Die Stacking Recess Notches for Precise Angular Sensor Alignment
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Solution Overview
Problem
Existing methods for assembling multiple-axis sensors in a single package face challenges in achieving precise angular alignment of individual devices, leading to inaccuracies due to limitations in automated assembly systems.
Innovation Solution
The use of alignment recesses in covers with notches and protrusions to control the angular orientation of substrates and dies within a multi-chip package, allowing for precise angular separation of less than two degrees through mechanical features that constrain rotational alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated assembly systems are used to assemble multiple-axis sensors, then productivity is improved, but manufacturing precision deteriorates due to inability to achieve precise angular alignment
Solution Approach 1:
The cover structure includes self-aligning features (notches and protrusions) that automatically guide the substrate into the correct angular position during assembly, eliminating the need for high-precision automated positioning systems while maintaining sub-degree alignment accuracy
Solution Approach 2:
The alignment recesses and notches act as intermediary mechanical features between the cover and substrate, providing a physical reference system that translates loose automated placement into precise angular alignment, bridging the gap between low-precision automation and high-precision requirements
2Manufacturing precision
If mechanical alignment features are added to control angular orientation, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The cover incorporates asymmetric notches and corresponding protrusions at specific corners, creating a unique angular reference system that enables precise orientation control through simple geometric features rather than complex mechanical mechanisms
Solution Approach 2:
The alignment function is segmented into discrete features (alignment recesses, notches, protrusions) that can be independently manufactured and assembled, allowing precise angular control through modular geometric elements rather than monolithic complex structures
Data Source
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AI summary
An alignment recess formed in a cover substrate such as a cover for a MEMS device allows a second substrate to be bonded to the cover substrate. The alignment recess is larger than the second substrate and has two corner regions diagonally opposite each other where a wall of the recess protrudes to form a notch. The notch is dimensioned such that when the second substrate is disposed within the recess with two opposing corners surrounded by respective notches of the recess, the angular position of the second substrate relative to the cover substrate can be controlled to within a desired amount of rotation.