Abstract: A dewar assembly is cleaned, baked out, assembled, and joined in a single vacuum system without exposing the components to ambient atmosphere. The vacuum system preferably has a first chamber with multiple subchambers that can be isolated from each other, and a second chamber that can be isolated from the first chamber. The multiple chambers and subchambers prevent cross contamination during the various process steps, and also permit multiple dewar assemblies to be batch processed at different stages simultaneously. The components of the dewar assembly are loaded into one subchamber and cleaned, and thereafter moved to another subchamber for bakeout. The dewar getter is heated in the second chamber and moved to one of the subchambers for assembly. The components of the dewar assembly are assembled and joined.

Abstract: A vacuum package assembly (20) is prepared by self-welding the flanges (32 and 43) of two housings (28 and 36) together under an applied pressure, while the housings (28 and 36) and any enclosed structure or device are contained within an evacuated enclosure. The flanges (32 and 43) are preferably made of copper, with their respective self-welding members (34 and 46) specially prepared to enhance self-welding performance. The preferred treatment for the self-welding members (34 and 46) is to deposit a thin layer of nickel onto the self-welding members (34 and 46 ), deposit a thin layer of gold over the nickel, and heat the bonding member to elevated temperature to interdiffuse the gold into the self-welding member (34 and 46 ).

Abstract: A method for bonding the ends of the conductors 52 to circuit pads 54 is disclosed whereby the cable 20 is placed over the circuit pads 54; a bonding tool 44 is pressed against an upper surface 58 of the cable 20; the substrate 46 of the cable 20 is compressed beyond its elastic limit; and ultrasonic energy is applied to the bonding tool 44 and transmitted through the substrate 46 to effect a metallic bond between the conductors 52 and circuit pads 54.

Abstract: A thin film electrical cable 20 is disclosed having a polyimide substrate 46, a layer of titanium 48 on a lower side 50 of the substrate 46, and a plurality of gold conductors 52 on the titanium 48. The thin layers of titanium and gold are preferably sequentially deposited on a clean polyimide film by sputtering. Additional gold is electroplated and separate conductors are delineated. The use of organic adhesive materials to attach the conductors 52 to the substrate 46 is avoided.

Abstract: An infrared detector assembly (10) of the type used in munition and night vision systems having an RF activated getter (50). Such detector assemblies (10) include a tubular coldfinger (22) surrounded by a vacuum and which supports infrared detector array (26) and related components. In accordance with this invention, RF getter (50) is located remote from detector array (26) and engages an inner wall surface (56) of a metallic dewar housing (14). The RF getter (50) is activated via RF inductive heating directly through the metal dewar housing (14) such that sensitive IR detector components and hermetic braze joints are kept below their critical temperature. As a result, the present invention provides longer vacuum life and greater operational reliability of infrared detector assembly (10).

Abstract: The present invention is directed to an integrated detector dewar cryoengine (10). The integrated detector dewar cryoengine (10) includes a detector (12) for detecting received electromagnetic radiation. The integrated detector dewar cryoengine (10) further comprises expander end cap (18) for removing thermal energy from said detector (12) which is in mechanical communication with said detector (12).

Abstract: An apparatus for mounting a device used for detecting infrared signals is disclosed. The apparatus includes a housing and an expander upon which the device is mounted. An insulating material comprising polymeric foam is disposed between the expander and the housing which allows the apparatus to be cooled without requiring evacuation of the apparatus.