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A manufacturing process suitable for the large-scale production of silicon solar array modules at a cost of less than $500/peak kW is described. Factors which control the efficiency of ion implanted silicon solar cells, screen-printed thick film metallization, spray-on antireflection coating process, and panel assembly are discussed. Conclusions regarding technological readiness or cost effectiveness of individual process steps are presented.
Adaptive optics are used in telescopes for both viewing objects with minimum distortion and for transmitting laser beams with minimum beam divergence and dance. In order to test concepts on a smaller scale, NASA MSFC is in the process of setting up an adaptive optics test facility with precision (fraction of wavelengths) measurement equipment. The initial system under test is the adaptive optical telescope called PAMELA (Phased Array Mirror Extendible Large Aperture). Goals of this test are: assessment of test hardware specifications for PAMELA application and the determination of the sensitivities of instruments for measuring PAMELA (and other adaptive optical telescopes) imperfections; evaluation of the PAMELA system integration effort and test progress and recommended actions to enhance these activities; and development of concepts and prototypes of experimental apparatuses for PAMELA.
A technique for self-calibrating and phasing a lens-feed array antenna, while normal operation is stopped, utilizes reflected energy of a continuous and coherent wave broadcast by a transmitter through a central feed while a phase controller advances the phase angles of reciprocal phase shifters in radiation electronics of the array elements at different rates to provide a distinct frequency modulation of electromagnetic wave energy returned by reflection in one mode and leakage in another mode from the radiation electronics of each array element. The composite return signal received by a synchronous receiver goes through a Fourier transform processing system and produces a response function for each antenna element. Compensation of the phase angles for the antenna elements required to conform the antenna response to a precomputed array pattern is derived from the reciprocal square root of the response functions for the antenna elements which, for a rectangular array of NXM elements, is a response function T(n,m). A third mode of calibration uses an external pilot tone from a separate antenna element. Respective responses are thus obtained from the three modes of calibration.
The development of two 256 by 256 hybrid HgCdTe focal plane array (FPA) families is described, and their performance is discussed. The hybrid FPAs employ a PV HgCdTe detector array and custom Si CMOS readouts. The PACE-1 process was used to fabricate the detectors, whereby the liquid phase epitaxial growth of HgCdTe occurs on sapphire substrates buffered by a layer of CdTe. The performance characteristics of the detector arrays are given. A tactical 256 by 256 CMOS readout is tested, in which a high functional yield was achieved. Updated test results are given for a 256 by 256 readout circuit developed for use in an orbital replacement instrument for the Hubble Space Telescope. The characterizations of several MWIR and SWIR FPAs were thorough and shown to be reliable. The pixel yield, maximum FPA responsivity nonuniformity, and SWIR FPA read noise for the tests are given. The high contrast and insignificant fixed pattern noise of the imagery from the MWIR 256 by 256 FPA are emphasized. These qualities were obtained when the device was operating at 80 k and utilizing f/2 optics with an 8-in. focal length and a 4.4 micron high pass filter.
The ferroelectric reflectarray is a new type of scanning antenna under development for space and ground communications and radar applications at the NASA Glenn Research Center. The reflectarray offers tremendous cost, gain, and efficiency advantages in comparison to the state-of-the-art phased arrays, but there is an inherent intersymbol interference (ISI) problem with digital communication data streams processed through the array because of the way the reflectarray is operated. This interference stems from the fact that the antenna beam is formed by the superposition of reflected waves from the array elements. The delays from the elements to the observation point of each wave differ. Ferroelectric phase shifters are designed to compensate for the modulo-2p phase differences so that the waves will constructively interfere at the sinusoidal carrier level; however, the delays of the integer-number multiple of the carrier period are not compensated for. This lack of compensation causes ISI in digital modulated signals. ISI has not been a problem with analog modulations and low-rate digital modulations since the distortion (or ISI) introduced is negligible. The problem becomes acute when the data rate gets higher, and the electrical size of the array gets bigger. Moreover, there are intrinsic transient effects associated with the phase shifters and the controller that executes the algorithm to direct the beam. That is, phase shifter updates to redirect the beam may be initiated simultaneously, but nonlinearity will cause different settling times. The ISI problem and other effects ultimately limit the size (gain) and data rate of the reflectarray. An ISI analysis was required to prove or disprove the suitability of the reflectarray antenna for high-rate digitally modulated signals and to give guidance for determining antenna parameters. In this research, the nature of the ISI of the reflectarray has been mathematically modeled.
