Infrared Sensor Filter Assembly for Low-Crosstalk Satellite Sensing
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Solution Overview
Problem
Existing IR sensor assemblies for small satellites face challenges in withstanding mechanical loads, suffer from crosstalk between spectral bands, and are complex and costly, lacking flexibility for filter changes.
Innovation Solution
An IR sensor assembly design featuring planar optical filters arranged close to the detector on an adhesive tape, held by a frame-shaped holding part with compressible glue, allowing for easy adaptation and resilience to mechanical loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If planar optical filters are arranged close to the sensor, then crosstalk between spectral bands is reduced, but mechanical stability during launch is compromised
Solution Approach 1:
The filter assembly is segmented into individual planar filters that can be independently positioned and secured on separate adhesive tapes, allowing each filter to be optimally positioned close to the sensor while maintaining individual mechanical stability
Solution Approach 2:
Adhesive tapes serve as intermediary elements between the planar filters and the sensor housing, providing both precise positioning for minimal crosstalk and mechanical coupling for stability during launch
2Device complexity
If integrated filter assemblies are used for small satellites, then device complexity is reduced, but manufacturing cost increases to over 25k€ per unit
Solution Approach 1:
Multiple planar filters are merged into a single integrated assembly that uses common mounting infrastructure (adhesive tapes and housing), reducing overall complexity while maintaining the ability to use cost-effective individual filter components
Solution Approach 2:
The adhesive tape mounting system serves multiple functions: mechanical support, precise positioning, thermal coupling, and vibration damping, eliminating the need for separate components for each function and reducing manufacturing cost
3Device complexity
If filter assemblies are finalized for small satellites, then device complexity is reduced, but flexibility for filter changes is lost
Solution Approach 1:
The filter assembly is segmented into independently removable planar filters mounted on adhesive tapes, allowing individual filters to be replaced without affecting the entire assembly or requiring complex disassembly procedures
Solution Approach 2:
The mounting system transitions from rigid permanent fixation to a dynamic configuration where filters can be easily removed and replaced by simply detaching from adhesive tapes, enabling mission updates and filter optimization
4Ease of manufacture
If existing filter mount solutions are used, then ease of manufacture is improved, but crosstalk between spectral bands occurs
Solution Approach 1:
The successful adhesive tape mounting approach from other optical applications is copied and adapted for IR filter mounting, achieving both ease of manufacture and precise positioning to eliminate crosstalk through simple, proven technology
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
The design reduces crosstalk, achieves thermal coupling, and withstands mechanical stress, providing a cost-effective, compact solution for multi-spectral observations.
Implementation Method 1
an adhesive tape provided (e.g., applied, attached, or affixed) on the front surface, outside of the window portion. The adhesive tape may at least partially surround the window portion. Further, the one or more planar optical filters may be arranged to cover at least part of the window portion, with at least part of each planar optical filter resting on the adhesive tape
Implementation Method 2
one or more planar optical filters. Preferably, the IR sensor assembly may comprise a plurality of planar optical filters. The planar optical filters may have rectangular shape, for example
Implementation Method 3
Since the optical filters can be arranged very close to the sensor, cross talk between different spectral bands (e.g., associated with neighboring filters) can be significantly reduced and excellent thermal coupling between sensor and filters can moreover be achieved
Data Source
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AI summary
This application relates to an infrared (IR) sensor assembly for use in a satellite. The assembly includes an IR sensor, wherein the IR sensor comprises a substantially plane front surface with a window portion, the window portion covering an active area of the IR sensor, one or more planar optical filters, and an adhesive tape provided on the front surface outside of the window portion, the adhesive tape at least partially surrounding the window portion. The one or more planar optical filters are arranged to cover at least part of the window portion, with at least part of each planar optical filter resting on the adhesive tape. The application further relates to a method of manufacturing such IR sensor assembly.