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NASA NTRS2002

Method and Apparatus for Obtaining a Precision Thickness in Semiconductor and Other Wafers

A method and apparatus for processing a wafer comprising a material selected from an electrical semiconducting material and an electrical insulating material is presented. The wafer has opposed generally planar front and rear sides and a peripheral edge, wherein said wafer is pressed against a pad in the presence of a slurry to reduce its thickness. The thickness of the wafer is controlled by first forming a recess such as a dimple on the rear side of the wafer. A first electrical conducting strip extends from a first electrical connection means to the base surface of the recess to the second electrical connector. The first electrical conducting strip overlies the base surface of the recess. There is also a second electrical conductor with an electrical potential source between the first electrical connector and the second electrical connector to form. In combination with the first electrical conducting strip, the second electrical conductor forms a closed electrical circuit, and an electrical current flows through the closed electrical circuit. From the front side of the wafer the initial thickness of the wafer is reduced by lapping until the base surface of the recess is reached. The conductive strip is at least partially removed from the base surface to automatically stop the lapping procedure and thereby achieve the desired thickness.

Okojie, Robert S.↗

NASA NTRS2002

Science Fairs and Observational Science: A Case History from Earth Orbit

Having judged dozens of science fairs over the years, I am repeatedly disturbed by the ground rules under which students must prepare their entries. They are almost invariably required to follow the "scientific method," involving formulating a hypothesis, a test of the hypothesis, and then a project in which this test is carried out. As a research scientist for over 40 years, I consider this approach to science fairs fundamentally unsound. It is not only too restrictive, but actually avoids the most important (and difficult) part of scientific research: recognizing a scientific problem in the first place. A well-known example is one of the problems that, by his own account, stimulated Einstein's theory of special relativity: the obvious fact that when an electric current is induced in a conductor by a magnetic field , it makes no difference whether the field or the conductor is actually (so to speak) moving. There is in other words no such thing as absolute motion. Physics was transformed by Einstein's recognition of a problem. Most competent scientists can solve problems after they have been recognized and a hypothesis properly formulated, but the ability to find problems in the first Place is much rarer. Getting down to specifics, the "scientific method" under which almost all students must operate is actually the experimental method, involving controlled variables, one of which, ideally, is changed at a time. However, there is another type of science that can be called observational science. As it happens, almost all the space research I have carried out since 1959 has been this type, not experimental science.

Lowman, Paul D., Jr.↗

NASA NTRS1986

Flexible Circuits

Adflex Solutions, Inc.'s flexible circuits may be molded to the shape of a chassis for bulk reduction. Particularly valuable when circuitry must be moved. They are produced by combining a plastic film, a metallic conductor and an adhesive. One adhesive, LARC-TPI, developed by the Langley Research Center, is a thermoplastic polyimide resin used to produce laminates by Rogers Corporation. It can be processed at a lower temperature, has good moisture resistance and excellent adherence. It is used to bond film to copper foil conductor materials in flexible circuits. The circuits have both aerospace and commercial applications.

Source record↗

NASA NTRS1976

Flat Wire

The N.Y. State Urban Development Corp., Amp Inc., and Western Electric Corp. are working with NASA to produce flat conductor electrical cable. Flat conductor electrical cable originally designed for spacecraft by the Marshall Space Flight Center, has been installed in a housing project. Because it is very thin the wire can be mounted on surfaces of walls and floors instead of inside of them. Installation costs reduced significantly due to single installation time.

Source record↗

NASA NTRS2002

Oceans, Ice Shells, and Life on Europa

The four large satellites of Jupiter are famous for their planet-like diversity and complexity, but none more so than ice-covered Europa. Since the provocative Voyager images of Europa in 1979, evidence has been mounting that a vast liquid water ocean may lurk beneath the moon's icy surface. Europa has since been the target of increasing and sometimes reckless speculation regarding the possibility that giant squid and other creatures may be swimming its purported cold, dark ocean. No wonder Europa tops everyone's list for future exploration in the outer solar system (after the very first reconnaissance of Pluto and the Kuiper belt, of course). Europa may be the smallest of the Galilean moons (so-called because they were discovered by Galileo Galilei in the early 17th century) but more than makes up for its diminutive size with a crazed, alien landscape. The surface is covered with ridges hundreds of meters high, domes tens of kilometers across, and large areas of broken and disrupted crust called chaos. Some of the geologic features seen on Europa resemble ice rafts floating in polar seas here on Earth-reinforcing the idea that an ice shell is floating over an ocean on this Moon-size satellite. However, such features do not prove that an ocean exists or ever did. Warm ice is unusually soft and will flow under its own weight. If the ice shell is thick enough, the warm bottom of the shell will flow, as do terrestrial glaciers. This could produce all the observed surface features on Europa through a variety of processes, the most important of which is convection. (Convection is the vertical overturn of a layer due to heating or density differences-think of porridge or sauce boiling on the stove.) Rising blobs from the base of the crust would then create the oval domes dotting Europa's surface. The strongest evidence for a hidden ocean beneath Europa's surface comes from the Galileo spacecraft's onboard magnetometer, which detected fluctuations in Jupiter's magnetic field consistent with a conductor inside Europa. The most likely conductor: a somewhat salty ocean.

