Patent Description:
Example embodiments in general relate to night vision systems and, more particularly, image intensifier tubes and a method of manufacturing such tubes on a wafer fabrication and photolithography scale. The image intensifier tube comprises doped electron multipliers and addressable electron emitters that generate multiplied secondary electrons and addressed electron emissions from a backside surface of one or more transmission mode secondary electron (TMSE) image intensifiers shown as a display within the tube.

Night vision system such as night vision goggles typically include an image intensifier tube. The image intensifier tube, or "image intensifier", can include an electron multiplier arranged between a photocathode and a sensor anode. The photocathode detects infrared light in the form of photons from an object, and the image intensifier amplifies or multiplies the resulting photoelectrons, or "electrons", emitted from the photocathode. The multiplied electrons can be drawn to the anode, where they can be converted back to photons displayed on a screen. The anode or screen can include a sensor that upon receiving the increased number of electrons senses those electrons and produces an intensified representation of the image on the screen. The photocathode, the electron multiplier, and the anode is typically supported by a vacuum housing with gaps between the photocathode, electron multiplier, and sensor anode to provide gain and facilitate the flow of electrons therebetween.

Each of these devices within the vacuum tube can be classified as an analog image intensifier if the anode is an optical imager that converts electrons to photons displayed on a screen without any conversion to digital electrical signals (binary <NUM> and <NUM>) prior to display. Thus, an analog image intensifier tube is one having an analog channel of nighttime image intensification of low intensity infrared or near infrared radiation reflected from a target or object and received by a vacuum-sealed spaced photocathode, electron multiplier and phosphor-covered anode screen absent any conversion to a binary digital electrical signal in the interim.

Night vision based on analog image intensifiers have been in use for many years. In addition to the analog image intensifier, many night vision systems can also include a digital display to provide the users with situation awareness, symbology, and additional images of different wavelength modalities from a digital imager camera mounted on the night vision system. The additional data is provided from the digital imager camera as digital signal binary bits (binary <NUM> and <NUM> logic values) to an electronic digital display mounted on the night vision system. The electronic digital display produces an optical output image overlaid upon the optical output image from the analog image intensifier by an optical beam combiner configured within the night vision system. The beam combiner and the additional digital display consume power, increases the size/weight of the system, and adds complexity to the manufacturing of the night vision system.

The image from the analog image intensifier is generated as normal, except the output brightness is often increased to account for the transmission loss of a beam combiner. The beam combiner is used to combine the output optical image from the analog image intensifier with the output optical image from the digital display. The additional electronic digital display is generally fixed onto one surface of the beam combiner in a manner that provides the same focal distance as the output of the analog image intensifier on a separate channel of the beam combiner. If a secondary image from the electronic digital display is to be overlaid and coherently related to what is displayed on the analog image intensifier screen, then manufacturing complexity must be added to register the two images. The typical night vision system eyepiece must be designed to account for the additional distance of the beam combiner. The optical beam combiner adds size, weight and manufacturing complexity to the system. The analog channel size of the analog image intensifier is large compared to the digital channel size of the digital imager camera, causing a mismatch and allowing only limited overlay of the image from the digital display onto the image from the analog image intensifier. Another option to combine the optical image with additional information is described in <CIT>.

The present disclosure provides a night vision system as defined in appended claim <NUM> that creates an electronically addressable display within the analog image intensifier tube itself. Symbology and images of the same or different wavelength modalities are sent to one or more semiconductor-based electron multipliers within the analog image intensifier tube. The symbols and images can then be added to the display output of the analog image intensifier tube without adding size and weight to the overall night vision system. The present night vision system also utilizes a cathodoluminescent screen, which is a highly efficient light source that reduces system power.

The night vision system comprises an analog image intensifier, interchangeably an analog image intensifier tube, and an addressable display within the analog image intensifier. The addressable display is configured to receive electrical signals from an external digital imager to create an electronically addressable output from the analog image intensifier.

The night vision system includes a digital imager configured to receive an optical image from a target or object. The digital imager is configured to produce a plurality of electrical signal bits for each pixel corresponding to the optical image being displayed through a transparent anode sensor screen of the analog image intensifier. The analog image intensifier tube is configured to receive the optical image and to produce multiplied electrons from an electron multiplier within the analog intensifier tube. The analog image intensifier tube can also produce electrons from electron emitters on the electron multiplier that are addressed on a pixel-by-pixel basis corresponding to the plurality of electrical signals.

The image intensifier tube is preferably an analog image intensifier tube that forwards multiplied and gained electrons to a phosphor-covered screen that displays those converted electrons absent any conversion to digital electrical signals in the interim. The image intensifier tube, according to this example, comprises a photocathode secured to a vacuum sealed housing. The image intensifier tube can also include a primary electron multiplier spaced from the photocathode within the vacuum sealed housing, wherein the primary electron multiplier comprises a backside surface facing away from the photocathode and containing a first plurality of spaced electron emitters dielectrically spaced from respective first plurality of doped regions.

The image intensifier tube can also include a secondary electron multiplier spaced from the primary electron multiplier within the vacuum sealed housing. The secondary electron multiplier comprises a backside surface facing away from the primary electron multiplier and containing a second plurality of spaced electron emitters dielectrically spaced from respective second plurality of doped regions. The image intensifier tube further comprises a sensor anode secured in the vacuum housing, along with the secondary electron multiplier, the primary electron multiplier, and the photocathode. The sensor anode can include a phosphor covered fiber optic screen, for example.

