This invention relates to microsensors that are constructed utilizing semiconductor fabrication processes and, more particularly, to a thermal radiation sensor. The sensor us useful for detecting low level radiation absorbed in microstructures at power levels of a nanoWatt and less into microstructures. This invention is typically used for the detection of low level infrared radiation. However, the low level radiation may be comprised of any electromagnetic radiation absorbed into a pyro-optical film within the radiation sensor and thus may include wavelengths ranging from the ultraviolet, visible, near infrared, far infrared, and into the millimeter wave regions. The present invention can be devised as a single sensor element or as an array of pixels including a focal plane array.
There are many types of infrared or low level radiation sensors for imaging and non-imaging applications. The most widely used infrared imagers employ photon detection and thermal detection. Most thermal detectors utilize sensor elements including thermistors, piezoelectric, and ferroelectric elements that change electrical characteristics with temperature. In each of these sensor types there is a direct electrical connection between the sensor element and the readout electronics or readout integrated circuit ROIC. A limitation in this type of radiation sensor is that the direct electrical connection mentioned serves as a pick-up for parasitic noise sources due to capacitive, inductive, and electromagnetic pick-up of unwanted signal levels. The present invention has no electrical connection between the sensor structures for low level radiation and the readout ROIC and thus avoids many of the aforementioned parasitic noise problems.
Micromachining has been developed as a means for accurately fabricating small structures and is now being applied to microstructures for radiation sensors. Such processing involves the selective etching of a substrate and the deposition thereon of layers of thin films. Various sacrificial layers are employed to enable the fabrication of relatively complex interactive structures. This technology is generally referred to as MOEMS (micro-optical electromechanical systems) technology and is utilized in a wide range of application devices. In the present invention we utilize MOEMS technology to fabricate microplatforms that contain a pyro-optical film as a key component of a radiation sensor system. These microplatforms are a key component within the radiation sensor system which includes a high level source of photonic radiation and a detector for the modulated high level photonic beam. The pyro-optical film modulates the amplitude of the photonic carrier beam to the detector. Thus, the photonic carrier beam may also be referred to as the interrogation beam. The high level photonic radiation is typically a visible or near infrared wavelength beam. The photon detector is typically a two-dimensional array of silicon charge coupled diodes (CCD) or CMOS silicon diodes. When low level radiation is incident on a pyro-optical thin film, an incremental heating occurs which in turn causes a change in the transmissivity or reflectivity of the interrogation carrier beam. This change in the pyro-optical characteristics modulates the amplitude of a photonic beam exiting to an ROIC detector. In the present invention the resulting video signal output from the ROIC and associated circuitry is highly sensitive to the amplitude of incident low level radiation.
A thermal imager that includes an infrared sensitive light valve and a light source arranged to illuminate the valve was described by Elliott and Watton in U.S. Pat. No. 4,594,507. This imager contains an infrared sensitive optically active liquid crystal cell and an analyzer adjusted to near extinction. An optical processor comprising a lens and an apodized stop filter lies in the light path between the valve and the detector array. The thermal imager described in this patent uses an interrogation light beam but does not mention microplatforms, microstructures, or thermal gain.
An infrared sensor scheme is described and without thermal gain by Hanson in U.S. Pat. No. 5,512,748 in which an infrared sensitive film is used to amplitude modulate a photonic carrier beam. This patent describes a focal plane array including a plurality of thermal sensors mounted on a substrate. An image is formed on an infrared sensitive film layer in response to infrared radiation from a scene. Electromagnetic radiation from a source is used to reproduce or transfer the image from the thermal sensors onto the first surface of the substrate. In the Hanson patent there is no mention made of a pyro-optical film in which the absorption of a visible or near infrared carrier beam increases with temperature to achieve a photo-thermal gain.
Cross et al in U.S. Pat. No. 4,994,672 describe an infrared imaging system which includes a pyro-optic sensor for receiving a low level thermal image on one of its sides, the sensor exhibiting a substantial change in refractive index in response to changes in its temperature. A high level light beam is projected onto the sensor and locally reflected in accordance with local changes in the refractive index of a pyro-optic film. This detector and imager description does not mention any structures or techniques for obtaining thermal gain.
