Protective Caps for Small Image Sensor Coating and Mounting
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Solution Overview
Problem
Conventional masking, coating, and mounting processes for small image sensors with widths of one millimeter or less are inefficient, labor-intensive, and unsuitable for precise handling, leading to low production throughput and increased costs due to manual labor and difficulty in accurate taping and un-taping processes.
Innovation Solution
The use of protective caps, both short and long, to automate the coating and mounting processes of small image sensors, where the short cap applies a dark coating agent and the long cap protects the sensor during surface mount technology (SMT) processes, reducing manual intervention and ensuring reliable coating and contamination prevention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional masking and coating processes are used for small image sensors, then manual labor can be applied, but production throughput is low and costs increase
Solution Approach 1:
The patent introduces a protective cap as an intermediary tool that enables automated coating processes for small image sensors. The cap serves as a masking element that can be precisely positioned and removed through automated means, eliminating the need for manual masking and coating operations while maintaining coating quality on the sensor's side walls.
Solution Approach 2:
The protective cap is positioned on the image sensor before the coating process begins. This preliminary action establishes the masking pattern in advance, allowing the coating material to be applied automatically without requiring real-time manual adjustment or intervention during the coating process.
2Manufacturing precision
If manual taping and un-taping processes are used for small image sensors, then coating can be applied, but the process is labor-intensive and imprecise
Solution Approach 1:
The protective cap acts as a precision intermediary that replaces manual taping operations. It provides a consistent, pre-formed masking structure that can be automatically positioned and removed, eliminating the imprecision and labor associated with manual taping while ensuring accurate coating application on the sensor's side walls.
3Reliability
If conventional mounting processes are used for small image sensors, then sensors can be mounted, but contamination risk increases during SMT processes
Solution Approach 1:
The protective cap is positioned on the image sensor before mounting operations begin. This preliminary protective measure is in place during the entire SMT process, preventing contamination of the sensor surface while allowing automated mounting operations to proceed without additional protective steps or increased process complexity.
Solution Approach 2:
The protective cap serves as a beforehand protective barrier that cushions the sensor against potential contamination during mounting operations. By having this protection in place before the SMT process begins, the sensor is shielded from contaminants without requiring complex contamination control measures during the actual mounting process.
Data Source
AI summary
A method of processing an image sensor system, comprising steps of placing a first cover member on top of an image sensor; coating the image sensor and the first cover member with a dark coating agent; removing the first cover member from the image sensor; placing a second cover member on top of the image sensor; affixing the image sensor on to a permanent mount to form an electrical coupling between the image sensor and the permanent mount; removing the second cover member from the image sensor; wherein the first cover member completely covers a top portion of the image sensor; and wherein the second cover member includes an internal rib configured to form a contact seal with the image sensor.