In accordance with yet another example of the disclosure, a method is provided for manufacturing an image intensifier tube. However, this method does not form part of the claimed invention. The method comprises bonding a GaAs epitaxially grown wafer to a glass wafer to form a faceplate wafer. A backside of a primary doped silicon wafer can also be bonded to a primary glass spacer wafer to form a primary electron multiplier wafer. A backside of a secondary doped silicon wafer can be bonded to a secondary glass spacer wafer to form a secondary electron multiplier wafer. A fiber optics screen wafer can be bonded to a tertiary glass wafer to form a sensor anode wafer. The primary electron multiplier wafer, the secondary electron multiplier wafer and the sensor anode wafer can then be hermetically sealed within a vacuum along with the faceplate wafer. The faceplate wafer, the primary electron multiplier wafer, the secondary electron multiplier wafer and the sensor anode wafer are spaced from each other with a vacuum gap therebetween. Once hermetically sealed, the faceplate wafer, the primary electron multiplier wafer, the secondary electron multiplier wafer and the sensor anode wafer are altogether simultaneously diced along a seal member arranged in the scribe line. Scribing or dicing along the seal member between the faceplate wafer and the primary electron multiplier forms a first cavity. Scribing along a seal member between a primary electron multiplier wafer and the secondary electron multiplier wafer forms a second cavity. Scribing along a seal member between the secondary electron multiplier and sensor anode wafer forms a third cavity. The first, second and third cavities are gaps that are evacuated less than one atmosphere during hermetic sealing within a vacuum. A resulting die, for example, can be mounted behind an objective lens as the analog image intensifier tube. Alternatively, the resulting die can be mounted behind another objective lens as part of the digital imager. Since each die is identical, the analog channel dimension of the analog image intensifier tube is the same size as the digital channel dimension of the digital imager. Thus, the digital imager display output is overlaid upon and across the entire analog image intensifier display output using addressable electron emitters within the analog image intensifier tube display.

Examples of the present disclosure are best understood from the following detailed description when read in connection with the accompanying drawings. According to common practice, the various features of the drawings are not drawn to scale, or are only shown in partial perspective. The dimension of the various embodiments are shown arbitrarily expanded or reduced for clarity. Like numerals are used to represent like elements among the drawings. Included in the drawings are the following features and elements, and reference will now be made to each drawing in which:.

The following discussion is directed to various example embodiments. However, one of ordinary skill in the art will understand that the examples disclosed herein have broad application, and that the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to suggest that the scope of the disclosure, including the claims, is limited to that embodiment.

As noted above, the drawing figures are not necessarily to scale. Certain features and components herein may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in interest of clarity and conciseness.

In the following discussion and in the claims, the terms "including" and "comprising" are used in an open-ended fashion, and thus should be interpreted to mean "including, but not limited to. " Also, the term "couple" or "couples" is intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct connection of the two devices, or through an indirect connection that is established via other devices, components, nodes, and connections. In addition, as used herein, the terms "axial" and "axially" generally mean along or parallel to a given axis (e.g., x, y or z direction or central axis of a body, outlet or port), while the terms "radial" and "radially" generally mean perpendicular to the given axis. For instance, an axial distance refers to a distance measured along or parallel to the axis, and a radial distance means a distance measured perpendicular to the axis.

Referring now to <FIG>, a partial block diagram of a night vision system <NUM> is shown having a beam combiner <NUM>. Night vision system <NUM> is illustrated of the current technology for performing an optical overlay. Beam combiner <NUM> sends to the display <NUM> both the output of an analog imager intensifier <NUM> and also an output from a digital electronic display <NUM>. Night vision <NUM> thereby proves advantageous in that an image of an object <NUM> can be taken both by a digital imager camera <NUM> and an analog image intensifier <NUM>. Image from an object or target <NUM> can be passed through lenses <NUM> and <NUM>, and then onto respective digital imager camera <NUM> and analog image intensifier <NUM>.

In some circumstances needed to enhance a soldier's vision in finding and localizing threats, digital images must be taken, along with analog images normally associated with low light level night vision viewing. While digital imager <NUM> typically cannot match the performance of an analog image intensifier tube <NUM> at extremely low light levels, digital imagers can be used to display information to a soldier about the scene in front of that soldier, such as directions or other symbol indicia, about the scene or image object <NUM>. In addition, the digital imager <NUM> can take other imaging modalities, including sensitivities to different wavelengths, such as LWIR for thermal imaging of object <NUM> rather than SWIR or NWIR imaging sensitivity that might occur in the analog image intensifier tube <NUM>. The sensor within the digital imager <NUM> can therefor pickup different wavelengths than the sensor within the analog image intensifier tube <NUM>, or can produce symbol indicia on the overlaid scene of the combined optical images via a controller <NUM>. The image from the digital imager <NUM>, or the indicia from the controller <NUM> arrives on the digital display <NUM> as digital electrical signals on bus <NUM>. Those electrical signals are converted to optical signals, or optical images, that are combined with the optical image from analog image intensifier <NUM> by beam combiner <NUM>.

As shown in <FIG>, the channel width, or dimension, of the image capture at which digital imager <NUM> can accommodate is referenced as DCW. DCW is typically less than the channel width, or dimension, of the analog channel ACW. This is evident in the output image of the combined display <NUM> of <FIG>, as shown in <FIG> illustrates the difference in the DCW versus ACW of an output image of a digital display overlaid upon an output image of an analog image intensifier tube utilizing the night vision system of <FIG>. For example, the digital imager camera <NUM> in <FIG> could superimpose a thermal image output of a soldier <NUM> that may not be detectable by the low light detection of an analog image intensifier <NUM> output <NUM>. Still referring to the combination of <FIG> and <FIG>, controller <NUM> may send a plurality of electrical signals representing a symbol <NUM> onto digital electronic display <NUM>. The digital display output <NUM>, which can also include symbol <NUM>, can be overlaid onto the analog image intensifier output <NUM> by beam combiner <NUM>.

Referring to <FIG>, a digital imager camera or display sensor device <NUM> of <FIG> is shown. Digital sensor <NUM> is used in many night vision systems to allow display and viewing, recording, and other image processing including fusion with other imagery such as from a forward looking infrared sensor within, for example, an analog image intensifier tube <NUM>. Image sensing devices that incorporate an array of image sensing pixels <NUM> are commonly used in electronic cameras. Each pixel produces an electrical output signal in response to incident light or photons. The electrical signals are oftentimes read out, typically one row at a time, to form an image. Digital imager cameras <NUM> can use charged coupled devices (CCDs) as the pixelized image sensor. For example, the pixel array <NUM> can be controlled by a timing and control circuit <NUM>, and the signals can be processed by processors <NUM>, which may comprise analog-to-digital converters arranged on each column as the signals are read out by a column select unit <NUM>. The electrical signals corresponding to each pixel output can be then placed on a bus <NUM>.