Grossman and Reintsema in U.S. Pat. No. 6,323,486 B1 describe a bolometer in which the vanadium oxide sensor film is heated from a current source to achieve a negative electrothermal feedback with electrical readout. This teaching does not mention using vanadium oxide or other film to modulate a photonic light beam and the use of a CCD readout. The use of a positive feedback factor to enhance the responsivity is not mentioned.
Blodgett et al in U.S. Pat. No. 5,608,568 describre using a thin film of vanadium oxide as a spatial light; modulator in which the thermally isolated thin film of vanadium oxide is electrically heated to proviide a bistable reflection of incident, optical radiation. Micromachined, thermally isolated platforms are not mentioned. This teaching does not describe a feature sensitive to low level incident radiation.
It is an object of this invention to provide an improved radiation sensor wherein micromachining of a thermally isolated platform is used with selected pyro-optical thin films to accomplish a sensor with thermal gain. This means of thermal gain is powered by the high level carrier beam.
It is another object of this invention to provide a pyro-optical sensor with an increased sensitivity to low level radiation wherein the readout noise and photonic noise contributions to the system output are relatively reduced. The result is a decrease in the net equivalent temperature differential NETD of a source of low level radiation that can be detected by the radiation sensor.
In the present invention we describe a radiation sensor for low level radiation where typically less than a nanoWatt is absorbed in a pyro-optical microstructure. The radiation sensor contains an absorbing microplatform that is thermally isolated from a substrate, a high level interrogating carrier beam and source, and a sensitive detector for the carrier beam exiting the microplatform. The carrier beam is modulated by the pyro-optical thin film in the microplatform and detected by the ROIC. The microplatform contains an integral pyro-optical film which modulates the high level photonic carrier source in addition to and an electrical heater element. The low level radiation to be sensed is partially absorbed on the microplatform causing a first incremental increase in temperature. The intensity of the photonic carrier beam exiting the microplatform is amplitude modulated by the temperature of the pyro-optical film.
The microplatform contains the integral pyro-optical film and the heater element where (1) a first source of low level radiation or heat is incident upon the sensor platform and partially absorbed causing a first incremental heating of said film, (2) a power source of constant voltage or constant current driving the resistive heater element with a thermal coefficient of resistance thereby causing a further incremental heating of the microplatform, and where the combined temperature rise of the pyro-optical film due to both the first and second incremental temperature increases is greater than that due to the first source of radiation alone, and (3) used with an optical carrier beam for readout by a photonic CCD or CMOS readout ROIC. The structure with cooperating sensing and heating structures comprise a sensitive sensor for low level radiation, with an internal photonic carrier beam for interrogating the temperature of the pyro-optical film.
The resistor heater establishes a quiescent temperature level TQ or Too for the microplatform which is several degrees above the heat sink temperature of the underlying substrate. Typically the first incremental heating is on the order of microdegrees to millidegrees Centigrade. The first incremental heating level ΔTir causes a further increase in the electrical power dissipated from the heater element in the microplatform due to it's thermal coefficient of resistivity. The amplitude of the second incremental heating is ultimately limited by the nonlinearity of the thermal hysteresis of the pyro-optical film. The enhanced heating of the microplatform in excess of that obtained from the low level radiation alone is a stable gain maintained around the quiescent temperature operating point TQ.
The electro-thermal gain of the present invention can be described further by examining the basic theory of optical absorption in the microplatform.
Typical hysteresis 200 of a pyro-optical thin film such as vanadium oxide as a function of temperature is shown in
ΔT=ΔTiρ+ΔTelec
The temperature increase is due to the electrical power V2/R and inversely proportional to the thermal conductivity G of the microplatform tether beams.
ΔTelec=Vo2/GR
The resistance R of the heater element is the quiescent resistance RQ reduced by the first incremental heating.
R═RQ−ΔRiρ
The heater element change of resistance ΔRiρ due to the first increment of heating is:
ΔRiρ=kiρΔTiρ
The quiescent temperature TQ of the heater is determined by the quiescent resistance RQ
TQ=Vo2/G RQ
From the above relationships, the final microplatform temperature T
T−TQ=ΔT=(1+kirVo2/R)ΔTir
where ΔT>>ΔTir.
