The present disclosure relates to an optical device, and more particularly to an optical device including a block structure.
In an optical system (e.g., light scanning sensor, distance finding sensor, background-light sensing system), light emitters (e.g., vertical-cavity surface-emitting LASER (VCSEL) or light emitting diodes (LED)) and/or light detectors are used to detect whether any object is located adjacent to the optical system or an electronic component including the optical system. The light emitter is configured to emit light toward a target object, and the light reflected from the target object is received by the light detector. However, some of the light emitted from the light emitter may enter the light detector directly, which would cause an unacceptable cross-talk issue and reduce the signal-noise ratio (SNR) of the optical system.
In accordance with an aspect of the present disclosure, an optical device includes a substrate, an electronic component, a lid and a barrier. The electronic component is disposed on the substrate. The electronic component has an active surface faces away from the substrate. The lid is disposed on the substrate. The lid has a wall structure extending toward the active surface of electronic component and is spaced apart from the active surface of the electronic component. The barrier is disposed on the active surface of the electronic component and is spaced apart from the wall structure of the lid.
In accordance another aspect of the present disclosure, an optical device includes a substrate, an electronic component, a barrier and a lid. The electronic component is disposed on the substrate. The electronic component has an active surface facing away from the substrate. The barrier is disposed on the active surface of the electronic component. The lid is disposed on the substrate. The lid has a wall structure extending toward the active surface of electronic component and is spaced apart from the active surface of the electronic component. The barrier is spaced apart from the wall structure and adjacent to at least one lateral surface of the wall structure of the lid.
In accordance another aspect of the present disclosure, a method for manufacturing an optical device includes (a) providing a substrate; (b) disposing an electronic component on the substrate, the electronic component having an active surface facing away from the substrate; (c) disposing a barrier on the active surface of the electronic component; (d) removing a portion of the barrier to form a recess; and (e) placing a lid disposed on the substrate, the lid having a wall structure extending within the recess and spaced apart from a sidewall and a bottom surface of the recess.
Common reference numerals are used throughout the drawings and the detailed description to indicate the same or similar components. The present disclosure can be best understood from the following detailed description taken in conjunction with the accompanying drawings.
The substrate 10 may include, for example, a printed circuit board, such as a paper-based copper foil laminate, a composite copper foil laminate, or a polymer-impregnated (p.p.) glass-fiber-based copper foil laminate. The substrate 10 may include an interconnection structure, such as a plurality of conductive traces, pads or through vias. In some embodiments, the substrate 10 includes a ceramic material or a metal plate. In some embodiments, the substrate 10 may include an organic substrate or a leadframe. In some embodiments, the substrate 10 may include a two-layer substrate which includes a core layer and a conductive material and/or structure disposed on an upper surface and a bottom surface of the substrate 10. The conductive material and/or structure may include a plurality of traces, pads, or vias. In some embodiments, the substrate 10 includes a hole 10h (e.g., a vent hole) penetrating the substrate 10 to vent the air within a cavity defined by the substrate 10, the lid 15 and the cover 17, which can mitigate or eliminate the popcorn issue.
The electronic component 12 (a die or a chip) is disposed on the substrate 10 and connected to the substrate 10 for example, by way of flip-chip or wire-bond techniques. In some embodiments, as shown in
The light emitter 13 is disposed on the electronic component 12. In some embodiments, the light emitter 13 is disposed on the active surface 121 of the electronic component 12 and can be electrically connected to the electronic component 12 by bonding wires. In some embodiments, the light emitter 13 is configured to radiate a light (e.g., L11) toward an object TB. The light emitter 13 may include an emitting die or other optical die. For example, the light emitter 13 may include a light-emitting diode (LED), a laser diode, a vertical-cavity surface-emitting Laser (VCSEL) or another device that may include one or more semiconductor layers. The semiconductor layers may include silicon, silicon carbide, gallium nitride, or any other semiconductor materials.
The light detector 11 is disposed on the substrate 10 and is physically separated from the light emitter 13 and the electronic component 12. In some embodiments, the light detector 11 has an active region (or light detecting area) facing away from the substrate 10 and configured to receive the light (e.g., L12) reflected from the object TB. In some embodiments, the light detector 11 may include, for example, a PIN diode (a diode including a p-type semiconductor region, an intrinsic semiconductor region, and an n-type semiconductor region) or a photo-diode or a photo-transistor. In some embodiments, the light detector 11 is an ambient light sensing (ALS). The light detector 11 can be connected to the substrate 10, for example, by way of flip-chip or wire-bond techniques.