The array of pixels <NUM> can be a photodiode type pixel structure. When reverse biased, current will flow through the photodiode with incident light creating photocurrent. Depending on the photodiode bias to a drain voltage, a photogenerated charge current is produced, and the charge can be amplified by a source follower transistor and sense unit within the analog processing portion of the analog-to-digital output structures <NUM>. Depending on the magnitude of the sensed analog signal, a binary bit value of logic <NUM> or logic <NUM> can be created and placed on bus <NUM>. Digital sensor imagers <NUM> that incorporate an amplifier into each pixel for increased sensitivity are known as active pixel sensors. Moreover, digital imaging sensor <NUM> can either be implemented as a CCD, or a combination of p-type transistors and n-type transistors utilizing CMOS fabrication technology as a CMOS sensor. Most modern-day digital imaging sensors use a CMOS sensor chip, or die, to perform the photon or electron sensing. Regardless of whether a CCD or CMOS device is used by digital sensor <NUM>, a plurality of electrical signals are sent on bus <NUM> representative of the image or symbol to address a digital display <NUM> for thereafter emitting light from the corresponding pixel(s). When the electrical signals on bus <NUM> cause an array of diodes in display <NUM> to forward bias, light is emitted from those diodes on pixel-by-pixel bases as electrical energy is converted to light or photons that are then combined in beam combiner <NUM>.

Referring back to <FIG>, analog image intensifier tube <NUM> is beneficial over images generated by digital imager <NUM>, in that tube <NUM> can generate high quality images over a wide range of light levels, including extremely low light levels such as those encountered under starlight. Night vision system <NUM> utilizing analog image intensifier <NUM> are fairly well known, and based on Generation-III (GaAs photocathode) or Generation-II (multi-alkali photocathode) image intensifier fiber that can be thereafter optically coupled to a CCD or CMOS sensor device to form an image intensified low light level camera.

Image intensifier <NUM>, however, is an analog image intensifier. Analog image intensifier <NUM> produces an analog image onto beam combiner <NUM>, and does not convert that image to a digital electrical signal representation thereof. The analog image is produced on the eyepiece <NUM> directly, without any photon to electrical signal conversion within the image intensifier tube itself. The image produced from analog image intensifier <NUM> is not a plurality of binary <NUM> or <NUM> as in the digital sensor <NUM> output. Instead, analog image intensifier <NUM> produces multiplied and gained electrons converted to photons and displayed through a transparent fiber optic screen, for example.

Analog image intensifier <NUM> begins with a photocathode, such as a transmission photocathode <NUM>. Photocathode <NUM> may comprise a faceplate made of glass and coated with GaAs on a backside surface of the faceplate <NUM> facing an electron multiplier <NUM>. Other type III-V materials can be used such as GaP, GaIn, AsP, InAsP, InGaAs, etc. Alternatively, the photocathode <NUM> may be known as a Bi-alkali photocathode. Photoemissive semiconductor material of photocathode <NUM> absorbs photons. The absorbed photons of the optical image arriving on the faceplate of photocathode <NUM> causes the carrier density of the semiconductor material to increase, thereby causing the material to generate a photocurrent of electrons <NUM> emitted from the backside surface of photocathode <NUM>. According to one example, a semiconductor wafer may have GaAs epitaxially grown on a frontside surface of the wafer, and the backside surface thereafter thinned, and then bonded to the glass faceplate so that the GaAs epitaxially grown surface faces the electron multiplier <NUM>. Alternatively, the semiconductor structure may be another type of semiconductor material other than silicon that contains epitaxially grown GaAs. That alternative semiconductor structure can be GaAs itself.

Image intensifier tube <NUM> utilizes photocathode <NUM>, according to one example, for conversion of non-visible light sources such as near infrared or short wave infrared to visible. In many image intensifiers, the electrons emitted from photocathode <NUM> are accelerated towards a transparent anode coated with phosphor, such as electron sensing anode <NUM>. The electrons that strike the phosphor with high energy can cause the phosphor coating 29a on anode <NUM> to generate photons. The emitted photons are directed by optics, such as a fiber optic bundle 29b, directly to an eyepiece. The combination of the phosphor coating and fiber optic bundle are shown as 29a and 29b, respectively. The phosphor coated fiber optic screen, or sensor anode <NUM>, is vacuum sealed within the analog image intensifier <NUM>. The fiber optic taper or transfer lens within the fiber optic unit 29b transfers the amplified visual image via beam combiner <NUM> to the eyepiece <NUM> for viewing by the user.

In the existing analog image intensifiers <NUM>, there are numerous interfaces in which the image is sampled, and image degrades and adds noise to the incoming optical signal. This image degradation and reduction in resolution is disadvantageous in night vision systems <NUM> that require high quality output. To offset the image degradation resulting from the multiple optical interfaces in the image intensifier <NUM>, a microchannel plate (MCP) electron multiplier <NUM> is oftentimes used. The MCP type electron multiplier receives the electrons <NUM> that are focused onto it by the photocathode <NUM>, and the MCP-type electron multiplier intensifies the electron image by producing secondary multiplication of those electrons at the output thereof, as shown by reference numeral <NUM>. Although MCP-type electron multiplier <NUM> applies gain or amplification to the image intensifier <NUM>, and while an MCP-type electron multiplier maintains the geometric integrity of the incoming image, MCP's are relatively noisy as an electron amplifier. The added noise can degrade the low light level image quality. Moreover, due to the density by which each MCP channel opening must be placed near the adjoining MCP channel opening, the backside surface of an MCP <NUM>, as shown in <FIG>, has little if no room for mounting anything else on that backside surface between openings 21a and 21b, for example.