This paper describes the implementation of a Digital Signal Processing (DP) subsystem for a single Long Wavelength Array (LWA) station.12 The LWA is a radio telescope that will consist of many phased array stations. Each LWA station consists of 256 pairs of dipole-like antennas operating over the 10-88 MHz frequency range. The Digital Signal Processing subsystem digitizes up to 260 dual-polarization signals at 196 MHz from the LWA Analog Receiver, adjusts the delay and amplitude of each signal, and forms four independent beams. Coarse delay is implemented using a first-in-first-out buffer and fine delay is implemented using a finite impulse response filter. Amplitude adjustment and polarization corrections are implemented using a 2x2 matrix multiplication
We describe our current fabrication process for arrays of superconducting transition edge sensor microcalorimeters, which incorporates superconducting Mo/Au bilayers and micromachined silicon structures. We focus on materials and integration methods for array heatsinking with our bilayer and micromachining processes. The thin superconducting molybdenum bottom layer strongly influences the superconducting behavior and overall film characteristics of our molybdenum/gold transition-edge sensors (TES). Concurrent with our successful TES microcalorimeter array development, we have started to investigate the thin film properties of molybdenum monolayers within a given phase space of several important process parameters. The monolayers are sputtered or electron-beam deposited exclusively on LPCVD silicon nitride coated silicon wafers. In our current bilayer process, molybdenum is electron-beam deposited at high wafer temperatures in excess of 500 degrees C. Identifying process parameters that yield high quality bilayers at a significantly lower temperature will increase options for incorporating process-sensitive auxiliary array components (AAC) such as array heat sinking and electrical interconnects into our overall device process. We are currently developing two competing technical approaches for heat sinking large compact TES microcalorimeter arrays. Our efforts to improve array heat sinking and mitigate thermal cross-talk between pixels include copper backside deposition on completed device chips and copper-filled micro-trenches surface-machined into wafers. In addition, we fabricated prototypes of copper through-wafer microvias as a potential way to read out the arrays. We present an overview on the results of our molybdenum monolayer study and its implications concerning our device fabrication. We discuss the design, fabrication process, and recent test results of our AAC development.
In the current work, multi-function beam control arrays have been fabricated and have successfully demonstrated amplitude control of transmitted beams in the W and D bands (75-170 GHz). While these arrays are designed to provide beam control under DC bias operation, new designs for high-speed electronic and optical control are under development. These arrays will fill a need for high-speed watt-level beam switches in pulsed reflectometer systems under development for magnetic fusion plasma diagnostics. A second experimental accomplishment of the current work is the demonstration in the 100-170 GHz (D band) frequency range of a new technique for the measurement of the transmission phase as well as amplitude. Transmission data can serve as a means to extract ('de-embed') the grid parameters; phase information provides more complete data to assist in this process. Additional functions of the array beam controller yet to be tested include electronically controlled steering and focusing of a reflected beam. These have application in the areas of millimeter-wave electronic scanning radar and reflectometry, respectively.
Phase compensation technique for signals received at widely spaced antennas and processed at central location
Development of electronic circuit for combining input signals on two separate antennas to form two processed signals
Work was done to verify the technological readiness of a select process sequence with respect to satisfying the Low Cost Solar Array Project objectives of meeting the designated goals of $.50 per peak watt in 1986 (1975 dollars). The sequence examined consisted of: (1) 3 inches diameter as-sawn Czochralski grown 1:0:0 silicon, (2) texture etching, (3) ion implanting, (4) laser annealing, (5) screen printing of ohmic contacts and (6) sprayed anti-reflective coatings. High volume production projections were made on the selected process sequence. Automated processing and movement of hardware at high rates were conceptualized to satisfy the PROJECT's 500 MW/yr capability. A production plan was formulated with flow diagrams integrating the various processes in the cell fabrication sequence.
The development of integrated horn antennas since their introduction in 1987 is reviewed. The integrated horn is fabricated by suspending a dipole antenna, on a thin dielectric membrane, in a pyramidal cavity etched in silicon. Recent progress has resulted in optimized low- and high-gain designs, with single and double polarization for remote-sensing and communication applications. A full-wave analysis technique has resulted in an integrated antenna with performance comparable to that of waveguide-fed corrugated-horn antennas. The integrated horn design can be extended to large arrays, for imaging and phased-array applications, while leaving plenty of room for the RF and IF processing circuitry. Theoretical and experimental results at microwave frequencies and at 90 GHz, 240 GHz, and 802 GHz are presented.
