Patent Description:
Various applications may use sensor arrays. An exemplary sensor array includes a hydrophone array. A hydrophone array may be implemented in a sonobuoy that is dropped or ejected from an aircraft or a ship. The sonobuoy and the array may be dropped into an environment for acoustic observation. For example, the sonobuoy may be dropped in the ocean for underwater acoustic research. A sonobuoy may be used in military applications, such as in anti-submarine warfare. After the sonobuoy reaches the intended environment, the sensor array is deployed from the sonobuoy. During deployment, the sensor array may expand from a compacted structure to an expanded structure in which the sensor array is operable to perform the intended function, such as underwater surveillance.

Sonobuoys typically have a small size such that stowage and deployment of the hydrophone array presents challenges. Prior attempts to package and deploy hydrophone arrays include using rigid structures to support the shape of the array and external actuation devices such as motors, pumps and extra batteries. Using the rigid structures and external actuation devices may be a disadvantage for small-sized sonobuoys due to space constraints. Another disadvantage of using the rigid structures is that the structures provide limited deployment options for the sensors and thus limited directionality for the sensor array.

<CIT> discloses a marine seismic detector array with a self erector which comprises: (a) a pair of plates having a central shaft extendin therebetween, (b) a rotatable hub mounted on said shaft, (c) a plurality of resilient strips prestressed to a nonplanar transverse configuration each anchored at one end thereof to the surface of said hub and wound onto said hub, (d) a like plurality of guides secured between said plates radially spaced from said hub and through which said strips extend, (e) cable means for supporting said plates at a preselected depth at a marine listening station, (f) a seismic sensor secured to the free end of each of said strips with said strips normally coiled about said hub, (g) a restraining band encircling the sensors to prevent said strips from unwinding from said hub, and (h) actuating means for removing said band to permit said strips to unwind from said hub for the support of said sensors in an array wherein each of said sensors is spaced from the axis of said hub.

<CIT> discloses that TiNi-base alloys, particularly those near stoichiometric TiNi composition, have applications as self-erecting aerospace and hydrospace components, low acoustic noise machine mountings and devices, prestressed bindings and reinforcements, stored energy tools, energy converters, temperature actuated devices (switches, fire alarms, etc.), clock mechanisms, cryogenic components.

To enable both compact stowage of a sensor array and expansion of the sensor array into a three-dimensional volumetric array shape that enables improved directionality of the sensor array during operation, a deployment module according to claim <NUM> is provided. The deployment module includes a support shell that is configured to retain a cable of the sensor array separately from sensors of the sensor array and an expandable deployment body formed of a superelastic shape memory alloy that uses superelasticity and stored energy for deployment of the sensor array. During deployment, the deployment body is removed from the support shell and the sensors are subsequently pulled out of the support shell. The deployment body then expands and holds the cable to retain the three-dimensional volumetric shape of the deployed sensor array.

The deployment module is modular in that a plurality of deployment sub-modules are axially stacked to form the deployment module. Each deployment sub-module includes a deployment body and a support shell. During deployment, the support shells are sequentially emptied of the sensors until all of the sensors are deployed. The deployment module may be vertically deployed such that the deployment sub-modules are deployed starting from an uppermost deployment sub-module and continuing until a lowermost deployment sub-module is deployed or vice versa.

The support shell may be formed using additive manufacturing and is formed to have spaced walls that define discrete slots for retaining the cable. Using the support shell prevents hockling or tangling of the cable during stowage and deployment. The shape of the support shell also positions each sensor on top of the walls by way of each sensor being seated after wrapping a segment of the cable in the walls until an open seat for a sensor is reached.

The deployment body may include a central hub and springs that are spirally wound around the central hub during stowage. One end of each spring is secured to the central hub. During deployment, the entire deployment body spins due to the superelasticity and stored spring energy of the springs, such that each spring is unwound and straightens radially outwardly to a normal shape of the spring. The extended end of the spring has an arm secured to the spring that engages the cable to maintain the shape of the sensor array.