The lid (or housing) 15 is disposed on the substrate 10. The lid 15 has a wall structure 15w extending from the lid 15 toward the electronic component 12. The wall structure 15w is disposed between the light detector 11 and the light emitter 13. The wall structure 15w is disposed over the electronic component 12. In some embodiments, the wall structure 15w is spaced apart from the active surface 121 the electronic component 12. For example, the wall structure 15w is not in contact with the active surface 121 of the electronic component 12. For example, there is a gap between the wall structure 15w and the active surface 121 of the electronic component 12. The lid 15 has an opaque material or a light absorbing material to prevent undesired light (e.g., L13) emitted by the light emitter 13 from being directly transmitted to the light detector 11.
The barrier 14 is disposed on the electronic component 12 (e.g., on the active surface 121 of the electronic component 12). The barrier 14 is in contact with the active surface 121 of the electronic component 12. In other embodiments, the barrier 14 may be in contact with the active surface 121 and lateral surfaces of the electronic component 12. The barrier 14 is spaced apart from the lid 15 and the wall structure 15w of the lid 15. For example, there is a gap between the barrier 14 and the lid 15 or between the barrier 14 and the wall structure 15w of the lid 15. The barrier 14 is disposed between the light emitter 13 and the light detector 11 and adjacent to the wall structure 15w of the lid 15. As shown in
As shown in
In some embodiments, the barrier 14 is formed of or includes an opaque material or light absorbing material. In some embodiments, a height of the barrier 14 is equal to or greater than a distance between the wall structure 15w and the active surface 121 of the electronic component 12. In some embodiments, a height of the barrier 14 is about 0.2 millimeter (mm) and a width of the barrier 14 is about 0.4 mm. In other embodiments, the height and the width of the barrier 14 can be changed depending on different design specifications. The barrier 14 and the wall structure 15w of the lid 15 alone or together can prevent the light emitted by the light emitter 13 from directly transmitted to the light detector 11. For example, the light L14 passing through the gap between the wall structure 15w and the active surface 121 of the electronic component 12 can be blocked by the barrier 14. Compared to an optical device without the barrier 14 (only has a wall structure), the optical device 1 in
In some embodiments, the barrier 14 is disposed between the wall structure 15w and the active surface 121 of the electronic component 12 and is directly in contact with the wall structure 15w and the active surface 121 of the electronic component 12. However, during the process (e.g., reflow process) for manufacturing the optical device, as the temperature increases, the barrier 14 will expand. The expansion of the barrier 14 would compress the electronic component 12, rendering the electronic component 12 under stress, which may cause damage to the electronic component 12. In addition, since two spaces/cavities (one for accommodating the light emitter 13 and the other for accommodating the light detector 11) are completely separated or isolated by the wall structure 15w and the barrier 14, two vent holes are included for the cavities to avoid popcorn issue, which would increase the manufacturing cost and time.
In accordance with the embodiments as shown in
The cover 17 is disposed on the lid 15. The cover 17 defines apertures 17h1 and 17h2. The lid 15 defines apertures 15h1 and 15h2. The apertures 17h1 and 15h1 are over the light detector 11. The apertures 17h2 and 15h2 are over the light emitter 13. The lens 16a is disposed within the apertures 17h1 and 15h1. The lens 16b is disposed within the apertures 17h2 and 15h2. The lenses 16a and 16b are arranged to allow the light (e.g., L11) emitted by the light emitter 13 and the light (e.g., L12) reflected by the object TB passing through. In some embodiments, the lenses 16a and 16b are plano-convex lenses, which can increase the density of the light and improve the performance of the optical device 1.
As shown in
The wall structure 15w and the barrier 14 are disposed the light emitter 13 and the sensing area 22s of the electronic component 22. The barrier 14 is disposed between the light emitter 13 and the wall structure 15w. In some embodiments, the barrier 14 can be disposed between the wall structure 15w and the sensing area 22s of the electronic component 22. In some embodiments, the barrier 14 can be disposed at both sides of the wall structure 15w. For example, there are two barriers, one is disposed between the light emitter 13 and the wall structure 15w and the other is disposed between the wall structure 15w and the sensing area 22s of the electronic component 22.
The flat transmissive films 36a and 36b are respectively disposed within the apertures 17h1 and 17h2 defined by the cover 17. The flat transmissive films 36a and 36b are used to break up and evenly distribute light radiated toward light detector 11, which would enhance the uniformity of the light received by the light detector 11. In some embodiments, the flat transmissive films 36a and 36b are formed by dispensing transmissive gel within the apertures 17h1 and 17h2 or by transfer molding. In some embodiments, the flat transmissive films 36a and 36b may include a ground glass, Teflon, a holographic, an opal glass, and a greyed glass. In some embodiments, the flat transmissive films 36a and 36b may be formed of GaN or fused silica.