As highly porous solids possessing low density and low dielectric permittivity combined with good mechanical properties, polyimide (PI) aerogels offer great promise as an enabling technology for lightweight aircraft antenna systems. While they have been aggressively explored for thermal insulation, barely any effort has been made to leverage these materials for antennas or other applications that take advantage of their aforementioned attributes. In Phase I of the NARI Seedling Project, we fabricated PI aerogels with properties tailored to enable new antenna concepts with performance characteristics (wide bandwidth and high gain) and material properties (low density, environmental stability, and robustness) superior to the state of practice (SOP). We characterized electromagnetic properties, including permittivity, reflectivity, and propagation losses for the aerogels. Simple, prototype planar printed circuit patch antennas from down-selected aerogel formulations were fabricated by molding the aerogels to net shapes and by gold-metalizing the pattern onto the templates via electron beam evaporation in a clean room environment. These aerogel based antennas were benchmarked against current antenna SOP, and exhibited both broader bandwidth and comparable or higher gain performance at appreciably lower mass. Phase II focused on the success of the Phase I results pushing the PI aerogel based antenna technology further by exploring alternative antenna design (i.e., slot coupled antennas) and by examining other techniques for fabricating the antennas including ink jet printing with the goal of optimizing antenna performance and simplifying production. We also examined new aerogel formulations with better moisture and solvent resistance to survive processing conditions. In addition, we investigated more complex antenna designs including passive phased arrays such as 2x4 and 4x8 element arrays to assess the scalability of the aerogel antenna concept. Furthermore, we explored the possibility of developing these arrays in thin, flexible form to make conformable antennas.
In the process of connecting widely distributed antennas into a coherent array, it is necessary to synchronize the timing of signals at the various locations. This can be accomplished by distributing a common reference signal from a central source, usually over optical fiber. A high-frequency (RF or microwave) tone is a good choice for the reference. One difficulty is that the effective length of the optical fiber changes with temperature and mechanical stress, leading to phase instability in the received tone. This innovation provides a new way to stabilize the phase of the received tone, in spite of variations in the electrical length of the fiber. Stabilization is accomplished by two-way transmission in which part of the received signal is returned to the transmitting end over an identical fiber. The returned signal is detected and used to close an electrical servo loop whose effect is to keep constant the phase of the tone at the receiving end.
Device design, fabrication, and operation of a linear charge coupled device (CCD) detector array integrated with a thin film optical waveguide and applications of this structure to integrated optical signal processing and fiber optical communications were discussed. A two phase, overlapping-gate CCD is connected in parallel by means of a series of gates to an array of photodiodes. The photodiode provides an electrode free surface region so that a highly efficient waveguide detector coupling technique can be implemented. A thermally-oxidized layer of SiO2 forms an effective substrate for the optical waveguide.
Feasibility of signal processor with phase isolator for adaptive antenna array
To assess the integrity and reliability of an adhesive joint in an automotive composite component, several non-destructive evaluation (NDE) methodologies are correlated to lap shear bond strengths. A glass-fabric-reinforced composite structure was bonded to a metallic structure with a two-part epoxy adhesive. Samples were subsequently cut and tested in shear, and flaws were found in some areas. This study aims to develop a reliable and portable NDE system for service-level adhesive inspection in the automotive industry. The results of the experimental investigation using several NDE methods are presented and discussed. Fiberglass-to-metal bonding is the ideal configuration for NDE via thermography using excitation with induction heating, due to the conductive metal and non-conductive glass-fiber-reinforced composites. Excitation can be either by a research-grade induction heater of highly defined frequency and intensity, or by a service-level heater, such as would be used for sealing windshields in a body shop. The thermographs thus produced can be captured via a high-resolution infrared camera, with principal component analysis and 2D spatial Laplacian processing. Alternatively, the thermographs can be captured by low resolution thermochromic microencapsulated liquid crystal film imaging, which needs no post-processing and can be very inexpensive. These samples were also examined with phased-array ultrasound. The NDE methods are compared to the lap shear values and to each other for approximate cost, accuracy, and time and level of expertise needed.
In a system according to the proposed technique, the signal received by each element of the array antenna would be subjected to downconversion, and spread-spectrum demodulation and correlation as necessary; this processing would be performed separately from, and simultaneously with, similar processing of signals received by the other antenna elements. For the GPS implementation, following downconversion to baseband, the signals would be digitized, and all subsequent processing would be digital. In In the digital process, residual carriers would be removed and each signal would be correlated with a locally generated model pseudo random-noise code, all following normal GPS procedure. As part of this procedure, accumulated values would be added in software and the resulting signals would be phase-shifted in software by the amounts necessary to synthesize the desired antenna directional gain pattern of peaks and nulls. The principal advantage of this technique over the conventional radio-frequency-combining technique is that the parallel digital baseband processing of the signals from the various antenna elements would be a relatively inexpensive and flexible means for exploiting the inherent multiple-peak/multiple-null aiming capability of a phased-array antenna. In the original intended GPS application, the peaks and nulls could be directed independently for each GPS signal being tracked by the GPS receiver. This will improve the SNR simultaneously for each GPS signal being tracked while steering multiple nulls toward sources of interference. The technique could also be applied to other code-division multiple-access communication systems.