The sensors of the sensor array may be formed using a micro inductive welding process. Clamshell portions are fused together to form a clamshell body that surrounds a flexible piezo element of each sensor. A plastic membrane is sealed onto the clamshell body to cover the piezo element. Using micro inductive welding enables a rapid sealing process that results in watertight, pressure tolerant, and precise sealing for the sensor electronics.

The invention provides a deployment module for a sensor array having a plurality of sensors and a cable connecting the plurality of sensors comprising: a deployment body formed of a shape memory alloy that is expandable to hold the cable and retain a shape of the sensor array after deployment; and a support shell configured to support the sensor array and the expandable deployment body in a stowage state before deployment, the support shell having spaced walls configured to retain the cable separately from the plurality of sensors, wherein the spaced walls define discrete slots that each accommodate a segment of the cable corresponding to one of the plurality of sensors.

According to an embodiment, the deployment body is formed of a superelastic material having stored spring energy when in the stowage state.

According to an embodiment, the deployment body is spinnable to release the spring energy whereby the deployment body expands from a compacted shape to an expanded shape.

According to an embodiment, the deployment body includes a central hub and a plurality of springs that each have a fixed end secured to the central hub.

According to an embodiment, deployment body includes a plurality of arms that are secured to opposite ends of the plurality of springs relative to the central hub and are configured to engage the cable.

According to an embodiment, the plurality of arms includes clamping portions to engage the cable.

According to an embodiment, the central hub has a plurality of blades, wherein the fixed end of each of the plurality of springs is held between two adjacent blades of the plurality of blades.

According to an embodiment, the deployment module includes a plurality of deployment bodies and a plurality of support shells, wherein the plurality of support shells and the plurality of deployment bodies are axially stacked.

According to an embodiment, the deployment module includes a central electro-mechanical cable that supports each of the plurality of deployment bodies.

To the accomplishment of the foregoing and related ends, the invention comprises the features hereinafter fully described and pointed out in the claims. The following description and the annexed drawings set forth in detail certain illustrative embodiments of the invention. These embodiments are indicative, however, of but a few of the various ways in which the principles of the invention may be employed within the scope of the invention, as defined by the claims. Other objects, advantages and novel features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the drawings.

The principles described herein have particular application in systems used for sensing extremely large environments or environments that are not easily accessible. Examples of environments in which a sensing system or array may be used include underwater, air, and space. The deployment module and method disclosed herein may be used for packing and deploying sensors in a particular environment. Military applications, such as anti-submarine warfare, or non-military applications, such as underwater acoustic research applications, may be suitable applications. In an exemplary application, a sonobuoy that includes a hydrophone array having any size may be suitable, and more particularly, a small-size or "A-size" sonobuoy for deploying a hydrophone array may be suitable. The hydrophone array may be deployed into the ocean from any suitable platform, such as an aircraft, sea vessel, or land vehicle. The deployment module and method disclosed herein may be used with many other sensor systems, environments, and platforms.

Referring first to <FIG> and <FIG>, a deployment module <NUM> for a sensor array <NUM> includes a deployment body <NUM> and a support shell <NUM>. As shown in <FIG>, the deployment module <NUM> has a stowage state in which the sensor array <NUM> and the deployment body <NUM> are supported in the support shell <NUM>. The deployment body <NUM> and the sensor array <NUM> may be axially stacked in the support shell <NUM> along a central axis C. The deployment module <NUM> may be cylindrical in shape such that the central axis C is a longitudinal axis of the deployment module <NUM>. Shapes other than cylindrical for the deployment module <NUM> may be suitable, such as spherical or rectangular, and the shape may be dependent on the application.

The sensor array <NUM> includes a plurality of sensors <NUM> and a cable <NUM> that connects the plurality of sensors <NUM> to form the sensor array <NUM>. In an exemplary embodiment, the sensor array <NUM> may be a hydrophone array and the sensors <NUM> may be hydrophones, such as piezoelectric transducers. Other sensors may be suitable for the sensor array <NUM>, such as other acoustic sensors or optical sensors. Sensors that are configured to detect other environmental characteristics may also be suitable. For example, suitable sensors include sensors that detect pressure, temperature, or depth or distance. Each sensor <NUM> is connected to an adjacent sensor by a segment or length of the cable extending between axial ends <NUM> of the sensors.

