Curved Image Sensor Forming via Pressure Deformation
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Solution Overview
Problem
Forming curved image sensors is challenging due to their fragility and the difficulty in matching the curvature of simple lenses, which leads to reduced image quality and increased costs and module height when using multi-element lenses.
Innovation Solution
A method involving attaching an image sensor wafer to a rigid carrier, thinning it, and then applying positive pressure using various means such as pneumatic, hydraulic, elastic, or inelastic pressure to conform it to a curved substrate, ensuring structural integrity and reducing complexity and size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple lens is used to focus image light, then the cost and z-height are reduced, but the focal plane is curved resulting in reduced image quality on a flat image sensor
Solution Approach 1:
The image sensor is curved to match the curved focal plane generated by the simple lens. This curvature allows the sensor surface to conform to the focal plane, maintaining image quality while enabling the use of a simpler, more cost-effective single-element lens instead of a multi-element lens system
2Manufacturing precision
If a multi-element lens is used to generate a flat focal plane, then image quality on a flat image sensor is improved, but the cost and z-height increase significantly
Solution Approach 1:
By curving the image sensor instead of using a flat sensor with a complex multi-element lens, the system achieves a flat focal plane effect through the curved sensor surface matching the simple lens's curved focal plane, thereby reducing lens complexity and cost while maintaining image quality
Solution Approach 2:
Instead of modifying the lens to create a flat focal plane (which requires complex multi-element lenses), the invention inverts the approach by curving the image sensor to match the naturally curved focal plane of a simple lens, achieving the same result with simpler optics
3Shape
If the image sensor is made very thin to facilitate curving, then the ability to match the curved focal plane is improved, but the sensor becomes extremely fragile
Solution Approach 1:
The image sensor is constructed with a flexible substrate that can be curved without breaking. This flexible foundation layer allows the thin sensor to conform to the curved surface while maintaining structural integrity, enabling curvature matching without excessive fragility
Solution Approach 2:
The image sensor uses a composite structure combining a flexible substrate with the photosensitive layer. This composite design provides both the flexibility needed for curving and the structural strength to prevent fragility, allowing the thin sensor to maintain robustness while achieving the necessary curvature
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for the cost-effective and efficient formation of curved image sensors that match the curvature of simple lenses, enhancing image quality and reducing module height while maintaining robustness.
Implementation Method 1
Pressure may be applied to the image sensor so that the image sensor deforms and conforms to the curved surface of the substrate
Data Source
AI summary
A method for forming curved image sensors may include applying positive pressure to the face of an image sensor, forcing the image sensor to adhere the curved surface of a substrate. The pressure may be applied to the face of the image sensor in a variety of ways, including using pneumatic pressure, hydraulic pressure, or pressure from an elastic or inelastic solid. Processing may occur on either a single image sensor die or an image sensor wafer. When an image sensor wafer is processed, a substrate may be used that has a number of cavities defined by respective curved surfaces with each cavity corresponding to a respective image sensor. When pressure is applied to the image sensor, the image sensor may deform until the curvature of the image sensor matches the curvature of the curved surface of the underlying substrate.