Curved sensor formed from silicon fibers

Abstract

Methods and apparatus for fabricating a curved sensor from silicon fibers are disclosed. In another embodiment, a curved sensor is produced having mini-sensors of differing sizes. In another embodiment, these mini-sensors are configured so that every other mini-sensor in a row of mini-sensors is shifted upwards slightly relative to its neighboring mini-sensors in the same row.

1 . A method for making a sensor, comprising the steps of:
 providing a plurality of light transmissive fibers;   arranging said plurality of light transmissive fibers into a first group and a second group;   configuring said first group of said plurality of light transmissive fibers so that they are all generally parallel to each other;   said first group and said second group of said plurality of light transmissive fibers being configured so that they are generally orthogonal to each other;   weaving said second group of said plurality of light transmissive fibers into said first group of said plurality of light transmissive fibers into a woven fabric;   placing said woven fabric over a first heated mandrel;   compressing said woven fabric on said first heated mandrel using a second heated mandrel;   fusing both of said first and said second groups of said plurality of light transmissive fibers together to form a woven fabric; and   trimming away excess fabric.   
     
     
         2 . A method as recited in  claim 1 , in which said plurality of light transmissive fibers are formed from silicon. 
     
     
         3 . A method as recited in  claim 1 , in which said both of said first and said second mandrels are curved so that a curved woven fabric is produced. 
     
     
         4 . A method for making a sensor, comprising the steps of:
 providing a plurality of light transmissive fibers;   arranging said plurality of light transmissive fibers so that they are generally parallel to each other;   heating said plurality of light transmissive fibers to form an unwoven laminate; said unwoven laminate being generally flat; and   heating said unwoven laminate on a mold.   
     
     
         5 . A method as recited in  claim 4 , in which said plurality of light transmissive fibers is formed from silicon. 
     
     
         6 . A method as recited in  claim 4 , in which said mold is curved to produce a curved unwoven laminate. 
     
     
         7 . A method comprising the steps of:
 providing a first set and a second set of light transmissive fibers;   arranging said first and said second set of light transmissive fibers at right angles;   heating said first and said second set of light transmissive fibers to form a fused laminate; and   forming said fused laminate into a sensor.   
     
     
         8 . A method as recited in  claim 7 , in which said first and said second sets of light transmissive fibers are formed from silicon. 
     
     
         9 . A method as recited in  claim 7 , in which said fused laminate in formed into a curved sensor. 
     
     
         10 . A method comprising the steps of:
 providing a sensor;   providing a plurality of generally flat mini-sensors; and   affixing said plurality of generally flat mini-sensors to said sensor so that said generally flat mini-sensors are arranged in horizontal rows, and so that each successive row is less densely populated with said generally flat mini-sensors.   
     
     
         11 . A method as recited in  claim 10 , in which two edges of said mini-sensors are generally parallel to the base of said sensor. 
     
     
         12 . A method as recited in  claim 10 , in which every other mini-sensor in each row of mini-sensors is positioned slightly higher than its two neighboring mini-sensors in the same row. 
     
     
         13 . A method as recited in  claim 10 , in which said sensor is generally continuously rotated about its vertical axis. 
     
     
         14 . A method as recited in  claim 10 , in which said sensor is a generally curved sensor.