<FIG> shows an exploded view of the deployment module <NUM>. The support shell <NUM> includes a plurality of spaced walls <NUM> that are configured to retain the cable <NUM> separately from the plurality of sensors <NUM> during the stowage state. The walls <NUM> are formed in a spiraled or leaved pattern. Discrete slots <NUM> are defined between the walls <NUM> and each discrete slot <NUM> accommodates a segment of the cable <NUM> that extends between two of the plurality of sensors <NUM>. When retained in the walls <NUM>, the cable <NUM> is nested in the walls <NUM>. Each wall <NUM> may form a loop <NUM> proximate a center <NUM> of the support shell <NUM> that engages a corresponding loop of an adjacent wall <NUM>, such that the support shell <NUM> has a plurality of loops <NUM> proximate the center <NUM>. Using the support shell <NUM> is advantageous in preventing hockling or tangling of the cable <NUM> during both stowage and deployment.

A plurality of axially extending tabs <NUM> are formed on an outermost wall <NUM> and may be circumferentially spaced by recessed windows <NUM> about the support shell <NUM>. The axially extending tabs <NUM> and the recessed windows <NUM> are used to provide access to the sensors <NUM>, such as during packing the sensor array <NUM> into the deployment module <NUM>. Any suitable manufacturing process and material may be used to form the support shell <NUM>. The support shell <NUM> may be formed as an integral and monolithic body. An additive manufacturing process may be suitable to form the support shell <NUM>. Other manufacturing methods, such as injection molding, may also be suitable. The support shell <NUM> may be formed of a plastic material. Other materials, such as other polymer materials or metal materials, may also be suitable. The materials may be dependent on the environment of an intended application for the deployment module <NUM>.

The support shell <NUM> is further advantageous in positioning the plurality of sensors <NUM> during the stowage state and deployment. The sensors <NUM> may rest on top of the walls <NUM>. The walls <NUM> are formed to accommodate a predetermined length of the cable <NUM> such that after a predetermined length of the cable <NUM> is inserted into a corresponding discrete slot <NUM> of the support shell <NUM>, a sensor <NUM> at the end of the predetermined length of the cable <NUM> reaches an empty seat on top of the walls <NUM>. The empty seat is adjacent another sensor <NUM> that was previously placed on top of the walls <NUM>. The sensor <NUM> is then seated at the specific location on the plurality of walls <NUM> and another predetermined length of the cable <NUM> is inserted into another corresponding discrete slot <NUM> until the next empty seat for the sensor <NUM> is reached.

When seated on the walls <NUM>, the sensors <NUM> are spaced by a predetermined distance and the sensors <NUM> may be held in position via the cable <NUM> being wrapped around the walls <NUM>. The sensors <NUM> are placed independently and in succession such that a first sensor 28a is placed in the support shell <NUM>, a segment of the cable <NUM> is inserted in a corresponding one of the discrete slots <NUM>, another sensor 28b is placed on the support shell <NUM> adjacent the first sensor 28a, another segment of the cable <NUM> is inserted in another discrete slot <NUM>, and so on. The placing of the sensors <NUM> and insertion of the cable <NUM> occurs alternately until the support shell <NUM> is fully accommodated.

The support shell <NUM> may be sized to accommodate any number of sensors <NUM> of the sensor array <NUM> and the number may be dependent on the application. Between five and ten sensors <NUM> may be supported by the support shell <NUM>. Fewer than five and more than ten sensors may be suitable for other exemplary applications. The support shell <NUM> may be sized up or down for different applications. The size of the support shell <NUM> may be selected to accommodate a predetermined sensor array <NUM> using a minimal volume.

The shape of the support shell <NUM> may be formed to accommodate the sensors <NUM> in a one-by-one alignment such that each sensor <NUM> is arranged between two other sensors <NUM>. In other embodiments, the support shell <NUM> may be formed to accommodate the sensors <NUM> in a two-by-two alignment in which a pair of sensors is adjacent two other pairs of sensors. When the sensors <NUM> are seated in the support shell <NUM>, the sensors <NUM> may be uniformly oriented. As shown in <FIG> and <FIG>, the sensors <NUM> may have angled orientations relative to each other, such that a maximum number of sensors <NUM> are accommodated in the support shell <NUM>. Other arrangements of the sensors <NUM> may also be suitable.