Schenk, Paul↗

NASA NTRS2005

Methods for Anticipating Problems with Electrical Wiring

Passive and active methods for anticipating problems with electrical wiring are provided. An insulative material in contact with an electrical conductor has at least one impurity that is impregnated in the insulative material and/or disposed thereon. An environment around the electrical conductor is monitored for the presence or the level of the impurity(ies) emanating from the insulative material in the form of a gaseous effluent. An alarm signal is generated when a predetermined level of the gaseous effluent is detected.

William T Yost↗

NASA NTRS2006

Marking Electrical Wiring With Condition Indicators

A method is provided for marking electrical Wiring with condition indicators. One or more markers are added to one or both of the insulative material and a surface of an electrical conductor such that it bonds thereto. Each marker is capable of emanating into a surrounding atmospheric environment as a gaseous effluent in response to a specific condition experienced by the electrical conductor.

Yost, William T.↗

NASA NTRS2007

High Specific Power Motors in LN2 and LH2

A switched reluctance motor has been operated in liquid nitrogen (LN2) with a power density as high as that reported for any motor or generator. The high performance stems from the low resistivity of Cu at LN2 temperature and from the geometry of the windings, the combination of which permits steady-state rms current density up to 7000 A/cm2, about 10 times that possible in coils cooled by natural convection at room temperature. The Joule heating in the coils is conducted to the end turns for rejection to the LN2 bath. Minimal heat rejection occurs in the motor slots, preserving that region for conductor. In the end turns, the conductor layers are spaced to form a heat-exchanger-like structure that permits nucleate boiling over a large surface area. Although tests were performed in LN2 for convenience, this motor was designed as a prototype for use with liquid hydrogen (LH2) as the coolant. End-cooled coils would perform even better in LH2 because of further increases in copper electrical and thermal conductivities. Thermal analyses comparing LN2 and LH2 cooling are presented verifying that end-cooled coils in LH2 could be either much longer or could operate at higher current density without thermal runaway than in LN2.

Brown, Gerald V.↗

NASA NTRS1982

Pairwise comparison device

Apparatus for comparing first and second sets of voltages having one-to-one correspondence, and providing an indication responsive to the magnitudes of the pairwise differences of the voltages; typically comprising a plurality of channel waveguides (11), each having a first electrode (12) on one side of the channel (11) and a second electrode (13) on the opposite side of the channel (11); contacts (14) and conductors (16) for connecting each voltage of the first set to the first electrode (12) of one waveguide (11); contacts (b 15) and conductors (17) for connecting each voltage of the second set to the second electrode (13) of the waveguide (11) to the first electrode (12) of which the corresponding voltage of the first set is connected; a coupling prism (18), a beam splitter (19), and a waveguide portion (20) for directing to the input end (21,22) of each waveguide (11) a substantially plane wave of coherent light (as indicated at 23,24,25) having predetermined relative intensity and phase; and a detector (51) and associated circuitry (52,58) responsive to the light emerging (as indicated at 26) from the output end (28,29) of the waveguides (11) (via a beam splitter 44 and a coupling prism 45) for providing an indication that is a function of the pairwise relative magnitudes of the first set of voltages and the second set of voltages.

Verber, Carl M.↗

NASA NTRS2007

High Specific Power Motors in LN2 and LH2

A switched reluctance motor has been operated in liquid nitrogen (LN2) with a power density as high as that reported for any motor or generator. The high performance stems from the low resistivity of Cu at LN2 temperature and from the geometry of the windings, the combination of which permits steady-state rms current density up to 7000 A/sq cm, about 10 times that possible in coils cooled by natural convection at room temperature. The Joule heating in the coils is conducted to the end turns for rejection to the LN2 bath. Minimal heat rejection occurs in the motor slots, preserving that region for conductor. In the end turns, the conductor layers are spaced to form a heat-exchanger-like structure that permits nucleate boiling over a large surface area. Although tests were performed in LN2 for convenience, this motor was designed as a prototype for use with liquid hydrogen (LH2) as the coolant. End-cooled coils would perform even better in LH2 because of further increases in copper electrical and thermal conductivities. Thermal analyses comparing LN2 and LH2 cooling are presented verifying that end-cooled coils in LH2 could be either much longer or could operate at higher current density without thermal runaway than in LN2.