Alternatively, a doped electron multiplier must be used herein instead of an MCP. A doped electron multiplier not only produces the necessary multiplication and electron gain, but also have sufficient area on its backside surface to accommodate electron emitters of the Spindt type. The emission areas on the backside surface of the doped electron multipliers, between doped regions thereof, are activated to a negative electron affinity (NEA) state to facilitate the flow of electrons from the backside emission surfaces. Still further, in the regions between multiplied electron emission areas of the doped electron multiplier an array of electron emitters can be placed along with circuit actuators needed to activate those emitters on a pixel-by-pixel basis, each of which are selected by the digital signals providing across a bus <NUM> from an improved digital imager <NUM> shown in <FIG>.

<FIG> illustrates the backside surface, taken in profile, of a doped semiconductor electron multiplier <NUM>. Since this is a backside surface illustration, the multiplied electrons will extend vertically upward from the page as they emit from the backside surface between doping regions <NUM> (shown as regions 71a, 71b, 71c, etc.). <FIG> illustrates the backside surface of a doped semiconductor electron multiplier <NUM> prior to the addition of Spindt-type electron emitters and gate circuitry that are printed and diffused on and into that backside surface as will be described in further detail in <FIG>. <FIG> is presented to illustrate the sufficient real estate on the backside surface needed to add the electron emitters and control circuitry that is not available in the MCP-type electron multiplier <NUM> backside surface. Accordingly, the present embodiments utilize a doped semiconductor electron multiplier rather than an MCP-type electron multiplier between the photocathode and the sensor anode of an image intensifier tube that forms the analog image intensifier and, as will be discussed below, part of the digital imager <NUM>.

Turning now to <FIG>, a night vision system <NUM> according to the present invention is shown in block diagram. The improved night vision system <NUM> according to the present disclosure does not utilize a beam combiner <NUM> or a digital electronic display <NUM> as noted in the night vision system <NUM> of <FIG>. Night vision system <NUM> nonetheless combines an addressable display within analog image intensifier <NUM> onto eyepiece <NUM>. Instead of combining or overlaying an image derived from a digital display with an image derived from an analog image intensifier <NUM> using a beam combiner, electrical signals from digital imager <NUM> are sent across an electrical bus <NUM> onto at least one and preferably two electron multipliers 61a and 61b. Any symbology from controller <NUM> are also represented as binary bits and also sent as <NUM> and <NUM> across bus <NUM> onto the primary and secondary electron multipliers 61a and 61b, respectively.

Image intensifier <NUM> of <FIG> includes a photocathode <NUM> comprising a glass faceplate onto which a GaAs semiconductor die, or epitaxially grown GaAs on silicon die, is bonded to a backside surface, shown as reference numeral <NUM>. On the backside surface of the primary electron multiplier 61a is a semiconductor die having an array of electron emitters, as shown by reference numeral 64a. On the backside surface of secondary electron multiplier 61b can be an array of electron emitters formed also on a semiconductor die, as shown by reference numeral 64b. The conductive traces of electrical bus <NUM> are connected to printed conductors that are routed through gating logic to the array of electron emitters 64a and 64b. The array of electron emitters within the primary and secondary electron multipliers 61a and 61b are identical to one another and have the same spacing and are in alignment with one another.

On the frontside surfaces of the primary and secondary electron emitters 61a and 61b are optically transparent glass plates 65a and 65b. As noted herein, a frontside surface is a surface that faces towards the photocathode <NUM>, whereas a backside surface is a surface that faces towards the sensor anode <NUM>. Anode <NUM> can include a frontside surface of a transparent glass spacer die 69a, and a backside region of a fiber optic bundle or lenses 69b. The transparent glass spacer die 69a can be coated with phosphor to direct the photons light converted by the phosphor toward the eyepiece <NUM>. Primary electron multiplier 61a multiplies electrons using the doped semiconductor regions therein, and sends the multiplied electrons from a plurality of electron emission regions arranged pixel-by-pixel to corresponding pixelated emission regions in the secondary electron multiplier 61b, where the electrons are further multiplied to provide multiple electron gain and amplification onto the phosphor screen of sensor anode <NUM>.

The electron emitter are also arranged on the backside surfaces of the primary and secondary electron multipliers 61a and 61b so that each electron emitter is adjacent to a corresponding electron emission region. In this fashion, the electrons emitted from each emitter can be electrically addressed by control circuitry corresponding to that emitter. The control circuitry is actuated with a digital number corresponding to a set of binary <NUM> and <NUM> sent on bus <NUM>. The digital number can be converted to a corresponding analog value by the control circuitry having a digital to analog converter (DAC), and that analog voltage is applied to a pixel control gate. Within digital imager <NUM> is preferably another (second) analog image intensifier tube 58b. Image intensifier tube 58b is preferably identical to image intensifier <NUM>. At the backside of the image intensifier 58b is a digital sensor 56b mounted on or separate from the backside surface of image intensifier tube 58b. The digital sensor 56b comprises a plurality of active or passive pixel sensor devices arranged in an array operating as optical pixels with CMOS circuity to convert the photons emitted from image intensifier 58b to electrical signals, similar to the pixel array <NUM> shown in <FIG>. Digital sensor 56b can be a CMOS imager used as an active pixel sensor device or passive pixel device. Digital sensor 56b can be a CMOS imager chip or die with integrated amplifiers as an active pixel sensor device that incorporates both the photodiode and a read out amplifier.

Since the image intensifier tubes <NUM> and 58b are the same and have the same chip or die size, the improved night vision system <NUM> of <FIG> has a digital channel dimension or width DCW that matches the analog channel dimension or width ACW. Thus, the channel opening into the digital imager <NUM> is equal to the channel opening into the analog image intensifier <NUM>. As seen by a viewer when looking at the object <NUM>, the viewer will see the digitally derived image overlaid across the entire field of view of the analog derived image. Referring back to <FIG>, the DCW will extend outward equaling the field of view of ACW. However, the image viewed by the DCW can be of a different wavelength or contain different image modalities and symbols that may not be viewable by the ACW field of view seen by a user. Expanding the field of view of the DCW corresponding to the ACW not only provides the user with a more robust viewing experience, but provides more information at different image modalities and symbol indicia for a safer viewing experience. For example, the LWIR modality detectable by the digital imager <NUM> is displayed across the entire field of view (in both height and width) of the analog image intensifier tube <NUM>, and not just a small portion thereof.