The deployment body <NUM> is expandable and is configured to deploy the sensor array <NUM> from the support shell <NUM> without using an external actuation device. The expansion may occur radially outwardly. The deployment body <NUM> expands via the material properties of the material of the deployment body <NUM>. The material may be a superelastic shape memory alloy spring that retains spring energy during the stowage state. Due to the superelasticity of the shape memory alloy and the stored spring energy, the deployment body <NUM> is configured to expand from a contracted shape, as shown in <FIG> and <FIG>, to an expanded shape that is a regular or normal shape of the spring.

Using the self-contained deployment body <NUM> is particularly advantageous for small-sized sonobuoys in which space is constrained. The superelasticity of the shape memory alloy may be formed to achieve between <NUM> and <NUM>% recoverable strain, as compared with conventional shape memory alloys that rely on externally applied joule heat for actuation. Thus, the deployment body <NUM> does not require additional activation devices for expansion. In other exemplary embodiments of the deployment body <NUM>, such as in embodiments intended to be used in air environments, the shape memory alloy may be formed to activate in response to heat.

The deployment body <NUM> is configured to engage the cable <NUM> to hold the sensor array <NUM> in a deployed arrangement such that the expansion of the deployment body <NUM> may occur radially outwardly. The precise shape of the deployment body <NUM> is dependent on the application and many different shapes may be suitable. In an exemplary embodiment, the deployment body <NUM> may be cylindrical in shape. The cylindrical deployment body <NUM> may spin to expand from the contracted shape to the expanded shape, via the superelasticity of the shape memory alloy and the stored spring energy. The deployment body <NUM> may be formed of a central hub <NUM> and a plurality of springs <NUM> that are formed of the shape memory alloy.

Each spring <NUM> has an end secured to the central hub <NUM> and an arm <NUM> that is secured to an opposite end of the spring <NUM> relative to the central hub <NUM>. The spring <NUM> may always have an end secured to the central hub <NUM> during stowage and when deployed. Each arm <NUM> includes a cable engaging end <NUM> that is opposite a spring securing end <NUM> at which the arm <NUM> receives the spring <NUM>. The cable engaging end <NUM> may be formed of clamping portions <NUM> that engage the cable <NUM> for securing the deployment body <NUM> and the cable <NUM>. The arm <NUM> may have any suitable shape. For example, the arm <NUM> may be cylindrical in shape.

In the stowage state, the springs <NUM> are spirally wound in two-dimensions about the central hub <NUM> to form a cylindrical shape and each arm <NUM> is circumferentially spaced about an outer peripheral surface <NUM> defined by the wound springs <NUM>. The central hub <NUM> may be fan-shaped with a plurality of blades <NUM>. Each spring <NUM> has a fixed end <NUM> that is held between adjacent blades <NUM>. When the deployment body <NUM> is expanded, the fixed end <NUM> remains secured to the central hub <NUM> and the body of the spring <NUM> expands or straightens out such that the spring <NUM> moves to a normal or regular shape of the spring <NUM>. The straight or unconstrained shape of the spring <NUM> holds the cable <NUM> that is engaged by the spring <NUM> in the three-dimensional shape. Other arrangements of the spring <NUM> may be suitable. For example, the deployment body <NUM> may be formed to have a single spring coil or counterrotating springs.

Referring now to <FIG>, an exemplary embodiment of the sensor <NUM> of the sensor assembly <NUM> is shown. The exemplary sensor <NUM> includes a flexible piezo element <NUM> for sensing acoustic energy. The piezo element <NUM> may have any suitable shape, such as a disc shape. Voltage of the sensor <NUM> is generated by straining the piezo element <NUM>. The sensor <NUM> includes a clamshell body <NUM> formed of two clamshell halves or portions 68a, 68b that are fused together to surround the piezo element <NUM> in a compact arrangement. The clamshell body <NUM> may be formed of any suitable material for protecting the internal electronics of the sensor <NUM>. An exemplary material includes thermoplastic.