Brown, Gerald V.↗

NASA NTRS1995

Method for fabricating an interconnected array of semiconductor devices

A method of forming an array of interconnected solar cells. A flexible substrate carrying semiconductor and conductive layers is divided into individual devices by slitting the substrate along the web length. The individual devices are then connected with one another in series by laminating the substrate onto an insulating backing and by depositing conducting interconnection layers which join the lower conductor of one device with the top conductor of the adjoining device.

Grimmer, Derrick P.↗

NASA NTRS1989

Multi-port, optically addressed RAM

A random access memory addressing system utilizing optical links between memory and the read/write logic circuits comprises addressing circuits including a plurality of light signal sources, a plurality of optical gates including optical detectors associated with the memory cells, and a holographic optical element adapted to reflect and direct the light signals to the desired memory cell locations. More particularly, it is a multi-port, binary computer memory for interfacing with a plurality of computers. There are a plurality of storage cells for containing bits of binary information, the storage cells being disposed at the intersections of a plurality of row conductors and a plurality of column conductors. There is interfacing logic for receiving information from the computers directing access to ones of the storage cells. There are first light sources associated with the interfacing logic for transmitting a first light beam with the access information modulated thereon. First light detectors are associated with the storage cells for receiving the first light beam, for generating an electrical signal containing the access information, and for conducting the electrical signal to the one of the storage cells to which it is directed. There are holographic optical elements for reflecting the first light beam from the first light sources to the first light detectors.

Johnston, Alan R.↗

NASA NTRS2007

Wireless Fluid Level Measuring System

A level-sensing probe positioned in a tank is divided into sections with each section including (i) a fluid-level capacitive sensor disposed along the length thereof, (ii) an inductor electrically coupled to the capacitive sensor, (iii) a sensor antenna positioned for inductive coupling to the inductor, and (iv) an electrical conductor coupled to the sensor antenna. An electrically non-conductive housing accessible from a position outside of the tank houses antennas arrayed in a pattern. Each antenna is electrically coupled to the electrical conductor from a corresponding one of the sections. A magnetic field response recorder has a measurement head with transceiving antennas arrayed therein to correspond to the pattern of the housing's antennas. When a measurement is to be taken, the measurement head is mechanically coupled to the housing so that each housing antenna is substantially aligned with a specific one of the transceiving antennas.

Taylor, Bryant D.↗

NASA NTRS2009

Radial Halbach Magnetic Bearings

Radial Halbach magnetic bearings have been investigated as part of an effort to develop increasingly reliable noncontact bearings for future high-speed rotary machines that may be used in such applications as aircraft, industrial, and land-vehicle power systems and in some medical and scientific instrumentation systems. Radial Halbach magnetic bearings are based on the same principle as that of axial Halbach magnetic bearings, differing in geometry as the names of these two types of bearings suggest. Both radial and axial Halbach magnetic bearings are passive in the sense that unlike most other magnetic bearings that have been developed in recent years, they effect stable magnetic levitation without need for complex active control. Axial Halbach magnetic bearings were described in Axial Halbach Magnetic Bearings (LEW-18066-1), NASA Tech Briefs, Vol. 32, No. 7 (July 2008), page 85. In the remainder of this article, the description of the principle of operation from the cited prior article is recapitulated and updated to incorporate the present radial geometry. In simplest terms, the basic principle of levitation in an axial or radial Halbach magnetic bearing is that of the repulsive electromagnetic force between (1) a moving permanent magnet and (2) an electric current induced in a stationary electrical conductor by the motion of the magnetic field. An axial or radial Halbach bearing includes multiple permanent magnets arranged in a Halbach array ("Halbach array" is defined below) in a rotor and multiple conductors in the form of wire coils in a stator, all arranged so the rotary motion produces an axial or radial repulsion that is sufficient to levitate the rotor. A basic Halbach array (see Figure 1) consists of a row of permanent magnets, each oriented so that its magnetic field is at a right angle to that of the adjacent magnet, and the right-angle turns are sequenced so as to maximize the magnitude of the magnetic flux density on one side of the row while minimizing it on the opposite side. The advantage of this configuration is that it makes it possible to approach the theoretical maximum force per unit area that could be exerted by a given amount of permanent-magnet material. The configuration is named after physicist Klaus Halbach, who conceived it for use in particle accelerators. Halbach arrays have also been studied for use in magnetic-levitation ("maglev") railroad trains. In a radial Halbach magnetic bearing, the basic Halbach arrangement is modified into a symmetrical arrangement of sector-shaped permanent magnets mounted on the outer cylindrical surface of a drum rotor (see Figure 2). The magnets are oriented to concentrate the magnetic field on their radially outermost surface. The stator coils are mounted in a stator shell surrounding the rotor.