The optical device 5 includes a barrier 54 (or dam) disposed between the wall structure 15w of the lid 15 and the electronic component 12. The barrier 54 has a recess 54h (opening or aperture). The wall structure 15w extends within the recess 54h of the barrier 54 without contacting the barrier 54. For example, the wall structure 15w is spaced apart from lateral surfaces and a bottom surface of the recess 54h. As shown in
The optical device 5 may include a light transparent material 55 (e.g., a clear molding compound) disposed on the substrate 10 and covers the light detector 11, the electronic component 12, the light emitter 13 and the barrier 54. The light transparent material 55 covers the lateral surfaces and the bottom surface of the recess 54h of the barrier 54. The light transparent material 55 surrounds the wall structure 15w. The light transparent material 55 is spaced apart from the lid 15 (including the wall structure 15w). For example, there is a gap between the light transparent material 55 and the wall structure 15w. In some embodiments, the light transparent material 55 includes protrusion portions 55p extending within the apertures 15h1 and 15h2 of the lid 15. In some embodiments, the protrusion portions 55p may define plano-convex lenses, which can increase the density of the light and improve the performance of the optical device 5. In some embodiments, one of the protrusion portions 55p is located over the light detector 11 (e.g., over the light sensing area of the light detector 11), and the other one is located over the light emitter 13 (e.g., over the light emitting area of the light emitter 13).
Since the barrier 54 is disposed under the wall structure 15w of the lid 15, no further area on the electronic component 12 for placing the barrier 54 is included. Therefore, the barrier 54 in
Referring to
In other embodiments, as shown in
Referring to
Referring to
As used herein, the terms “substantially,” “substantial,” “approximately,” and “about” are used to denote and account for small variations. For example, when used in conjunction with a numerical value, the terms can refer to a range of variation of less than or equal to ±10% of that numerical value, such as less than or equal to ±5%, less than or equal to ±4%, less than or equal to ±3%, less than or equal to ±2%, less than or equal to ±1%, less than or equal to ±0.5%, less than or equal to ±0.1%, or less than or equal to ±0.05%. As another example, a thickness of a film or a layer being “substantially uniform” can refer to a standard deviation of less than or equal to ±10% of an average thickness of the film or the layer, such as less than or equal to ±5%, less than or equal to ±4%, less than or equal to ±3%, less than or equal to ±2%, less than or equal to ±1%, less than or equal to ±0.5%, less than or equal to ±0.1%, or less than or equal to ±0.05%. The term “substantially coplanar” can refer to two surfaces within 50 μm of lying along a same plane, such as within 40 within 30 within 20 within 10 or within 1 μm of lying along the same plane. Two components can be deemed to be “substantially aligned” if, for example, the two components overlap or are within 200 within 150 within 100 within 50 within 40 within 30 within 20 within 10 or within 1 μm of overlapping. Two surfaces or components can be deemed to be “substantially perpendicular” if an angle therebetween is, for example, 90°±10°, such as ±5°, ±4°, ±3°, ±2°, ±1°, ±0.5°, ±0.1°, or ±0.05°. When used in conjunction with an event or circumstance, the terms “substantially,” “substantial,” “approximately,” and “about” can refer to instances in which the event or circumstance occurs precisely, as well as instances in which the event or circumstance occurs to a close approximation.
In the description of some embodiments, a component provided “on” another component can encompass cases where the former component is directly on (e.g., in physical contact with) the latter component, as well as cases where one or more intervening components are located between the former component and the latter component.
Additionally, amounts, ratios, and other numerical values are sometimes presented herein in a range format. It can be understood that such range formats are used for convenience and brevity, and should be understood flexibly to include not only numerical values explicitly specified as limits of a range, but also all individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly specified.
While the present disclosure has been described and illustrated with reference to specific embodiments thereof, these descriptions and illustrations do not limit the present disclosure. It can be clearly understood by those skilled in the art that various changes may be made, and equivalent elements may be substituted within the embodiments without departing from the true spirit and scope of the present disclosure as defined by the appended claims. The illustrations may not necessarily be drawn to scale. There may be distinctions between the artistic renditions in the present disclosure and the actual apparatus, due to variables in manufacturing processes and such. There may be other embodiments of the present disclosure which are not specifically illustrated. The specification and drawings are to be regarded as illustrative rather than restrictive. Modifications may be made to adapt a particular situation, material, composition of matter, method, or process to the objective, spirit and scope of the present disclosure. All such modifications are intended to be within the scope of the claims appended hereto. While the methods disclosed herein have been described with reference to particular operations performed in a particular order, it can be understood that these operations may be combined, sub-divided, or re-ordered to form an equivalent method without departing from the teachings of the present disclosure. Therefore, unless specifically indicated herein, the order and grouping of the operations are not limitations of the present disclosure.
This application claims the benefit of and priority to U.S. Provisional Application No. 62/697,283, filed Jul. 12, 2018, the contents of which are incorporated herein by reference in their entirety.
Number | Date | Country | |
---|---|---|---|
62697283 | Jul 2018 | US |