The sensors <NUM> may be formed using any suitable manufacturing process. An example of a suitable manufacturing process includes micro inductive welding (MIW), such that a plurality of MIW susceptors <NUM> are formed between the clamshell portions 68a, 68b. A plastic membrane <NUM> is sealed onto the clamshell body <NUM> over the piezo element <NUM> to seal the sensor <NUM>. Any suitable material may be used for the plastic membrane <NUM>, such as a laminated polyethylene material. The plastic membrane <NUM> may have any suitable shape, such as a cylindrical shape. The arrangement of the sensor <NUM> is particularly advantageous in protecting the internal electronics of the sensor <NUM> using watertight and pressure resistant sealing that is provided by the MIW.

The sensor <NUM> may further include a telemetry circuit card assembly (CCA) <NUM> supported by the clamshell body <NUM> and connected to radially outwardly electro-mechanical cable terminations <NUM> of the sensor <NUM> via electrical connectors <NUM>. The telemetry CCA <NUM> is used to provide data from the sensor <NUM> to a receiver that may be located remotely from the deployed sensor array <NUM>. MIW susceptors may also be formed between the clamshell body <NUM> and the electro-mechanical cable terminations <NUM>. The electro-mechanical cable terminations <NUM> are plugged into the clamshell body <NUM> and are each connected to the cable <NUM> for connecting each sensor <NUM> to the cable <NUM>. Each sensor <NUM> may include two electro-mechanical cable terminations <NUM> that are mirrored on opposite sides of the sensor <NUM>. Each electro-mechanical cable termination <NUM> supports both of the clamshell portions 68a, 68b. Using the electro-mechanical cable terminations <NUM> is advantageous in enabling the sensors <NUM> to lay flat in the support shell <NUM> while enabling the cable <NUM> to be routed into the discrete slots <NUM>, as compared with conventional hydrophone arrangements in which the cable extends in an axial orientation.

Using MIW is advantageous in that the welding provides an effective seal between the elements in the sensor <NUM>, such as between the clamshell portions 68a, 68b, between the plastic membrane <NUM> and the clamshell body <NUM>, and between the clamshell body <NUM> and the cable <NUM>. MIW is used to rapidly and precisely fuse materials via a non-contact method as compared with conventional sensor forming methods that include potting hydrophones and cables with thermoset urethanes or shrink tubes to seal against water intrusion. Using MIW also eliminates the need for additional sealing elements, such as o-rings.

Referring now to <FIG>, a deployment module <NUM> includes a plurality of deployment sub-modules 20a, 20b, 20c that are axially stacked. Each deployment sub-module 20a, 20b, 20c may have the same features as the deployment module <NUM> shown in <FIG> and <FIG>. The deployment module <NUM> includes any number of deployment sub-modules 20a, 20b, 20c and the number of deployment sub-modules may be dependent on the application. Between four and ten deployment sub-modules may be suitable. Fewer than four and more than ten deployment sub-modules may be suitable in other applications. In an exemplary embodiment, the deployment module <NUM> may have a height that is between <NUM> and <NUM> centimeters (between <NUM> and <NUM> inches).

The number of deployment sub-modules may be selected based on the size of the sensor array <NUM> to be accommodated by the deployment module <NUM>. Each deployment sub-module 20a, 20b, 20c includes a separate support shell <NUM> and each support shell <NUM> may be formed to have the same height and diameter. The deployment module <NUM> includes a plurality of deployment bodies <NUM> that each correspond to one of the deployment sub-modules 20a, 20b, 20c such that each deployment sub-module 20a, 20b, 20c is separately deployed in succession. <FIG> also shows each arm <NUM> of the deployment body <NUM> engaging a corresponding segment of the cable <NUM>.