Eichenberg, Dennis J.↗

NASA NTRS2009

Large-Aperture Membrane Active Phased-Array Antennas

Large-aperture phased-array microwave antennas supported by membranes are being developed for use in spaceborne interferometric synthetic aperture radar systems. There may also be terrestrial uses for such antennas supported on stationary membranes, large balloons, and blimps. These antennas are expected to have areal mass densities of about 2 kg/sq m, satisfying a need for lightweight alternatives to conventional rigid phased-array antennas, which have typical areal mass densities between 8 and 15 kg/sq m. The differences in areal mass densities translate to substantial differences in total mass in contemplated applications involving aperture areas as large as 400 sq m. A membrane phased-array antenna includes patch antenna elements in a repeating pattern. All previously reported membrane antennas were passive antennas; this is the first active membrane antenna that includes transmitting/receiving (T/R) electronic circuits as integral parts. Other integral parts of the antenna include a network of radio-frequency (RF) feed lines (more specifically, a corporate feed network) and of bias and control lines, all in the form of flexible copper strip conductors on flexible polymeric membranes. Each unit cell of a prototype antenna (see Figure 1) contains a patch antenna element and a compact T/R module that is compatible with flexible membrane circuitry. There are two membrane layers separated by a 12.7-mm air gap. Each membrane layer is made from a commercially available flexible circuit material that, as supplied, comprises a 127-micron-thick polyimide dielectric layer clad on both sides with 17.5-micron-thick copper layers. The copper layers are patterned into RF, bias, and control conductors. The T/R module is located on the back side of the ground plane and is RF-coupled to the patch element via a slot. The T/R module is a hybrid multilayer module assembled and packaged independently and attached to the membrane array. At the time of reporting the information for this article, an 8 16 passive array (not including T/R modules) and a 2 4 active array (including T/R modules) had been demonstrated, and it was planned to fabricate and test larger arrays.

Karasik, Boris↗

NASA NTRS2010

Electrically Variable Resistive Memory Devices

Nonvolatile electronic memory devices that store data in the form of electrical- resistance values, and memory circuits based on such devices, have been invented. These devices and circuits exploit an electrically-variable-resistance phenomenon that occurs in thin films of certain oxides that exhibit the colossal magnetoresistive (CMR) effect. It is worth emphasizing that, as stated in the immediately preceding article, these devices function at room temperature and do not depend on externally applied magnetic fields. A device of this type is basically a thin film resistor: it consists of a thin film of a CMR material located between, and in contact with, two electrical conductors. The application of a short-duration, low-voltage current pulse via the terminals changes the electrical resistance of the film. The amount of the change in resistance depends on the size of the pulse. The direction of change (increase or decrease of resistance) depends on the polarity of the pulse. Hence, a datum can be written (or a prior datum overwritten) in the memory device by applying a pulse of size and polarity tailored to set the resistance at a value that represents a specific numerical value. To read the datum, one applies a smaller pulse - one that is large enough to enable accurate measurement of resistance, but small enough so as not to change the resistance. In writing, the resistance can be set to any value within the dynamic range of the CMR film. Typically, the value would be one of several discrete resistance values that represent logic levels or digits. Because the number of levels can exceed 2, a memory device of this type is not limited to binary data. Like other memory devices, devices of this type can be incorporated into a memory integrated circuit by laying them out on a substrate in rows and columns, along with row and column conductors for electrically addressing them individually or collectively.

