE
| Parameter | Specification |
|---|---|
| Material | Schott Borofloat 33 borosilicate glass |
| Dimensions | 25.00 mm × 25.00 mm × 6.000 mm ±0.025 mm |
| Flatness | <2 μm across full surface |
| Surface finish | <5 nm Ra, both faces |
| Edge chamfer | 0.20 mm × 45°, no chips >50 μm |
| Quantity | 3 identical substrates |
2.0 GRID LAYOUT
| Parameter | Specification |
|---|---|
| Grid type | 4×4 Cartesian |
| Pitch | 5.000 mm ±0.010 mm center-to-center |
| Origin (0,0) | Bottom-left corner of substrate |
| Grid offset X | 5.000 mm from left edge |
| Grid offset Y | 5.000 mm from bottom edge |
| Cavity positions (X,Y) mm | (0,0), (5,0), (10,0), (15,0) / (0,5), (5,5), (10,5), (15,5) / (0,10), (5,10), (10,10), (15,10) / (0,15), (5,15), (10,15), (15,15) |
3.0 CAVITY ARCHETYPES
| Parameter | TYPE S (△) | TYPE M (◼︎) | TYPE L (▲) |
|---|---|---|---|
| Symbol | △ | ◼︎ | ▲ |
| Diameter | 3.000 mm ±0.005 mm | 2.000 mm ±0.005 mm | 1.500 mm ±0.003 mm |
| Depth | 5.000 mm ±0.010 mm | 10.000 mm ±0.010 mm | 20.000 mm ±0.010 mm |
| Aspect ratio | 1.67:1 | 5:1 | 13.33:1 |
| Volume | 35.34 mm³ | 31.42 mm³ | 35.34 mm³ |
| Time constant (τ) | 0.50 s ±0.02 s | 1.00 s ±0.03 s | 2.30 s ±0.05 s |
| Wall angle | 90° ±0.3° | 90° ±0.3° | 90° ±0.3° |
| Wall finish | <0.1 μm Ra | <0.1 μm Ra | <0.1 μm Ra |
| Bottom finish | <0.2 μm Ra | <0.2 μm Ra | <0.2 μm Ra |
| Corner radius | <50 μm | <50 μm | <50 μm |
4.0 CAVITY ASSIGNMENTS, CORE FFT (SPATIAL FREQUENCY DECOMPOSITION)
| X (mm) | Y (mm) | Type | τ (s) |
|---|---|---|---|
| 0 | 15 | L | 2.30 |
| 5 | 15 | M | 1.00 |
| 10 | 15 | S | 0.50 |
| 15 | 15 | S | 0.50 |
| 0 | 10 | M | 1.00 |
| 5 | 10 | L | 2.30 |
| 10 | 10 | M | 1.00 |
| 15 | 10 | S | 0.50 |
| 0 | 5 | S | 0.50 |
| 5 | 5 | M | 1.00 |
| 10 | 5 | L | 2.30 |
| 15 | 5 | M | 1.00 |
| 0 | 0 | S | 0.50 |
| 5 | 0 | S | 0.50 |
| 10 | 0 | M | 1.00 |
| 15 | 0 | L | 2.30 |
Kernal type, Symmetric Hankel. Anti-diagonals constant. Sensitive to spatial frequencies. No directional preference..
