Optical Sensor Housing Trench Coating for Light Blocking
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Solution Overview
Problem
Existing methods for manufacturing optical sensor devices result in increased size and weight due to thick coating layers, complicating the production process and increasing power consumption, especially in small devices like digital cameras and cellular phones.
Innovation Solution
A method involving a carrier with multiple optical sensors, a transparent cover material, and an opaque coating applied only to the inner walls of trenches between sensors, allowing for efficient and cost-effective production by using spray coating or physical vapor deposition, which is thin, lightweight, and thermally compatible with the carrier material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If thick coating layers are used to create an opaque housing for optical sensor devices, then the housing provides sufficient light blocking, but the size and weight of the device increase
Solution Approach 1:
The patent applies opaque coating only to specific regions where light blocking is required (housing walls and trenches), while leaving other regions (cover material, aperture areas) transparent or open. This localized application provides sufficient light blocking functionality without the need for thick coating layers across the entire device, thereby reducing overall weight.
Solution Approach 2:
The housing structure is segmented into multiple components (cover material, housing walls, trenches, aperture layer) with opaque coating applied selectively to specific segments. This segmentation allows light blocking to be achieved in targeted areas rather than requiring thick coating throughout the entire housing structure.
2Object-affected harmful factors
If thick coating layers are used to create an opaque housing, then light blocking is sufficient, but the production process becomes complicated
Solution Approach 1:
Instead of applying thick coating layers to the entire housing structure, the patent uses thin opaque coating layers applied partially to specific regions (housing walls and trenches). This partial action approach simplifies the production process by reducing coating thickness requirements and enabling more efficient manufacturing methods.
Solution Approach 2:
The patent introduces trenches as a three-dimensional structural feature that provides light blocking through geometric configuration rather than relying solely on thick coating layers. This dimensional approach (creating depth and structure) simplifies the coating process while maintaining effective light blocking.
3Object-affected harmful factors
If opaque coating is applied to the housing, then light blocking is achieved, but the device size increases
Solution Approach 1:
The opaque coating is applied locally only to regions where light blocking is functionally required (housing walls and trenches), rather than uniformly across the entire device. This localized application achieves effective light blocking while minimizing the volume occupied by coating material.
Solution Approach 2:
The patent uses trenches to provide light blocking through vertical depth rather than horizontal thickness. By utilizing the third dimension (depth) for light blocking functionality, the overall device volume is reduced compared to using thick coating layers that would extend in multiple dimensions.
4Illumination intensity
If transparent cover material is used to allow light passage, then optical detection is enabled, but the housing becomes less opaque
Solution Approach 1:
The housing structure exhibits different optical properties in different regions: the cover material is transparent to allow light transmission to the sensor, while the housing walls and trenches are coated with opaque material for light blocking. This local differentiation of optical properties enables both light transmission and opacity requirements to be satisfied simultaneously.
Solution Approach 2:
The housing is segmented into transparent regions (cover material) for light transmission and opaque regions (coated housing walls and trenches) for light blocking. This segmentation allows each region to perform its specific function optimally without compromising the overall device performance.
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 enables the production of lightweight, efficient optical sensor arrangements that are fully functional before singulation, reducing production costs and avoiding thermal stress, while maintaining high optical density and adhesion, suitable for small devices with low power consumption.
Implementation Method 1
coating the inner walls with an opaque material such that an inner volume of the trench is free of the opaque material
Implementation Method 2
the cover material comprises a transparent material such that light can pass through the cover material and be detected by the optical sensors
Data Source
AI summary
A method for manufacturing optical sensor arrangements is provided. The method comprises providing at least two optical sensors on a carrier and providing a cover material on the side of the optical sensors facing away from the carrier. The method further comprises providing an aperture for each optical sensor on a top side of the cover material facing away from the carrier and forming at least one trench between the optical sensors from the carrier towards the top side of the cover material, the trench comprising inner walls. Moreover, the method comprises coating the inner walls with an opaque material, such that an inner volume of the trench is free of the opaque material, and singulating of the optical sensor arrangements along the at least one trench. Furthermore, a housing for an optical sensor is provided.