Liu, Shangqing↗

NASA NTRS2010

Electrical Capacitance Volume Tomography with High-Contrast Dielectrics

The Electrical Capacitance Volume Tomography (ECVT) system has been designed to complement the tools created to sense the presence of water in nonconductive spacecraft materials, by helping to not only find the approximate location of moisture but also its quantity and depth. The ECVT system has been created for use with a new image reconstruction algorithm capable of imaging high-contrast dielectric distributions. Rather than relying solely on mutual capacitance readings as is done in traditional electrical capacitance tomography applications, this method reconstructs high-resolution images using only the self-capacitance measurements. The image reconstruction method assumes that the material under inspection consists of a binary dielectric distribution, with either a high relative dielectric value representing the water or a low dielectric value for the background material. By constraining the unknown dielectric material to one of two values, the inverse math problem that must be solved to generate the image is no longer ill-determined. The image resolution becomes limited only by the accuracy and resolution of the measurement circuitry. Images were reconstructed using this method with both synthetic and real data acquired using an aluminum structure inserted at different positions within the sensing region. The cuboid geometry of the system has two parallel planes of 16 conductors arranged in a 4 4 pattern. The electrode geometry consists of parallel planes of copper conductors, connected through custom-built switch electronics, to a commercially available capacitance to digital converter. The figure shows two 4 4 arrays of electrodes milled from square sections of copper-clad circuit-board material and mounted on two pieces of glass-filled plastic backing, which were cut to approximately square shapes, 10 cm on a side. Each electrode is placed on 2.0-cm centers. The parallel arrays were mounted with the electrode arrays approximately 3 cm apart. The open ends were surrounded by a metal guard to reduce the sensitivity of the electrodes to outside interference and to help maintain the spacing between the arrays. Other uses for this innovation potentially include quantifying the amount of commodity remaining in the fuel and oxidizer tanks while on-orbit without having to fire spacecraft engines. Another orbit application is moisture sensing in plant-growth experiments because microgravity causes moisture in soil to distribute itself in unusual ways. At the moment, the hardware and image reconstruction technique may only be of interest to people involved in nondestructive evaluation. The reconstructed image takes almost a full week to reproduce with existing computer power. However, because computer power and speeds follows Moore s Law, execution times are likely to become acceptable within the next five to eight years. The code was written in Mathematica for dedicated use with the ECVT system. In its present form, it is not suitable to be used directly as a consumer product. However, the code could be likely improved by rewriting it in a compiled language such as C or Fortran.

Nurge, Mark↗

NASA NTRS2007

Aperture-Coupled Thin-Membrane L-Band Antenna

The upper part of the figure depicts an aperture-coupled L-band antenna comprising patterned metal conductor films supported on two thin polyimide membranes separated by an air gap. In this antenna, power is coupled from a microstrip line on the lower surface of the lower membrane, through a slot in a metal ground plane on the upper surface of the lower membrane, to a radiating metal patch on the upper surface of the upper membrane. The two-membrane configuration of this antenna stands in contrast to a three-membrane configuration heretofore considered as the basis for developing arrays of dual-polarization, wideband microwave antennas that could be thin and could be, variously, incorporated into, or supported on, thin structures, including inflatable structures. By reducing the number of membranes from three to two, the present design simplifies the problems of designing and fabricating such antennas or arrays of such antennas, including the problems of integrating such antennas or arrays with thin-membrane-mounted transmit/ receive modules. In addition, the use of aperture (slot) coupling eliminates the need for rigid coaxial feed pins and associated solder connections on thin membranes, making this antenna more mechanically reliable, relative to antennas that include coaxial feed pins. This antenna is designed for a nominal frequency of 1.26 GHz. The polyimide membranes are 0.05 mm thick and have a relative permittivity of 3.4. The radiating patch is square, 8.89 cm on each side. This radiating patch lies 1.27 cm above the ground plane. The feeding microstrip line is 0.12 mm wide and has a characteristic impedance of 50 . The aperture-coupling slot, etched in the ground plane, is 0.48 mm wide and 79.5 mm long. In order to maximize coupling, the microstrip line is extended beyond the middle of the slot by a length of 36 mm, which corresponds to a transmission- line electrical length of about a quarter wavelength. The other end of the microstrip line is transformed to a 50-Ohm coplanar waveguide line, which is used for connection to a transmit/receive module. Some plated-through vias are added to the outer conductors of the coplanar waveguide to suppress parallel-plate modes. The measured and calculated 10-dB-return-loss bandwidth of the antenna is 100 MHz. By eliminating the radiating patch and the upper membrane that supports it, and performing two other simple modifications, one can convert the two-membrane antenna described above to a paper-thin single-membrane antenna, shown in the lower part of the figure. One modification is to increase the slot length to 104.95 mm; the other is to extend the microstrip to 36.68 mm past the middle of the slot. With these modifications, the slot now becomes a half-wavelength radiator with a nearly omnidirectional radiation pattern. In one potential use, such a paper-thin antenna could be pasted on an automobile window to enable omnidirectional communication.

Huang, John↗