The improved night vision system <NUM> of <FIG> thereby eliminates the weight and enhances the overall system transmission efficiency over conventional designs. The space requirements and physics of current MCP-type electron multipliers also do not lend themselves to the incorporation of data from outside source to the conventional beam-combiner integral display. The present night vision system <NUM> uses wafer scale photolithography and the physics of electron bombarded gain and negative electron affinity (NEA) at the emission areas between doped regions of the silicon surfaces. Night vision system <NUM> advances the performance of analog night vision in both signal-to-noise ratio, modulation transfer function (MTF) with an associated power reduction. The added capability of incorporating external digital signals and binary <NUM> and <NUM> information is achievable on not just one but on two or more electron multipliers. Of benefit is the electrical signals sent to electron emitters on the backside surfaces of the electron multipliers. It is desirable that the digital electrical signals on bus <NUM> be sent to the electron multipliers instead of, for example, the backside surface of a photocathode. One advantage is the emission from the electron emitters on the primary electron multiplier will be further amplified or multiplied downstream on the secondary electron multiplier. The emission surfaces from two backside surfaces are also identical across the arrays of each and in registration with both backside surfaces. If the emitters are placed on the backside surfaces of the photocathode, the GaAs or other III-V materials of the photocathode backside are not of a semiconductor, photolithography-defined silicon surface. Silicon microfabrication is more readily achieved compared to any microfabrication into GaAs surface. Moreover, the GaAs backside surface of a photocathode is far too sensitive to residual gases in the vacuum than silicon. It is therefore desirable to minimize any current emitted from the GaAs photocathode backside because emitted electrons tend to ionize the residual gas. The ionized gas is of opposite charge compared to the electron so as to draw back the electrons to the photocathode backside by the internal field. Any backscattering of the ion to the GaAs of the photocathode tends to poison the surface, thereby decreasing its NEA capability. Thus, for the above reasons as well as others, it is far more desirable to incorporate the external digital signals upon the electron multipliers and not upon the photocathode.

The improved night vision system <NUM> not only incorporates external electrical digital signals to each electron emitter, but also allows electron emitters at each pixel to utilize the existing phosphor 69a for integral light generation. A digitally injected image can be correctly overlaid onto the intensified scene within the vacuum envelope of the image intensifier tube <NUM>. The improved night vision system <NUM> incorporates a second image intensifier tube 58b onto the digital imager to improve the performance of the digital imager <NUM>. The present digital imager <NUM> can match the low illumination light level performance or temporal response of image intensifier tubes, and can display more information to the user than just the scene in front of that user. This information can include directions (e.g., symbols) or other imaging modalities and image wavelengths onto the analog image intensifier <NUM>. Already present optically transparent screens 69b of an image intensifier tube <NUM> can be used to display digital data from other sensors such as sensor 56b or other digital symbology of binary <NUM> and <NUM> from controller <NUM>. The digital imager of the improved night vision system <NUM> also incorporates a wider and greater display area to incorporate symbology and other information to the entire field of view offered by the analog image intensifier tube <NUM>. The predominate reason for the wider display is that digital imager <NUM> incorporates an analog image intensifier tube 58b that is similar to the analog image intensifier tube <NUM>, and of the same chip or die size for each. Moreover, the photon-to-electron conversion into tube 58b matches that in tube <NUM>, and the tubes of each have one and preferably two electron multipliers for added low illumination performance.

Turning now to <FIG>, a side view of the analog image intensifier tube <NUM> or 58b in <FIG> is shown. Since tube 58b is the same as tube <NUM>, the reference numerals in tube <NUM> will also be applicable to those in tube 58b, and those reference numerals are taken from <FIG> illustrating tube <NUM>. It is important to note, however, the same items within analog image intensifier tube <NUM> are also in the analog image intensifier 58b within the digital imager <NUM> of <FIG>. Referring back to <FIG>, a photocathode within the analog image intensifier tube <NUM>/58b comprises a faceplate <NUM> having one surface directed towards the object being imaged, and the opposing surface having GaAs material thereon. GaAs material can be in a form of an epitaxially grown GaAs material, or can be GaAs semiconductor body. As noted above, other III-V materials can be used for item <NUM> on the backside surface of faceplate <NUM>. A seal member 70a can be arranged between GaAs material <NUM> and a glass spacer 65a. Getter material 72a can be placed on spacer 65a and adjacent to seal member 70a. Seal member 70a can be deposited using various semiconductor fabrication techniques, or through electroless plating, electro-deposition or various combinations thereof. Seal member 70a, as well as seal members 70b and 70c, as shown in <FIG>, can be made of one or more layers of metallic materials such as copper, gold, lead, tin, aluminum, platinum, or other suitable material or combinations of material that can provide a good wetting surface for solder.

Referring to another embodiment, the seal members 70a, 70b, and 70c may be made of non-metallic material, such as glass, frit, ceramics or other combinations of non-metallic substances. The seal mechanism is performed by compression, thermocompression, or by other techniques that seal against ingress/egress of any substance or molecules into vacuum gaps 74a, 74b and 74c. The vacuum gaps 74a, 74b and 74c are caused by hermetically sealing via seal member compression electron multipliers 61a and 61b a spaced distance between the photocathode 59a and the sensor anode <NUM>. The photocathode 59a comprising a faceplate <NUM> and a backside coating material <NUM>, whereas the sensor anode <NUM> comprising a phosphor material 69a on the frontside surface of a fiber optic screen 69b.

The vacuum sealed cavities, or gaps 74a, 74b and 74c, can contain getter material 72a, 72b and 72c within that internal cavity. The getter material <NUM> is used to maintain a target vacuum level inside those cavities. Using a seal member for hermetically sealing electron multipliers 61a and 61b between the photocathode 59a and anode <NUM> within a vacuum housing can suffer from a high leak rate when a single vacuum pumped structure occurs. Getter material <NUM> is applied as a coating to a surface adjacent to spacer members 65a, 65b and 69a. When activated through the evacuation process and/or when combined with thermal energy, the getter material <NUM> can remove gases to maintain the vacuum level within the spaced gaps or cavities <NUM>. Removal or maintenance of the vacuum is described herein as "getter pump or getter pumping. " The getter material within the vacuum continually removes residual gas as it is produced, often achieving a higher vacuum than the pump could achieve alone during the seal process.

