Infrared Camera Packaging Using Solder Preform Dimples
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Solution Overview
Problem
Existing methods for sealing hermetically sealed containers for infrared detectors and other electronic devices are costly and prone to leakage, as they rely on pinch tubes, which require labor-intensive crimping and cutting, and have a high failure rate due to subsequent leakage.
Innovation Solution
The use of solder preforms with features like dimples to maintain spacing between container sections during outgassing and sealing, eliminating the need for pinch tubes and through pins, and incorporating getters to enhance vacuum quality, with a vacuum positioning fixture for assembly and leak testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pinch tubes are used for sealing containers, then evacuation and backfilling can be performed, but the process becomes labor-intensive and prone to leakage
Solution Approach 1:
The invention eliminates the pinch tube from the sealing process entirely. Instead of using a pinch tube that requires crimping and cutting operations, the container is sealed directly using conventional sealing methods, extracting the problematic component and its associated complex manufacturing steps from the process.
Solution Approach 2:
The invention replaces the reusable pinch tube with a disposable sealing structure integrated into the container itself. The container incorporates a sealing flange or rim that is sealed once and discarded, eliminating the need for expensive, labor-intensive pinch tube operations while maintaining sealing reliability.
2Reliability
If pinch tubes are crimped and cut for sealing, then the container can be sealed, but costs increase due to labor and materials
Solution Approach 1:
The invention removes the pinch tube component and its associated crimping and cutting operations from the manufacturing process. By integrating the sealing function directly into the container structure, the process eliminates expensive specialized labor and additional materials, reducing overall manufacturing costs while maintaining atmosphere maintenance reliability.
Solution Approach 2:
The sealing function is merged with the container structure itself rather than being a separate operation using a pinch tube. The container incorporates integrated sealing features such as flanges or rims that are sealed as part of the container fabrication process, combining multiple functions into a single structure and reducing overall manufacturing complexity and cost.
3Ease of manufacture
If conventional sealing methods are used, then containers can be sealed, but leakage occurs due to pinch tube failure
Solution Approach 1:
The invention extracts the pinch tube component that is prone to leakage failure from the sealing process. By eliminating this unreliable component and using direct sealing of the container structure, the invention maintains sealing simplicity while dramatically improving leakage prevention through a more robust sealing architecture.
Solution Approach 2:
The container is designed with built-in sealing features such as flanges, rims, or grooves that provide redundant sealing paths and stress distribution. This beforehand cushioning ensures that even if one sealing path is compromised, the atmosphere remains intact, preventing leakage before it can occur during operation.
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
This method reduces manufacturing costs and enhances reliability by minimizing leakage and maintaining a consistent atmosphere within the container, improving the performance and longevity of infrared detectors.
Implementation Method 1
The array of bolometers can be enclosed within a hermetically sealed container to provide heat isolation
Implementation Method 2
Such containers are frequently outgassed as a part of the evacuation process, using a known process involving heating an item for a period of time in a reduced pressure atmosphere, so as to remove gasses that may otherwise be present after evacuation
Implementation Method 3
The first solder preform can have at least one feature that is configured to maintain the first section spaced apart from the second section during outgassing
Implementation Method 4
A bolometer is a detector that changes resistance in response to incident radiant energy
Implementation Method 5
For assembly, in accordance with one or more embodiments of the present invention, a vacuum positioning fixture can be used to assemble the components of a plurality of infrared detector assemblies and to place the infrared detector assemblies into a vacuum chamber or other processing device
Data Source
AI summary
Systems and methods for providing a sealed container having a reduced pressure atmosphere are disclosed. The container is suitable for housing an infrared detector array. Outgassing can be enhanced by adding features to solder preforms that maintain pathways for gasses to more readily exit the container prior to sealing thereof. Getters can be used to mitigate undesirable gases within the sealed container. One or more bolometers can be used to determine if the sealed container is leaking. A vacuum positioning fixture can be used to assemble the components of the infrared detector assembly and to place the infrared detector assemblies into a vacuum chamber. The cost of manufacturing such infrared detector assemblies may be reduced and the reliability thereof enhanced.