This application relates generally to multispectral imaging. Specifically, this application relates to multispectral imaging devices using nanowires and methods of making the same.
Conventional color imaging devices, such as digital cameras, use pixelated monochromatic image sensors, such as charge-coupled devices (CCDs), in connection with three different color filters to generate color images, as illustrated schematically in
“Multispectral imaging” uses more than three filters with narrower bandwidths than conventional RGB imaging and can therefore extend the capabilities of the human eye. An example of multispectral imaging is shown in
Accordingly, some embodiments are directed to an optical apparatus, comprising an optical filter comprising an array of nanowires oriented perpendicular to a light incidence surface of the filter, wherein the optical filter transmits light at a first wavelength that is incident on the incidence surface, wherein the first wavelength is based on a cross-sectional area of the nanowires.
Some embodiments are directed to a method of manufacturing an optical filter. The method includes forming a plurality of nanowires on a substrate, wherein the nanowires are arranged perpendicular to a surface of the substrate; embedding the plurality of nanowires in a polymer layer; and separating the polymer layer and plurality of nanowires from the substrate. forming a plurality of nanowires may include: forming a plurality of metallic masks on the substrate; and etching a portion of the substrate not covered with the plurality of metallic masks.
Some embodiments are directed to an imaging device including: an array of nanowires formed on a substrate, wherein at least one nanowire in the array of nanowires includes a photoelectric element to produce a photocurrent based, at least in part, on incident photons absorbed by the at least one nanowire. The at least one photoelectric element may be a p-n junction or a p-i-n junction. The at least two nanowires in the array may have different radii to selectively absorb incident photons at a particular wavelength.
Some embodiments are directed to a method of fabricating an imaging device. The method may include: forming an epitaxial structure comprising an n-type semiconductor layer and a p-type semiconductor layer on a substrate to create a p-n junction between the n-type layer and the p-type layer; etching the epitaxial structure to form an array of nanowires on the substrate, wherein each nanowire includes a p-n junction as formed in the epitaxial structure; and forming an electrical contact on at least one nanowire in the array of nanowires.
The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures is represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing. In the drawings:
The inventors have recognized and appreciated that conventional multispectral imaging devices are expensive and/or bulky and that more efficient multispectral imaging devices that may be manufactured more simply and efficiently are needed. Accordingly, some embodiments are directed to a filter comprising silicon nanowires that may be created with a single lithographic step. The nanowire filter uses the wavelength-dependent absorption and scattering of light by nanowires to filter light at particular wavelengths. The absorbed and scattered light at the particular wavelength are prevented from transmitting through the filter. The wavelength of light absorbed by a particular nanowire is proportional to the radius of the nanowire—the larger the radius, the larger the absorbed wavelength. Thus, the nanowire filters are subtractive color filters, which block light within a narrow wavelength range, as opposed to the example shown in
The inventors have also recognized and appreciated that a benefit of creating a nanowire filter that filters light at particular wavelengths based on the radius of the nanowires is that the filter may be created with only a single photolithography step. Even in embodiments where different portions of the filter include of nanowires with different radii, only a single photolithography step is required. This is advantageous compared to, for example, a multilayer dielectric interference filter, which requires multiple precisely made layers of dielectric material. The process of creating multilayer dielectric interference filters with different portions of the filter transmitting different wavelengths is even more complicated and may require multiple lithography steps.
The inventors have also recognized and appreciated that using a filter prior to detection by an image sensor has poor performance in low-light level environments because only a small portion of the incident light is detected, while the majority of the light is absorbed or reflected by the filter. Accordingly, some embodiments are directed to a nanowire device where each nanowire has a p-n junction and selectively detects light at a particular wavelength. In this way, each nanowire acts as a wavelength selective photodetector. Light at a wavelength other than the selected wavelength transmits through the nanowire array. The inventors have recognized and appreciated that rather than letting the transmitted light go to waste, a conventional photodetector may be placed under the nanowire structure to detect the transmitted light. In this way, very little light is wasted as most of the incident light is detected by either the nanowire photodetectors or the conventional photodetectors. Because the incident light is used more efficiently by such imaging devices, operation in low light environments is superior to conventional digital imaging devices.
