Conductive Support Struts for Low-Heat Cryogenic IR Cameras

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Solution Overview

Problem

Infrared camera systems cooled to cryogenic temperatures face increased heat load due to traditional electrical connections, necessitating larger cryocoolers that add size, weight, and power consumption.

Innovation Solution

Utilizing electrically-conductive structural support beams as electrical conductors to replace multiple wirebonds, reducing the number of electrical connections within the cryogenic temperature section and minimizing heat transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional wirebonds are used for electrical connections, then electrical interface requirements are met, but heat load increases and requires larger cryocoolers

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidheat load

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent combines the mechanical support function and electrical conduction function into a single structural support beam. The beam provides both mechanical support for the infrared camera sensor and electrical connection pathways, eliminating the need for separate wirebonds and reducing the number of electrical interfaces that generate heat load.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The structural support beam serves multiple functions simultaneously: it provides mechanical support for the sensor platform, acts as an electrical conductor for signal transmission, and functions as a structural element of the housing. This multi-functionality reduces the overall component count and minimizes heat-generating electrical interfaces.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If multiple wirebonds are used for electrical connections, then electrical interface requirements are met, but the number of components increases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidnumber of electrical connections

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges multiple electrical connection functions into a single structural support beam. Instead of using multiple separate wirebonds to establish electrical interfaces, the beam itself provides the conduction pathways, significantly reducing the number of electrical connections and simplifying the overall device structure.

Inventive Principle:

Principle #5Merging (Combining)

3Temperature

If larger cryocoolers are used to compensate for heat load, then cryogenic temperature maintenance is improved, but system size, weight, and power consumption increase

Engineering Contradiction:

Improvecryogenic temperature maintenanceVSAvoidsystem weight

Core Design Contradiction:

TemperatureVSWeight of moving object

Solution Approach 1:

The patent converts the potentially harmful heat conduction pathway into a beneficial dual-function element. The structural support beam, which could be seen as a heat conduction path, is designed to provide both mechanical support and electrical conduction while minimizing thermal load through optimized material selection and geometric design, thereby reducing the burden on the cryocooler system.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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

Reduces heat load, allowing for smaller cryocoolers, thereby decreasing the overall size, weight, and power consumption of the infrared camera system.

Implementation Method 1

at least one electrically-conductive spoke configured to electrically interface with at least one electrical interface connection of an infrared camera sensor

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

at least one support strut mechanically supporting the platform

Methodology Applied

Scientific EffectMechanical support: Mechanical Force

Implementation Method 3

components in infrared camera systems are cooled to cryogenic temperatures during operation, typically via cryocooler devices

Methodology Applied

Scientific EffectCryogenic cooling: Cooling

Implementation Method 4

The vacuum environment limits the transfer of heat from the housing to the infrared camera sensor via convection

Methodology Applied

Scientific EffectVacuum insulation: Vacuum

Data Source

PatentUS20250365488A1Structural support beams used as electrical conductors in cooled infrared camera housings

Publication Date: 2025.11.27 RAYTHEON CO

AI summary

A system includes an infrared camera sensor. The infrared camera sensor includes at least one electrical interface connection and a platform. The system also includes a cryocooler thermally coupled to the platform and at least one support strut mechanically supporting the platform. The at least one support strut includes at least one electrically-conductive spoke configured to interface with the at least one electrical interface connection.