The digital sensor 56b is spaced from or coupled to a backside of the analog image intensifier tube 58b. The digital imager <NUM>, and specifically, the CMOS digital sensor 56a sends the electrical signals corresponding to the optical readings on the pixel array to the backside surfaces 64a and 64b of corresponding primary and secondary electron multipliers 61a and 61b. The electrical signals are sent to addressable electron Spindt emitters on the backside surfaces 64a and 64b. The electron emitters can be electrically conductive protrusions <NUM> printed as an array of protrusions using conventional semiconductor photolithography and deposition techniques across the backside surfaces. Surrounded by and coupled to each protrusion <NUM> is actuating circuitry that couples to the bus <NUM> to receive a corresponding electrical signal. Depending on whether the logic value is binary <NUM> or binary <NUM>, an emitter protrusion <NUM> will emit electrons or not. Each electron emitter <NUM> emits electrons from the backside surface of an electron multiplier 61a or 61b between a pair of spaced emission surfaces from which multiplied electrons are emitted toward the sensor anode <NUM>.

The analog image intensifier tube <NUM> and 58b can be simultaneously formed from a series of bonded, spaced, and sealed wafers. The wafers consist of glass spacer wafers bonded to an appropriate processed silicon wafer, with seal members and getter members spaced between bonded wafers near the scribe line. The seal member <NUM> is configured around each individual die or chip to be formed so that, when sealed, a die or chip results having primary and secondary electron multipliers 61a and 61b sealed in vacuum from each other and between photocathode 59a and anode <NUM>.

Since primary electron multiplier 61a comprises a scribed semiconductor wafer die 64a that is identical to scribed semiconductor wafer 64b of the secondary electron multiplier 61b, each electron emitter <NUM> in one electron multiplier 61b is aligned with the corresponding electron emitter <NUM> in the other electron multiplier 61a. More specifically, there are a plurality of emitter axes <NUM> extending through the central portion of each emitter protrusion <NUM>, with a center of emitter protrusion <NUM> within the primary electron emitter 61a aligned along that same axis with a center of emitter protrusion <NUM> within the secondary electron multiplier 61b. The emitter axis <NUM> is shown parallel to and spaced from an emission axis <NUM>. The emission axis shows alignment between the multiplied electron emission areas of the primary and secondary electron multipliers 61a and 61b. Of course, the number of emitter axes <NUM> corresponds to the number of paired electron emitters within each of the primary or secondary electron multipliers 61a and 61b. The emitter tip of emitter protrusion <NUM> will extend through that axes and is centered on that axis <NUM>.

The emission axis <NUM> is spaced from a corresponding emitter axis <NUM>, parallel to the adjacent to a corresponding emitter axis <NUM>. The combination of the emitter axis <NUM> and the emission axis <NUM> comprise the pathway at which electrons are emitted as a single pixel for display. By forming the image intensifier tube through vacuum spaced bonding of processed silicon wafers to corresponding glass spacer wafers, and thereafter separating vacuum-sealed die or chips, the electron emission surfaces of a corresponding pixel will be aligned along axis <NUM>, and the electron emitter protrusion surfaces will be aligned along axis <NUM> so that misalignment or blurring of resolution at the pixel level cannot occur. The DCW and ACW is confined to be the same size and a product of only the photolithography scale, which is much less than the format normally used in conventional beam combiners, where the ACW must be <NUM> or larger in height and width. Still further, the present image intensifier <NUM> or 58b produces gain on the electron multipliers 61a and 61b while incorporating an electronically addressed display in those multipliers. Each electron multiplier 61a and 61b is identical and uses negative electron affinity membranes in place of the conventional MCP used in most current image intensifiers. The electron multiplier device is based on MEMS processing and wafer scale technology as further illustrated in <FIG>.

Turning now to <FIG>, a total of <NUM> wafers are used to create the image intensifier tube. The eight wafers comprise spacer wafer 65a bonded to processed silicon wafer 64a to form the primary electron multiplier wafer 61a. Spacer wafer 65b is bonded to processed silicon wafer 64b to form the secondary electron multiplier wafer 61b. Spacer wafer 69a bonded to fiber optic wafer 69b to form the sensor anode wafer <NUM>, and the GaAs wafer <NUM> bonded to faceplate wafer <NUM> to form the photocathode wafer 59a. Phosphor <NUM> can be applied to either the spacer wafer 69a or the fiber optic wafer 69b of sensor anode <NUM>. Getter material <NUM> and seal member <NUM> is applied to spacer wafers 65a, 65b and 69a.

According to a preferred embodiment, the overall thickness of the bonded spacer and processed silicon wafers, including the faceplate and the fiber optic wafer of the photocathode and anode 59a and <NUM> is considerably thinner than a conventional image intensifier tube. Preferably, the faceplate <NUM> is between <NUM>-80mil in thickness. The bonded primary electron multiplier wafer 61a is between <NUM> and 4mil thick, and the secondary electron multiplier wafer 61b is also between <NUM> and 4mil in thickness. The bonded fiber optic screen and spacer wafer 69a, including the phosphor coating <NUM> used to form sensor anode <NUM> is preferably less than 80mil in thickness. The faceplate can be thinned from conventional faceplates, and various spacers can also be thinned provided there is sufficient structural integrity remaining. Each of the semiconductor wafers can have their backside surfaces thinned before bonding to the corresponding spacer wafers. The spacer wafers are optically transparent glass, and provide vacuum cavities that hold the getter and the seal material. Once sealed, the gaps between the photocathode and the primary electron multiplier, as well as between the primary electron multiplier and the secondary electron multiplier is preferably less than 10mil in thickness. The gap between the secondary electron multiplier is preferably less than 15mil. The glass spacer wafers 69a is thermal expansion-matched to the fiber optic wafer 59b and like all spacer wafers 65a and 65b, getter and seal members are applied to the ensuing cavity. An atomic layer deposited (ALD) thin filmed phosphor <NUM> is applied to the spacer wafer 69a or the fiber optic wafer 69b to provide the highest imaging quality.