Some embodiments are directed to an optical apparatus comprising an array of nanowires embedded in a polymer. By way of example and not limitation, the optical apparatus may be an optical filter, an imaging device that includes an optical filter, or a display device that includes an optical filter.
The nanowires 210 may be formed in any shape. The nanowires 210 extend longitudinally in a first direction. The nanowires may be any suitable length. By way of example and not limitation, the nanowires may be 1.0 to 2.0 μm long. The cross-sectional area of the nanowires perpendicular to the first direction determines the spectral response of the nanowires.
Any suitable number of nanowires may be included in an array. Also, any suitable spacing between nanowires in an array may be used.
The nanowires 210 may have any suitably sized cross-section. For example, circular silicon nanowires that absorb light in the visible and NIR spectrum may range from 45-80 nm in radius. The wavelength of light absorbed by the nanowires is proportional to the radius of the circular cross-section.
Embodiments of optical filter 200 may use any suitable polymer 212. In embodiments where light transmitted by the filter is detected by a photodetector, it is preferable that the polymer 212 be substantially transparent for the detected spectral range. In some embodiments, the polymer may be polydimethylsiloxane (PDMS).
As mentioned above, some embodiments may use elliptical nanowires. In such embodiments, the spectral response of the nanowires is dependent on the polarization of the incident light.
The filter 570 may be affixed to the monochromatic image sensor 560 in any suitable way. In some embodiments, the filter 570 is applied directly to the detection surface of the monochromatic image sensor 560. In other embodiments, there may be one or more optical elements between the filter 570 and the monochromatic image sensor 560.
As described above, the nanowires of the filter 570 may be created with a single lithography step. The array of nanowires may be split into a plurality of sub-arrays, each sub-array associated with a sub-pixel. Any number of nanowires may be included in a sub-array associated with a sub-pixel. For example, in some embodiments, a sub-pixel is 24 μm×24 μm and the sub-pixel contains a sub-array of 24×24 nanowires (576 nanowires per sub-array). The array associated with the filter as a whole may consist of any suitable number of sub-arrays. For example, a unit cell representing a pixel may comprises any number of sub-pixels, each sub-pixel filtering a different set of wavelengths. Thus, each unit cell (pixel) of the 3×3 pixel imaging device 550 illustrated in
At act 710, a plurality of nanowires 604 are formed on a first surface of a substrate 602. The nanowires 604 are arranged “vertically” such that the longitudinal axis of the nanowires is perpendicular to the first surface of the substrate 602. As described above, the nanowires may be of any suitable length and shape. The nanowires 604 may be formed in an array comprising a plurality of sub-arrays, wherein each sub-array comprises nanowires of the same radius, but nanowires in other sub-arrays have different radii. The nanowires 604 may have any suitable cross-sectional shape, such as circular or elliptical. In some embodiments, the nanowires 604 are formed from the substrate material itself, such that the substrate 602 is made from the same material as the nanowires 604. In other embodiments, the nanowires 604 may be formed from a different material than the substrate 602. Details of one exemplary method of forming nanowires on a substrate are described below in connection with
At act 720, the plurality of nanowires are embedded in a polymer layer 606. Any suitable polymer may be used, such as PDMS. The nanowires may be embedded in the polymer in any suitable way. For example, the PDMS may be spin coated onto the wafer with the vertical nanowires. The PDMS layer 606 may then be cured and cooled.
At act 730, the polymer layer 606 with the embedded nanowires 604 is separated from the substrate 602. This may be done in any suitable way. For example, the polymer layer 606 may be cut away from the substrate 602 using a cutting device, such as a razor blade 610. Separating the polymer 606 from the substrate 602 leaves a filter comprising a polymer 606 where both surfaces of the filter are free from other layers (e.g., the substrate layer was cut away). This, either the top surface or the bottom surface may be used as a light incidence surface and the other surface would be used as a light output surface.