During deployment, the deployment sub-modules 20a, 20b, 20c are sequentially deployed and within each deployment sub-module 20a, 20b, 20c, the sensor array <NUM> is sequentially deployed. The deployment body <NUM> of a corresponding deployment sub-module 20a, 20b, 20c is first removed from the support shell <NUM> and the sensor array <NUM> is subsequently pulled out of the support shell <NUM>. One of the plurality of sensors <NUM> is pulled out of the support shell <NUM>, which is followed by pulling out a segment of the cable <NUM> from a corresponding one of the walls <NUM> of the support shell <NUM>, which is followed by subsequently pulling out another sensor <NUM> arranged at the opposite end of the segment of the cable <NUM>. The removal of the sensors <NUM> and the cable <NUM> from the support shell <NUM> continues in an alternating manner until the support shell <NUM> is emptied of the sensor array <NUM>. In an exemplary application, using the deployment module described herein, three or more meters of cable <NUM> may be deployed per second.

When a support shell <NUM> is emptied, the support shell <NUM> of the corresponding deployment sub-module 20a, 20b, 20c may be displaced and the deployment body <NUM> of an axially adjacent deployment sub-module 20a, 20b, 20c is then deployed. In an exemplary embodiment, the support shell <NUM> may be displaced into the environment, or the support shell <NUM> may be recoverable for future use. The deployment sequence may continue for each deployment sub-module 20a, 20b, 20c until all of the deployment sub-modules 20a, 20b, 20c are emptied and the entire sensor array <NUM> is deployed. In an exemplary application, the deployment module <NUM> has a vertical orientation during deployment, such that an uppermost deployment sub-module 20a is first deployed and the remaining deployment sub-modules 20b, 20c are deployed until a lowermost deployment sub-module 20c is emptied. In other exemplary applications, deployment of the deployment sub-modules 20a, 20b, 20c occurs from the lowermost deployment sub-module 20c and continues upwardly to the uppermost deployment sub-module 20a.

Referring now to <FIG>, the deployment module <NUM> during deployment is shown. The sensor array <NUM> has a vertical orientation and a three-dimensional volumetric shape in which the sensors <NUM> are radially spaced. The deployed shape of the sensor array <NUM> may have a diameter that is between <NUM> and <NUM> times the diameter of the deployment module <NUM> when in the stowage state. The deployment body <NUM> is in the expanded shape in which springs 50a arranged at a deployed end of the deployment module <NUM> are straightened out relative to the central hub <NUM> and extend between the central hub <NUM> and the cable <NUM>. The stiffness of the springs 50a being in their regular shape holds the segments of the cable <NUM> in the vertical orientation. The springs 50b at an opposite end of the deployment module <NUM> are shown during deployment in which the springs 50b are straightening out from the wound structure to move to the structure in which the springs 50a are shown. The cable <NUM> extends between all the sensors <NUM> of the sensor array <NUM> such that the cable <NUM> is continuous.

A central electro-mechanical cable <NUM> is provided as a strength member that retains an axial spacing of the central hubs <NUM> for each spring 50a, 50b. The central electro-mechanical cable <NUM> defines the central axis of the deployed sensor array <NUM>. Power for the cable <NUM> may also be provided by the central electro-mechanical cable <NUM> via a portion of the cable <NUM> being connected to the central electro-mechanical cable <NUM>. The central electro-mechanical cable <NUM> may extend an entire axial length of the deployed sensor array <NUM>. Accordingly, using the deployment module <NUM> enables a three-dimensional volumetric arrangement that provides directionality of the sensors <NUM>, as compared with a conventional line array or other sensor arrays that be limited in flexibility of the deployed shape for the sensor array. In an exemplary embodiment, after operation of the sensor array <NUM> is ceased, the entire deployment module <NUM> may be recoverable and able to be repackaged and re-deployed.

Referring in addition to <FIG> and <FIG>, exemplary applications for the deployment modules <NUM>, <NUM> are shown. <FIG> shows the deployment module <NUM>, <NUM> being deployed from a platform <NUM> that is shown as an aircraft. In other exemplary applications, the platform <NUM> may be a sea vessel or land vehicle. The packing module <NUM>, <NUM> may be arranged in a sonobuoy <NUM> that is deployed from the platform <NUM>. <FIG> shows the deployment module <NUM> and the deployed sensor array <NUM> after deployment from a sea vessel <NUM>, or after the packing module <NUM>, <NUM> is deployed from an aircraft and connected to a sea vessel <NUM>. After deployment, the sensor array <NUM> is a volumetric array such that the sensors <NUM> and the cable <NUM> are arranged in a vertically extending three-dimensional arrangement. The sensor array <NUM> is operable for the intended application when in the three-dimensional arrangement.