Once all the wafers are bonded with the seal member surrounding each individual die, as shown in step <NUM>, the sealed wafers are placed on a vacuum post and diced the full thickness of the combination of the vacuum sealed wafers at step <NUM>. After being diced, individual die are removed as shown by step <NUM>. The combination of faceplate wafers, primary and secondary electron multiplier wafers, and the sensor anode wafer are diced along the seal member arranged along the saw or scribed line in between the faceplate wafer, the primary and secondary electron multipliers and sensor anode wafer to form vacuum sealed cavities there between. The processed components on each of the sealed wafers are therefore aligned with one another and the emission and emitter axis of the primary and second electron multiplier are also photolithography aligned. For example, one resulting die <NUM> can be sent to the analog imaging channel, and specifically image intensifier tube <NUM>, whereas the other die <NUM> can be bonded within the digital imager <NUM> as a second image intensifier tube 58b. The bonded image intensifier tube 58b can be further molded into a package material with leads extending therefrom, as shown. The analog image intensifier tube <NUM> is coupled within the analog intensifier channel of the night vision system <NUM>, whereas the packaged image intensifier 58b within the digital imager <NUM> is electrically coupled to sockets with a printed bus <NUM> coupled to those sockets and extending towards and coupling to electron emitters <NUM> on both the primary and secondary electron multipliers 61a and 61b.

Turning now to <FIG>, a detailed view along region <NUM> of <FIG> is shown. <FIG> illustrates the placement of the electrically addressable electron emitters <NUM> extending from a backside surface of processed silicon semiconductor die 64b. Processed silicon semiconductor die 64b multiplies electrons <NUM> entering the electron multiplier to present gained, multiple electrons <NUM> produced therefrom. Processed silicon semiconductor die 64b includes doped regions <NUM> that are doped from the backside surface toward the frontside surface, wherein the doped regions do not extend all the way to the frontside surface. Additional doped regions <NUM> are also formed. The doped regions <NUM> are doped with boron or aluminum, and constitute a p-type doped material. Doped regions <NUM> are doped heavily relative to doped regions <NUM>, which are also doped with p-type doping materials. The multiplied electrons <NUM> are emitted from emission regions <NUM>, which are activated to a negative electron affinity state to facilitate the flow of electrons from the emission regions <NUM>. Shown between emission regions <NUM> are emitters <NUM>, and specifically Spindt emitter tips that extend as protrusions <NUM> from the backside surface. The protrusions are conductive and are coupled to gating circuitry <NUM>. The gating circuitry includes various actuators that receive the electrical signals on bus <NUM> (<FIG>) turn on or off a corresponding emitter.

The gating circuitry <NUM> can include printed conductors and deposited multiple conductive regions that are placed on a dielectric, such as oxide <NUM> to separate those conductive members <NUM> from doped regions <NUM>. The conductive materials can reduce electron backscattering and reduce any dark current by the ratio of the area blocked by the metallic materials that are deposited. On the frontside surface of the processed silicon substrate die 64b are etched recesses that can assist in channeling the electron beam into the appropriate pixel region directly above the electron emission surface <NUM>. The texture frontside surface helps mitigate halo and improves gain at low incident electron energy.

Each protrusion of emitter tips <NUM> allows addressable electron to be emitted on a pixel-by-pixel basis next to the emission areas thereby making an image independent of the intensified image. The processed silicon semiconductor die 64b, or silicon membrane, is lightly p-type doped in regions <NUM> relative to regions <NUM>. The ensuing product indicates the halo intensity will be reduced by 40x and the size by 2x, making the overall device having a near zero halo. The electron receiving surface that receives electrons <NUM> is more heavily p-type doped to push the electrons towards the emission surface on the opposite side (backside) of the device. When the electrons impact the front surface, they dissipate their energy creating additional electrons by impact ionization. The noise figure of this amplification is approximately <NUM>, much lower than the noise figure of the MCP which ranges from <NUM> to <NUM>. The result is an increase in signal-to-noise ratio of <NUM> compared to <NUM> for an MCP-type intensifier. The gained electrons diffuse to the emission surface. If the p-type doping profiles were not in place the electrons would diffuse laterally as they move toward emission surface <NUM>. It is the active receiving the electrons <NUM> on one side, gaining those electrons, then diffusing them to the opposite surface <NUM> and re-emitting them that gives the present device its name of transmission mode secondary electron (TMSE) intensifier. The doping profiles funnel the electrons to the smaller emissions surface. In a MCP-based intensifier, the hole at the input and output are about the same size so there is no focusing of the electrons. In the TMSE device, the receiving area is larger than the emission area. This helps to improve the modulation transfer function, or image fidelity. In a MCP intensifier, the largest loss in modulation transfer function is the radial energy the electron possess as they leave the back of the MCP. This radial energy, or mean transfer energy, allows the electrons to spread to the vacuum gap between the components. The negative electron affinity surface of the GaAs photocathode, and the silicon gain wafers, have MTE that are an order of magnitude smaller than the MCP. These features, small emission area, doping profiles, low MTE, and front surface texture, lead to a device which will have improved MTF across all the spatial frequencies and have resolution of <NUM> lp/mm compared to MCP-based intensifiers with resolution of <NUM> to <NUM> lp/mm. In the actual TMSE electron multiplier device, there are two silicon gain layers as both primary and secondary electron multipliers to produce the same gain as the MCP-based intensifier. The MTF improvement would allow a <NUM> die size electron multiplier to have the same range recognition as the current <NUM> MCP-based image intensifier. Therefore, the night vision system size can be reduced by the reduction of the image intensifier channel ACW and DCW, and the associate optics.