The ratio of the final increase in temperature ΔT to the first incremental heating ΔTir is the electro-thermal gain factor Get:
Get=1+kirVo/R
We describe a radiation sensor which contains an internal photonic carrier beam to monitor extremely small variations in the temperature of a microplatform. The reflection or transmission of the exiting photonic carrier beam with respect to a microplatform is monitored by a detector. The present invention uses micro-opto-electromechanical-systems MOEMS technology to form a single microplatform or an array of microplatforms for detecting low level radiation. Each microplatform contains a resistive heater with a high temperature coefficient of resistance. Each resistive heater is driven by a current or voltage source as appropriate to cause the microplatform to heat with the absorption of low level incident radiation.
An array of microplatforms 300 may be used as part of a wide variety of low level radiation detectors and thermal imaging systems. The invention may be used with either “staring” or “scanning” detection means. A staring detector is a large area detector onto which the entire thermal image is focused at once and read out electronically. A scanning detector uses a mirror or tethered means to sweep the low level radiation across the microplatform array. Usually, although not necessary for the invention, both types of detection means consist of a plurality of sensor elements, with the output of each thermal sensor representing a portion of the viewed scene. For example, the output of each microplatform 300 may represent a single pixel of the total image. Thermal sensors described in
High level light source 303 is provided for use in transferring the low level radiation spot or pattern formed on the microplatform or microplatforms 300 to photosensors 304 disposed in the path of the high level radiation beam 306 from source 303 as illustrated in
Electronics are used to format the electrical signal output in photodetector 304. Electronics are provided to perform selected operations on the photodetector output including digitization, synchronizing with the chopper, zooming, general image processing, formatting for a display with techniques well known to the art of imaging and low level signal processing. The large signal level of the detected high level beam 306 contains a small signal modulation due to the low level beam 305. Image processing within or in cascade with the photodetector 304 is used to eliminate the large signal component from 306 to provide an unbiased output representative of the intensity pattern of the low level incident beam 305. For the display application embodiment, a special viewing device such as a CRT or LCD display is driven by the electronics. The image on a display obtained through the electronics from the radiation sensor system is typically a visual representation of the radiance image of the microplatform 300 corresponding to points on the two dimensional scene 301. The radiation sensor system may include digitization electronics so that the signals can be stored and processed as digital data. This requires sampling, storage, image subtraction and processing circuits which are well known in the field of video and graphics processing and be included as part of the electronics. The radiation sensor system may function as a radiometer to provide temperature measurements of radiant energy sources present in source 301 or other sources focused onto the microplatform 300.
A chopper wheel or other optical switching device is generally used to synchronously interrupt the beam of low level radiation 305 to the microplatform 300 thereby providing a reference signal and a bias signal. Collection optics 302 and the chopper cooperate to form a reference temperature increment on the microplatform 300 corresponding to the background radiance. The electromagnetic energy 306 from light source 303 in cooperation with photosensor 304 will produce a signal corresponding to the total radiance filtered by the chopper from source 301 during any frame of time. Electronics included in the photodetector 304 and associated electronic processing will cooperate with each other to process the bias signal and the reference signal to generate an unbiased signal which may be transformed into a data stream for display or storage in a memory for later processing. The process of establishing a reference signal and receiving a bias signal is repeated in succession for a stream of video images in the case of imaging. The present invention contemplates either establishing a reference signal before or after the detection of a bias signal, or establishing a reference signal before or after a predetermined number of bias signals have been received and processed.
The electronics preferably include a control circuit to operate a thermoelectric cooler/heater to adjust the temperature of the substrate 300 to produce optimum sensitivity.
One embodiment of the
The two example microplatforms in embodiment
In another preferred embodiment the pyro-optical film is separate from the heater element. For instance, the heater element can be formed of a serpentine pattern of PECVD polysilicon or sputtered tantalum silicide. In this case, the pyro-optical film and the heater element are fabricated as separate structures within the microplatform. In this embodiment, each pixel heater is connected in series and the entire array of microplatforms is driven from a constant current source to achieve the desired electro-thermal gain.
It should be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims.