Infrared Detector Package Brazing with Segmented Metallized Layers

Solution Overview

Problem

Conventional methods for manufacturing infrared detector packages face significant challenges with material loss and improper sealing due to machining requirements and potential contamination during the brazing process, leading to high manufacturing costs and defects.

Innovation Solution

The use of a casing with concentric annular metallized layers and a window member with a corresponding metallized surface, where the brazing material is deposited between these layers, allowing it to solidify and flow under pressure in a vacuum environment, ensuring a clean and contamination-free bonding process without the need for machining or additional cleaning steps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If machining is performed on the brazing material to shape it, then the sealing structure is formed, but significant material loss occurs and the manufactured surface becomes contaminated

Engineering Contradiction:

Improvesealing structure formationVSAvoidbrazing material loss

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The bonding surface is divided into two separate concentric annular metallized layers: an inner layer that bonds to the window member and an outer layer that retains the brazing material. This segmentation allows the brazing material to be deposited in a controlled manner without requiring subsequent machining, eliminating material loss while achieving the required sealing structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The concentric annular metallized layers are formed on the bonding surfaces before brazing material deposition. This preliminary preparation creates a structured surface that guides the brazing material flow and defines the final bonding geometry, eliminating the need for post-deposition machining operations.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If machining is performed on the brazing material, then the sealing structure is formed, but the metal surface becomes contaminated with oxidized films and dross

Engineering Contradiction:

Improvesealing structure formationVSAvoidsurface contamination

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The bonding surface is divided into two separate concentric annular metallized layers: an inner layer that bonds to the window member and an outer layer that retains the brazing material. This segmentation allows the brazing material to be deposited in a controlled manner without requiring subsequent machining, eliminating material loss while achieving the required sealing structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The brazing process is performed in a vacuum environment, which prevents oxidation and contamination of the brazing material and metallized surfaces during heating and bonding. This inert environment eliminates the formation of oxidized films and dross that would otherwise contaminate the bonding surface.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

3Ease of manufacture

If scrubbing is performed on the window member during molten brazing material deposition, then cleaning is attempted, but improper brazing or imperfect sealing still occurs

Engineering Contradiction:

Improvecleaning processVSAvoidbrazing quality

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The bonding surface is divided into two separate concentric annular metallized layers: an inner layer that bonds to the window member and an outer layer that retains the brazing material. This segmentation allows the brazing material to be deposited in a controlled manner without requiring subsequent machining, eliminating material loss while achieving the required sealing structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The brazing process is performed in a vacuum environment, which prevents oxidation and contamination of the brazing material and metallized surfaces during heating and bonding. This inert environment eliminates the formation of oxidized films and dross that would otherwise contaminate the bonding surface.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

4Device complexity

If a single annular metallized layer is used, then the structure is simple, but the brazing material cannot be properly retained and bonded

Engineering Contradiction:

Improvemetallized layer structureVSAvoidbrazing bonding

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The bonding surface is divided into two separate concentric annular metallized layers: an inner layer that bonds to the window member and an outer layer that retains the brazing material. This segmentation allows the brazing material to be deposited in a controlled manner without requiring subsequent machining, eliminating material loss while achieving the required sealing structure.

Inventive Principle:

Principle #1Segmentation

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 achieves a reliable and air-tight seal with minimal material loss, reducing manufacturing costs and defects by ensuring a clean metallic surface and proper bonding performance, thus enhancing the sealing and bonding quality of the infrared detector package.

Implementation Method 1

heating the assembly. Thereby, the brazing material 98 joins the window member 95 with the ceramic casing 94

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

The deposited brazing material 98 is allowed to cool and solidify. Because the metallized layer 96 has a high affinity with the molten brazing material 98

Methodology Applied

Scientific EffectVacuum: Vacuum

Data Source

PatentUS7479635B2Infrared detector package

Publication Date: 2009.01.20 KYOCERA SOC CORP

AI summary

In an infrared detector package, a first annular metallized layer (6a, 6b) is formed along the annular shoulder (4a) of a casing member (4), and a second annular metallized layer (7) is formed along the annular mating surface of a window member (5). Brazing material (8) is integrally interposed between the first and second metallized layers. At least one of the first and second annular metallized layers comprises a mutually separated concentric portions (6a, 6b), and the brazing material extends across the two mutually separated concentric portions. During the manufacturing process, brazing material is deposited on one of the two mutually separated concentric portions, and is allowed to flow along the opposing metallized surface until the brazing material reaches the other of the two mutually separated concentric portions. Because the brazing material exposes a clean metallic surface as it flows so that the brazing material is properly interposed between the opposing annular metallized layer and the other of the mutually separated concentric portions of the corresponding annular metallized layer without any intervention of dross, oxidized film or other foreign matters. Thereby the brazing material ensures a favorable bonding and sealing performance.