The resolution of the screen is important for both the image intensified channel and the incorporated screen. The radius that the electrons travel from the initial emissions spot in emissions regions <NUM> is determined by the mean transverse energy of the emitted electrons. This is the amount of energy that is directed parallel to the surface. The radius is given by: <MAT> Gap is the distance between the silicon layer containing the emitter tip protrusion <NUM> and the sensor anode <NUM>. Vbias is the voltage between the silicon membrane of the emitter <NUM> and the sensor anode <NUM>. In the intensifier design, the gap and voltage bias are the same as in the standard intensifier at <NUM> microns and at <NUM> volts. For the negative electron affinity surfaces GaAs and silicon, the MTE are on the order of <NUM> and <NUM> volts respectively. In a case of the field emitter tips of the electron emitters <NUM>, the MTE and a collimated structure is on the order of <NUM> volts. Table <NUM> shows the projected radius of the three MTE values of negative electron affinity GaAs and negative electron affinity silicon, and the collimated field emission tip.

As shown in the Table <NUM> above, the spot radius of the field of the electron emitters is on the order of the spot from negative electron affinity GaAs and silicon. The electronically addressable screen will have about the same resolution as the image intensifier. Due to each intensifier pixel having the capability including an addressable field emission electron emitter array, the pixel count will also be the same. The intended pixel size for the intensifier is <NUM> microns, and the format is <NUM> horizontal and vertical. Thus the array size is <NUM> megapixel. This is in excess of most display requirements currently being specified by military systems. The geometry thus derived is a monochrome display of same color as the normal image intensifier.

Turning now to <FIG>, a bottom backside view within region <NUM> of <FIG> is shown. Specifically <FIG> illustrates the multiplied electron emission area <NUM> spaced between a pair of electron emitters <NUM>. In the region around the emission region <NUM> is reserved for control circuitry <NUM> used to actuate the adjacent electron emitter <NUM> on a pixel-by-pixel base. It is recognized that <FIG> shows only a portion of the backside surface of the secondary electron multiplier 64b. It is also recognized that the backside surface of the primary electron multiplier 64a is identical to that of the secondary electron multiplier 64b. As such, a first plurality of spaced emission surfaces <NUM> on the backside surface of the primary electron multiplier 64a are aligned with and along the same emission axis as the corresponding second plurality spaced emission surfaces <NUM> on the backside surface of the secondary electron multiplier 64b. The first plurality of spaced emission surfaces <NUM> are interlaced with the first plurality of spaced electron emitters <NUM>. The second plurality of spaced emission surfaces <NUM> are interlaced with the second plurality of spaced electron emitters <NUM>. Each of the first plurality of the spaced emission surfaces are aligned with respective ones of the second plurality of spaced emission surfaces along a plurality of emission axes that are parallel to each other and parallel to an inner wall of the vacuum housing. Moreover, the plurality of emitter axes are parallel to and interlaced with the plurality of emission axes.

To create a color display with red green blue (RGB) pixels in a spatial arrangement would reduce the resolution both the image intensifier and the incorporated electronically addressable display on the backside surfaces of the electron multipliers. A color display can be created by temporally splitting a fixed time period, utilizing a white phosphor screen, and adding an external set of electronically tunable color filters. For example, for a time period of <NUM>/<NUM> of a second, split into unequal portions, any pixels that are red will be addressed first, then pixels that are green will be addressed and actuated second, and finally on the third time slice a blue field emission points are actuated and a blue filter activated.

It is important to note that the construction and arrangement of the various example embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the the subject matter described herein. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Additionally, features from particular embodiments may be combined with features from other embodiments as would be understood by one of ordinary skill in the art. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various example embodiments without departing from the scope of the present invention as defined in the appended claims.

As used herein, the terms "about," "approximately," substantially," "generally," and the like mean plus or minus <NUM>% of the stated value or range. In addition, as used herein, the singular forms "a," "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. For example, reference to "a feature" includes a plurality of such "features. " The term "and/or" used in the context of "X and/or Y" should be interpreted as "X," or "Y," or "X and Y".

The illustrated embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be used, and other changes may be made, without departing from the scope of the subject matter presented herein. Additionally, particular aspects of each embodiment may also be used in conjunction with other embodiments of the present disclosure and thus, the disclosed embodiments may be combined as understood in the art. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, separated, and designed in a wide variety of different configurations, all of which are explicitly contemplated herein.

It should be noted that any use of the term "example" herein to describe various embodiments is intended to indicate that such embodiments are possible examples, representations, and/or illustrations of possible embodiments (and such term is not intended to connote that such embodiments are necessarily extraordinary or superlative examples). Further, as utilized herein, the term "substantially" and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed (e.g., within plus or minus five percent of a given angle or other value) are considered to be within the scope of the invention as recited in the appended claims. The term "approximately" when used with respect to values means plus or minus five percent of the associated value.

The terms "coupled" and the like as used herein mean the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another.

It should be noted that although the diagrams herein may show a specific order and composition of method steps, it is understood that the order of these steps may differ from what is depicted. For example, two or more steps may be performed concurrently or with partial concurrence. Also, some method steps that are performed as discrete steps may be combined, steps being performed as a combined step may be separated into discrete steps, the sequence of certain processes may be reversed or otherwise varied, and the nature or number of discrete processes may be altered or varied. The order or sequence of any element or apparatus may be varied or substituted according to alternative embodiments. Accordingly, all such modifications are intended to be included within the scope of the present disclosure as defined in the appended claims.

Claim 1:
A night vision system, comprising:
first analog image intensifier tube (<NUM>);
an addressable display within the first analog image intensifier tube (<NUM>) configured to create an electronically addressable output;
a digital imager (<NUM>) configured to receive an optical image and produce a plurality of digital electrical signals corresponding to the optical image; and
a controller (<NUM>) configured to produce a symbol digital electrical input onto the plurality of digital electrical signals;
characterized in that
the first analog image intensifier tube (<NUM>) is configured to receive the optical image and to produce multiplied electrons from the addressable display comprising a first electron multiplier (64a) within the first analog image intensifier tube (<NUM>), and to also produce electrons from electron emitters (<NUM>) on the first electron multiplier (64a) that are addressed on a pixel-by- pixel basis by the plurality of digital electrical signals.