5.0 CAVITY ASSIGNMENTS, CORE GX (X-AXIS GRADIENT)
| X (mm) | Y (mm) | Type | τ (s) |
|---|---|---|---|
| 0 | 15 | S | 0.50 |
| 5 | 15 | S | 0.50 |
| 10 | 15 | M | 1.00 |
| 15 | 15 | L | 2.30 |
| 0 | 10 | S | 0.50 |
| 5 | 10 | S | 0.50 |
| 10 | 10 | M | 1.00 |
| 15 | 10 | L | 2.30 |
| 0 | 5 | S | 0.50 |
| 5 | 5 | M | 1.00 |
| 10 | 5 | L | 2.30 |
| 15 | 5 | L | 2.30 |
| 0 | 0 | S | 0.50 |
| 5 | 0 | M | 1.00 |
| 10 | 0 | L | 2.30 |
| 15 | 0 | L | 2.30 |
Gradient principle, Left columns (X=0,5) fast S-dominant, Right columns (X=10,15) slow L-dominant. Center transition M. Left heating → early output peak. Right heating → late output peak. Skewness proportional to ∂T/∂x,
6.0 CAVITY ASSIGNMENTS, CORE GY (Y-AXIS GRADIENT)
| X (mm) | Y (mm) | Type | τ (s) |
|---|---|---|---|
| 0 | 15 | L | 2.30 |
| 5 | 15 | L | 2.30 |
| 10 | 15 | M | 1.00 |
| 15 | 15 | S | 0.50 |
| 0 | 10 | L | 2.30 |
| 5 | 10 | L | 2.30 |
| 10 | 10 | M | 1.00 |
| 15 | 10 | S | 0.50 |
| 0 | 5 | L | 2.30 |
| 5 | 5 | M | 1.00 |
| 10 | 5 | S | 0.50 |
| 15 | 5 | S | 0.50 |
| 0 | 0 | M | 1.00 |
| 5 | 0 | M | 1.00 |
| 10 | 0 | S | 0.50 |
| 15 | 0 | S | 0.50 |
Gradient principle, Top rows (Y=10,15) slow L-dominant. Bottom rows (Y=0,5) fast S-dominant. Middle transition M. Bottom heating → early output peak. Top heating → late output peak, Skewness proportional to ∂T/∂y..
7.0 UWA-1
| Component | Specification |
|---|---|
| Base | Pharmaceutical-grade paraffin wax, Tm = 60.0°C ±0.1°C |
| Latent heat | 185 J/g ±5 J/g |
| Dopant 1 | Pristine MWCNTs, Ø10-30 nm, L:1-10 μm, unfunctionalized, >95% purity |
| Loading 1 | 2.00 wt% ±0.05 wt% |
| Dopant 2 | n-Tetracontane (C₄₀H₈₂), >99% purity, Tm = 81.0°C ±0.5°C |
| Loading 2 | 0.50 wt% ±0.02 wt% |
| Thermal conductivity (solid) | 0.45 W/m·K |
| Thermal conductivity (liquid) | 0.38 W/m·K |
7.1 Composite Preparation
| Step | Action | Parameters |
|---|---|---|
| 1 | Melt paraffin | 82°C ±2°C, argon atmosphere |
| 2 | Add MWCNTs | High-shear 10,000 RPM, 30 min, 80-85°C |
| 3 | Add tetracontane | 5,000 RPM, 15 min, 80°C |
| 4 | Ultrasonic probe | 20 kHz, 100 W, pulse 5s/2s, 60 min, 78-82°C |
| 5 | Degas | <1×10⁻² mbar, 80°C, 60 min, until bubble-free |
| 6 | Store | Sealed, argon-filled, 6-month shelf life |
8.0 INFUSION PROTOCOL
| Step | Action | Parameters |
|---|---|---|
| 1 | Clean substrates | IPA ultrasonic, 40°C, 15 min → DI water rinse → N₂ dry → vacuum oven 120°C, 2 hr |
| 2 | Preheat | Substrate to 75°C ±1°C on vacuum hotplate |
| 3 | Evacuate | <1×10⁻³ mbar, hold 2 hr at 75°C |
| 4 | Introduce UWA-1 | Via heated manifold, 75°C, sufficient to cover all cavities + 2 mm |
| 5 | Backfill | Argon to 2.0 bar absolute |
| 6 | Pressure hold | 30 min at 2.0 bar, 75°C |
| 7 | Directional solidification | Gradient 5°C/mm across substrate thickness. Cool 0.20°C/min ±0.02°C/min from 75°C to 25°C under 0.5 L/min argon flow |
| 8 | Inspect | X-ray micro-CT, voxel <5 μm. Zero voids >0.01 mm³ in any cavity. Reject and rework if voids detected. |
9.0 THERMAL BUSES
| Parameter | Specification |
|---|---|
| Material | CVD single-crystal diamond |
| Dimensions | 25.00 mm × 25.00 mm × 0.100 mm ±0.005 mm |
| Thermal conductivity | >1800 W/m·K |
| Electrical resistivity | >10¹² Ω·cm |
| Surface finish | <1 nm Ra, both faces |
| Quantity per core | 2 (top incident face, bottom observer face) |
