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Metal-dielectric optical filter, sensor device, and fabrication method

a technology of dielectric optical filter and metal-dielectric filter, which is applied in the direction of radio frequency controlled devices, instruments, semiconductor devices, etc., can solve the problems of low efficiency, undesirable color shift, and large number of stacked dielectric layers of all-dielectric color filters, and achieves relatively thick, less brilliant colors, and undesirable color shi

Active Publication Date: 2017-08-10
VIAVI SOLUTIONS INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The present invention relates to an optical filter that includes one or more dielectric layers and one or more metal layers stacked in alternation with each other. Each metal layer has a tapered edge that is protectively covered by at least one dielectric layer. The optical filter can be used in a sensor device to filter light and protect the sensor elements. The method of fabricating the optical filter involves applying a photoresist layer, patterning it to create the filter region, and depositing a multilayer stack onto the patterned photoresist layer and the filter region of the substrate. The invention provides an improved optical filter that has better performance and reliability.

Problems solved by technology

Unfortunately, such dye-based color filters have relatively broad color passbands, resulting in less brilliant colors.
However, the color passbands of all-dielectric color filters undergo relatively large center-wavelength shifts with changes in incidence angle, resulting in undesirable shifts in color.
Furthermore, all-dielectric color filters, typically, include a large number of stacked dielectric layers and are relatively thick.
Consequently, all-dielectric color filters are expensive and difficult to manufacture.
In particular, all-dielectric color filters are difficult to etch chemically.
However, lift-off processes are, generally, limited to a filter spacing of about twice the filter height, which makes it difficult to achieve all-dielectric CFAs suitable for smaller color image sensors.
In addition to transmitting visible light in color passbands, both dye-based and all-dielectric color filters also transmit infrared (IR) light, which contributes to noise.
Typically, the metal layers in metal-dielectric optical filters, such as metal-dielectric color filters, are silver or aluminum layers, which are environmentally unstable and which deteriorate when exposed to even small amounts of water or sulfur.
Unfortunately, these requirements severely limit the possible optical designs for the metal-dielectric color filters.

Method used

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  • Metal-dielectric optical filter, sensor device, and fabrication method
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Examples

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first embodiment

[0044]In some embodiments, the one or more dielectric layers and the one or more metal layers are stacked without any intervening layers. With reference to FIG. 1A, the optical filter 100, disposed on a substrate 110, includes three dielectric layers 120 and two metal layers 130 stacked in alternation. The metal layers 130 are each disposed between and adjacent to two dielectric layers 120 and are, thereby, protected from the environment. The dielectric layers 120 and the metal layers 130 are continuous layers that do not have any microstructures formed therein.

[0045]The metal layers 130 have tapered edges 131 at a periphery 101 of the optical filter 100. In other words, the metal layers 130 are substantially uniform in thickness throughout a central portion 102 of the optical filter 100, but taper off in thickness at the periphery 101 of the optical filter 100. The tapered edges 131 extend along the entire peripheries of the metal layers 130 at the periphery 101 of the optical filt...

second embodiment

[0102]With reference to FIG. 8, the sensor device 890 includes a plurality of sensor elements 811 and a plurality of optical filters 800 and 804 disposed on the plurality of sensor elements 811. The plurality of optical filters 800 and 804 includes a first type of optical filter 800 having a first passband, and a second type of optical filter 804 having a second passband, different from the first passband. For example, the sensor device 890 may be an image sensor, the plurality of sensor elements 811 may form a CCD array, and the plurality of optical filters 800 and 804 may form a Bayer filter array, of which only a portion of one row is illustrated. The first type of optical filter 800 may be a green filter, such as the exemplary green filter of FIG. 4B, and the second type of optical filter 804 may be a red filter, such as the exemplary red filter of FIG. 4A, or a blue filter, such as the exemplary blue filter of FIG. 4C.

[0103]Any of the embodiments of the sensor device described ...

third embodiment

[0110]With reference to FIG. 15, a sensor device 1590 includes a first sensor element 1511 and a first optical filter 1500 according to the present invention disposed on the first sensor element 1511, forming a first type of optical sensor. The sensor device 1590 further includes a second sensor element 1512 and a second optical filter 1505 that is more environmentally durable disposed on the second sensor element 1512, forming a second type of optical sensor.

[0111]For example, the first type of optical sensor may be an ambient light sensor, and the first optical filter 1500 may be a silver-dielectric photopic filter, such as the exemplary photopic filter of FIG. 4D, or a silver-dielectric IR-blocking filter. The second type of optical sensor may, for example, be a UV sensor, and the second optical filter 1505 may be an aluminum-dielectric UV filter, such as the exemplary UVA, UVB, or 220-nm-centered filter of FIG. 12, or an all-dielectric UV filter. Alternatively, the second type o...

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Abstract

An optical filter, a sensor device including the optical filter, and a method of fabricating the optical filter are provided. The optical filter includes one or more dielectric layers and one or more metal layers stacked in alternation. The metal layers are intrinsically protected by the dielectric layers. In particular, the metal layers have tapered edges that are protectively covered by one or more of the dielectric layers.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This application is a continuation-in-part of U.S. patent application Ser. No. 13 / 720,728 to Ockenfuss, filed on Dec. 19, 2012, which is incorporated herein by reference.TECHNICAL FIELD OF THE INVENTION[0002]The present invention relates to a metal-dielectric optical filter, a sensor device including such an optical filter, and a method of fabricating such an optical filter.BACKGROUND OF THE INVENTION[0003]Optical sensors are used in optical sensor devices, such as image sensors, ambient light sensors, proximity sensors, hue sensors, and UV sensors, to convert optical signals into electrical signals, allowing detection of optical signals or image capture. An optical sensor, generally, includes one or more sensor elements and one or more optical filters disposed over the one or more sensor elements.[0004]For example, a color image sensor includes a plurality of color filters disposed in an array, i.e., a color filter array (CFA). The CFA i...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): G02B5/28G02B1/10H01L27/146
CPCG02B5/285G02B5/281G02B1/10H01L27/14621H01L27/14685G02B5/283
Inventor OCKENFUSS, GEORG J.GUSTAFSON, TIMKUNA, JEFFREY JAMESBILGER, MARKUSBRADLEY, RICHARD A.
Owner VIAVI SOLUTIONS INC