As described above, the nanowires 604 may be formed on substrate 602 in any suitable way.
At act 820, a plurality of holes in the desired size and shape of the nanowires are formed in desired locations in the resist layer. The holes may be formed in any suitable way. For example, electron beam lithography may be used to expose the desired regions of the resist such that when developed, the exposed regions of the resist layer may be rinsed away. The holes left in the resist layer expose the surface of the underlying substrate.
At act 830, the plurality of holes are at least partially filled with a hard mask material. Any suitable hard mask material may be used. Preferably the hard mask material etches at a lower rate than the rate at which the material of the substrate etches. For example, a metal material may be used as a hard mask material. In some embodiments, aluminum is used to fill the holes. The holes may be filled with aluminum in any suitable way. For example, aluminum may be evaporated using a thermal evaporator.
At act 840, the resist layer is removed so as to expose the surface of the substrate at all location other than the locations of the substrate covered with the hard mask (e.g., aluminum). The resist layer may be removed in any suitable way, such as immersing the entire wafer in acetone. Embodiments are not limited to using acetone. Any liquid that dissolves the resist material may be used.
At act 850, the portions of the substrate not covered by the hard mask are etched. Any suitable etching process may be used. In some embodiments, reaction ion etching is used using, for example, SF6 and/or C4F8 as an etchant. After etching, the nanowires are formed and are integrally attached to the substrate as they are formed from the original substrate material.
In some embodiments, a photoelectric element, such as a p-n junction or a p-i-n junction may be formed within a semiconductor nanowire. When such a photoelectric element is present, the nanowire acts as a photodetector with a spectral response controlled by the characteristics of the cross-sectional area of the nanowire, such as the radius.
In
The regions of the nanowire may be any suitable size. By way of example and not limitation, the total length of the nanowire may be 2.0-3.0 μm and the spacing between nanowires may be 1.0 μm. The first nanowire region 920 is 600 nm long, the second intrinsic nanowire region 920 is 1400 nm long, and the third p-type nanowire region 940 is 100 nm long. The radii of the nanowires vary from 80-140 nm based on the wavelength of light that each nanowire is designed to absorb.
The nanowire may be embedded in a polymer 960, such as poly(methyl methacrylate) (PMMA), which acts as a spacer. Embodiments are not limited to PMMA, as any polymer may be used. A transparent conductor 950 is placed on top of the polymer layer 960 and over the p-type third nanowire region 940 to form an electrical contact for the nanowire photodetector 900. By way of example and not limitation, the transparent conductor 950 may be formed from indium tin oxide (ITO).
The nanowire photodetector 900 structure of
At act 1110, an epitaxial structure comprising a substrate, an n-type layer and a p-type layer is formed. This may be achieved in any suitable way. For example, a silicon epitaxial wafer, which includes an n-type substrate 1010 and an n− silicon epitaxial layer 1020, may be used as a starting point. The n− silicon epitaxial layer may be any suitable thickness. By way of example and not limitation, it may initially be 1.5 μm thick. The p-type layer 1030 may be formed by doping the top portion of the n− silicon epitaxial layer to p+ using boron diffusion. This doping reduces the overall thickness of the n− silicon epitaxial layer and forms the basic structure of the p-i-n junction.
At act 1120, metallic masks 1040 are added to the top surface of the p-type layer 1030. The metallic masks may be formed with any desired spacing, and in any desired size or shape. The metallic masks may also be formed in any suitable way. For example, the technique used in the above description of the formation of the nanowire filter may be performed to create the metallic masks 1040. At act 1130, the portions of the epitaxial structure not covered by the metallic masks 1040 is etched away to create the nanowires 1050 comprising p-i-n junctions. This may be done in any suitable way, such as reactive ion etching. However, any dry etching technique may be used.