9.1 Bonding
| Parameter | Specification |
|---|---|
| Adhesive | BNNT-filled epoxy, 5 wt% loading |
| Bond line thickness | <5 μm |
| Thermal resistance | <0.1°C/W |
| Cure | 25°C, 24 hr, vacuum compression 0.5 MPa |
| Post-cure | 60°C, 4 hr, no pressure |
10.0 PYROELECTRIC OBSERVER
| Parameter | Specification |
|---|---|
| Material | z-cut LiTaO₃, single crystal |
| Dimensions | 25.00 mm × 25.00 mm × 0.100 mm ±0.005 mm |
| Pyroelectric coefficient | >2.0 × 10⁻⁴ C/m²·K |
| Relative permittivity | 46 at 1 kHz |
| Surface finish | <1 nm Ra |
10.1 Electrodes
| Parameter | Specification |
|---|---|
| Adhesion layer | Cr, 5 nm ±1 nm |
| Conductor | Au, 100 nm ±10 nm |
| Bottom electrode | Full-area ground plane, Z- face |
| Top electrodes | 16 individual, aligned to cavities |
| Electrode sizes | S: 3.2×3.2 mm, M: 2.2×2.2 mm, L: 1.7×1.7 mm |
| Alignment tolerance | ±10 μm to cavity centerlines |
| Patterning | Photolithography, lift-off |
| Edge pads | 16 signal + 2 ground, 0.5×0.5 mm, 0.8 mm pitch |
10.2 Poling
| Step | Parameters |
|---|---|
| Temperature | 85°C ±1°C |
| Voltage | 100 V DC (Z+ positive), field = 1 MV/m |
| Hold | 30 min at 85°C |
| Cool | 1°C/min to 25°C under field |
| Remove field | At 25°C |
| Verify | Pyroelectric coefficient >2.0 × 10⁻⁴ C/m²·K |
11.0 ENCAPSULATION
| Parameter | Specification |
|---|---|
| Lid | CVD diamond, 25×25×0.100 mm |
| Seal adhesive | BNNT-filled epoxy, <10 μm bond line |
| Internal atmosphere | argon, 6N purity, 1.10 bar absolute at 25°C |
| Getter | Barium flash, 5×5 mm, activated post-seal |
| Leak rate | <1×10⁻⁸ atm·cc/s helium |
12.0 CALIBRATION/ TFP...
| Step | Action | Parameters |
|---|---|---|
| 1 | Uniform step | 25°C → 30°C in <0.1 s. Record 16 ch at 200 Hz for 10 s. Extract τ per cavity. Verify within ±15% of nominal. Extract sensitivity (mV/°C). |
| 2 | Gradient GX | Left 30°C / Right 25°C. Record skewness. Calibration point +0.33°C/mm. Reverse for −0.33°C/mm. Fit linear model: ∂T/∂x = a·skewness + b. |
| 3 | Gradient GY | Top 30°C / Bottom 25°C. Record skewness. Calibration point −0.33°C/mm. Reverse for +0.33°C/mm. Fit linear model: ∂T/∂y = a·skewness + b. |
| 4 | Frequency sweep FFT | 0.1, 0.2, 0.5, 1.0, 2.0, 5.0 Hz sinusoidal modulation. Record 16×16 coupling matrix. |
12.1 Personality Map
- Core serial number and calibration date
- τ per cavity (16 values)
- Sensitivity per cavity (16 values)
- GX skewness coefficients (a, b)
- GY skewness coefficients (a, b)
- FFT coupling matrix (16×16)
- Thermal offset calibration
13.0 SYSTEM INTEGRATION
| Parameter | Specification |
|---|---|
| Configuration | 3 cores (FFT, GX, GY) on common thermal stage |
| Stage | Copper, Peltier-controlled, 25.0°C ±0.01°C |
| Spacing | 10 mm between cores |
| Optics (optional) | Ge lens, f/2, 50 mm FL, AR 8-14 μm, FOV 30°×30° |
| Flex circuit | Polyimide, 18 μm Cu traces, 20-pin ZIF, 100 mm length, shielded |
| Readout | 16-ch charge amplifier, 0.1-100 Hz BW, 200 Hz sample rate, 16-bit ADC |
13.1 Output Vector
| Quantity | Source | Units |
|---|---|---|
| Spatial frequency spectrum | FFT Core (16 components) | Normalized amplitude |
| ∂T/∂x | GX Core | °C/mm |
| ∂T/∂y | GY Core | °C/mm |
| ∇T | ||
| θ (gradient direction) | atan2(GY,GX) | radians |
u/Smooth-Month-277 — 7 days ago