In an exemplary application, prior to the subsequent deployment of the sensor array <NUM>, the sonobuoy <NUM> including the deployment module <NUM>, <NUM> is deployed by the platform <NUM>, such as the aircraft shown in <FIG>, toward the water. A release mechanism may be provided for the initial release of the deployment module <NUM>, <NUM> from the platform. A buoyant portion of the sonobuoy <NUM>, or the sea vessel <NUM> if deployment of the deployment module <NUM>, <NUM> occurs from the seal vessel <NUM>, remains on the surface of the water <NUM> and a weighted portion <NUM> of the sonobuoy <NUM> is displaced and travels downwardly to deploy the sensor array <NUM> through the water, such that the deployment module <NUM>, <NUM> is in a vertical orientation during and after deployment.

The weighted portion <NUM> or another bottom portion of the deployment module <NUM> may also include a battery pack to power the sensor array <NUM>. The battery pack may be in communication with the central electro-mechanical cable <NUM> for supplying power to the cable <NUM>. Electronics and radio may also be provided for processing data, such as telemetry data, that is received from the sensor array <NUM>. The data may be communicated to the sea vessel <NUM> via the cables <NUM> through the central electro-mechanical cable <NUM> and up to a main control system located in the sea vessel <NUM>. The control system receiving data from the sensor array <NUM> may be located proximate the sensor array <NUM> or remote from the sensor array <NUM>.

<FIG> shows a flowchart for a method <NUM> of forming a sensor deployment module, such as the deployment modules <NUM>, <NUM> shown in <FIG> and <FIG>. Step <NUM> of the method <NUM> includes forming a sensor array <NUM> having a plurality of sensors <NUM> and a cable <NUM> connecting the plurality of sensors <NUM> using a micro inductive welding process. Step <NUM> may include fusing clamshell bodies 68a, 68b together over a flexible piezo element <NUM> to form an enclosed clamshell body <NUM> for each of the plurality of sensors <NUM>, sealing a plastic membrane <NUM> onto the clamshell body <NUM> over the flexible piezo element <NUM>, and sealing the cable <NUM> to electro-mechanical cable terminations <NUM> of each of the plurality of sensors <NUM> (shown in <FIG>).

Step <NUM> of the method <NUM> includes forming an expandable deployment body <NUM> and step <NUM> may include forming the expandable deployment body <NUM> of a shape memory alloy. Step <NUM> of the method <NUM> includes forming a support shell <NUM> using an additive manufacturing process and step <NUM> may include forming the support shell <NUM> of a plastic material having spaced walls <NUM> configured to retain the cable <NUM> separately from the plurality of sensors <NUM>. Step <NUM> of the method <NUM> includes arranging the sensor array <NUM> and the expandable deployment body <NUM> in the support shell <NUM> for stowage before deployment. Step <NUM> of the method may include forming a plurality of expandable deployment bodies <NUM> and a plurality of support shells <NUM>, and axially stacking the plurality of support shells <NUM> and the plurality of expandable deployment bodies <NUM>.

Claim 1:
A deployment module (<NUM>) for a sensor array (<NUM>) having a plurality of sensors (<NUM>) and a cable (<NUM>) connecting the plurality of sensors, the deployment module comprising:
a deployment body (<NUM>) that is expandable to hold the cable and retain a shape of the sensor array after deployment; and
a support shell (<NUM>) configured to support the sensor array and the expandable deployment body in a stowage state before deployment, the support shell having spaced walls (<NUM>) configured to retain the cable separately from the plurality of sensors,
characterised in that
the deployment body (<NUM>) is formed of a shape memory alloy and
the spaced walls define discrete slots (<NUM>) that each accommodate a segment of the cable corresponding to one of the plurality of sensors.