At act 1140, a polymer layer 1060 is formed such that the nanowires 1050 are embedded in the polymer layer. Any suitable polymer may be used. In the example illustrated in
The nanowire photodetectors described above may be created in arrays where one nanowire photodetector detects a first wavelength and a second nanowire photodetector detects a second wavelength different from the first wavelength. Moreover, the light incident upon an imaging device comprising nanowire photodetectors may be efficiently detected by including the array of nanowire photodetectors above an array of conventional photodetectors, such as a CCD array. In this way, almost all of the light incident on the imaging device is detected.
Focusing on the nanowire photodetector 1230, which detects red light, it is shown that light of other wavelengths transmits past the nanowire photodetector 1230. Thus, the photodetector 1220 placed under the nanowire photodetector 1230, on the opposite side of the nanowire photodetector 1230 from the side on which the light is incident, detects the transmitted light. The conventional photodetector 1220 has a much broader spectral response than the nanowire photodetector 1230, so it is able to detect the light of other wavelengths. This description applies to the other nanowire photodetectors 1240 and 1250, except nanowire photodetectors 1240 and 1250 detect green and blue light, respectively.
As with the nanowire filter described above, the nanowire photodetectors may be arranged in sub-arrays associated with sub-pixels that all detect light of the same wavelength. In this way, a multispectral imaging device may be created that utilizes a higher percentage of the incident light than conventional imaging devices.
Embodiments may be used in a variety of applications. Filters based on nanowires may be used in any application where filters are typically used. For example, nanowire filters may be used in display devices, projector devices, and imaging devices. Nanowire photodetectors may be used in any imaging application. Imaging applications may include digital cameras that operate in the UV, visible, NIR and/or IR wavelengths. Digital cameras applications include both still and video cameras.
Having thus described several aspects of at least one embodiment, it is to be appreciated that various alterations, modifications, and improvements will readily occur to those skilled in the art. For example, the nanowire filter described above may be used in any suitable application, such as an image display device. Also, nanowires with varying radius may be used within a single sub-array to tune the spectral response of a filter. Moreover, the applications described above may be applied to other area of the electromagnetic spectrum outside of the visible and infrared wavelengths. For example, nanowire filters and photodetectors may be created for use in the ultraviolet and microwave radiation.
Moreover, any aspect of a particular embodiment described above may be combined with one or more aspects of any other embodiment described above. For example, nanowire filters without photodetectors may be used in conjunction with nanowire filters.
Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and scope of the invention. Accordingly, the foregoing description and drawings are by way of example only.
This invention is not limited in its application to the details of construction and the arrangement of components set forth in the foregoing description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” “having,” “containing”, “involving”, and variations thereof, is meant to encompass the items listed thereafter and additional items.
The invention may be embodied as a method, of which at least one example has been provided. The acts performed as part of the method may be ordered in any suitable way. Accordingly, embodiments may be constructed in which acts are performed in an order different than illustrated, which may include performing some acts simultaneously, even though shown as sequential acts in illustrative embodiments.
Use of ordinal terms such as “first,” “second,” and “third,” etc. in the claims and/or the specification does not by itself connote any priority, precedence, or order of one claim element over another or the temporal order in which acts of a method are performed, but are used merely as labels to distinguish one claim element having a certain name from another element having a same or similar name to distinguish the claim elements.
This application claims priority under 35 U.S.C. §119(e) to U.S. application No. 61/682,717, filed Aug. 13, 2012 and U.S. application No. 61/756,320, filed Jan. 24, 2013, the entire contents of which are incorporated herein by reference.
This invention was made pursuant to DARPA grant proposals numbers N66001-10-1-4008 and W911NF-13-2-0015, and NSF grant number ECCS-130756. The US government has certain rights in the invention.
Filing Document | Filing Date | Country | Kind |
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PCT/US2013/054524 | 8/12/2013 | WO | 00 |
Number | Date | Country | |
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61756320 | Jan 2013 | US | |
61682717 | Aug 2012 | US |