Variable Height Microlens Fabrication for Image Sensor Photosensitivity

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Solution Overview

Problem

Conventional image sensor devices suffer from reduced photosensitivity due to inefficient light focusing by microlens arrays, where the geometry of the microlens array results in varying focal depths and incident light angles, leading to a suboptimal use of incident light.

Innovation Solution

A method for fabricating image sensor devices involves forming a photosensitive layer on a substrate, exposing it through specific photomasks to create microlenses of different heights, allowing for improved control over microlens profiles and light focusing, which enhances photosensitivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If a microlens array is used to focus light onto the pixel array, then light focusing capability is improved, but photosensitivity is reduced due to varying focal depths and incident angles

Engineering Contradiction:
Improvelight focusing capabilityVSAvoidphotosensitivity
Core Design Contradiction:
Illumination intensityVSReliability

Solution Approach 1:

The patent applies local quality by creating microlenses with different heights tailored to specific locations. The method uses a photomask with variable thickness to expose the photosensitive layer, resulting in microlenses that have different focal depths at different positions. This local differentiation allows each microlens to focus light at the optimal depth for its specific location, improving photosensitivity while maintaining light focusing capability.

Inventive Principle:
Principle #3Local quality

2Ease of manufacture

If a conventional microlens array with uniform geometry is used, then manufacturing is simplified, but light focusing efficiency deteriorates due to fixed focal depth

Engineering Contradiction:
Improvemicrolens array fabricationVSAvoidlight focusing efficiency
Core Design Contradiction:
Ease of manufactureVSLoss of energy

Solution Approach 1:

The patent implements parameter changes by varying the height of microlenses across the array. Instead of using a uniform microlens geometry, the invention creates a gradient or varied height profile by controlling the exposure depth through a photomask with variable thickness. This parameter variation allows the focal depth to be optimized for different incident angles, improving light focusing efficiency while maintaining a relatively simple single-step exposure process.

Inventive Principle:
Principle #35Parameter changes

3Reliability

If microlenses with different heights are fabricated to improve photosensitivity, then light focusing is optimized, but manufacturing complexity increases

Engineering Contradiction:
ImprovephotosensitivityVSAvoidmicrolens fabrication process
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by pre-configuring the photomask with variable thickness before the exposure process. The photomask is designed in advance with specific thickness variations that correspond to the desired microlens height profile. During exposure, this pre-designed photomask automatically creates microlenses with different heights in a single step, avoiding the need for complex multi-step fabrication processes while achieving optimized photosensitivity.

Inventive Principle:
Principle #10Preliminary action

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

The method enables the fabrication of image sensor devices with microlenses of varying heights, improving light focusing and reducing light field curvature, thereby enhancing the photosensitivity of the device.

Implementation Method 1

forming a photosensitive layer on a substrate. The photosensitive layer is exposed through a first photomask to form an exposed portion and an unexposed portion. The unexposed portion is partially exposed through a second photomask

Methodology Applied
Scientific EffectPhotopolymerisation: Photopolymerisation

Implementation Method 2

The photosensitive structures are reflowed to form a first microlens and a second microlens having different heights

Methodology Applied
Scientific EffectReflow:

Data Source

PatentUS8283110B2Method for fabricating an image sensor device
Publication Date: 2012.10.09 VISERA TECH CO LTD
  • US8283110B2 patent drawing
  • US8283110B2 patent drawing
  • US8283110B2 patent drawing

AI summary

A method for fabricating an image sensor device is disclosed. The method for fabricating an image sensor device comprises forming a photosensitive layer on a substrate. The photosensitive layer is exposed through a first photomask to form an exposed portion and an unexposed portion. The unexposed portion is partially exposed through a second photomask to form a trimmed part, wherein the second photomask comprise a first segment and a second segment that has a transmittance greater than that of the first segment. The trimmed part is removed to form photosensitive structures. The photosensitive structures are reflowed to form a first microlens and a second microlens having different heights.