IMAGE SENSING MODULE AND METHOD FOR CONSTRUCTING THE SAME
FIELD OF THE INVENTION
The present invention is related to an image sensing module and the method of
forming an image sensor package.
BACKGROUND OF THE INVENTION
Many digital image products, e.g., video camera, PC digital video camera,
electronic camera, visual telephone, etc., acquire images by the use of an image
sensor. The image sensor can receive light beam transmitted by the image and convert
it into digital signal. Because of this light-receiving function, the packaging for the
image sensor requires different features than other common electronic products. It is
conventional for the image sensor package to have a chip containing housing with a
window so as to allow the image sensor chip to be exposed to the object to be optically
sensed. An image sensing module typically includes a package with a transparent
glass window, an image sensor chip placed inside the package, and a lens assembly
positioned over the transparent window for focusing light onto the image sensor. The
lens assembly requires sub-components to assemble and additional handling steps.
Thus, in order to incorporate all the necessary sub-components of the lens assembly,
the construction of the conventional image sensing module becomes complicated and
costly. Furthermore, the conventional image sensing module is bulky and heavy
because of all the necessary sub-components.
US Pat. No. 6,483,101 B1 issued to Webster introduces an approach toward simplifying the image module assembly. In one embodiment, Weber discloses an
image sensor package that includes an image sensor, a window, and a molding,
wherein the molding has a lens holder extension portion extending upwards from the
window. The lens holder extension portion includes a female threaded aperture
adaptable for receiving a threaded lens support. Even though Webster's image sensor
package has reduced complexity, it is not as simple in construction as it could be. A
joining step is required to fix the molding to a substrate and a window has to be molded
into the molding prior to installing the lens assembly.
SUMMARY OF THE SUMMARY OF THE INVENTION
The present invention provides an imaging sensing module that includes a
premolded package with an integral lens holder, an image sensor and an optical lens.
The premolded package includes a molded housing having an integral lens holder
extension and a base section with a raw lead frame partially embedded within the base
section. The image sensor is fastened to the base section of the molded housing and
the optical lens is attached to the lens holder extension.
The present invention also provides a method of forming the image sensor
package with an integral lens holder. To fabricate the image sensor package, a raw lead frame is inserted into a molding tool, and injection molding is performed so as to
produce a molded housing having a lens holder extension and a base section with the
lead frame partially embedded in the base section.
After the premolded package is fabricated, an image sensor is placed inside the
molded housing and attached to the base section of the housing. Subsequently, an optical lens is attached to the lens holder extension to provide an image sensing module in accordance with the present invention.
Another aspect of the present invention is a method of forming a plurality of
image sensor packages simultaneously by fabricating a plurality of molded housings
directly on an array of raw lead frames.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the isometric view of the premolded package with an integral lens
holder according to the preferred embodiment of the present invention.
FIG. 2 shows the cross-sectional view of the image-sensing module according to
the preferred embodiment of the present invention.
FIG. 3 illustrates the method of constructing the image sensing module according
to the preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention provides an imaging sensing module that includes a
premolded package with an integral lens holder and a lens assembly. FIG. 1 shows the
premolded package with an integral lens holder according to the preferred embodiment of the present invention. The premolded package includes a molded housing 2 with an
integral lens holder extension 3. The molded housing 2 with the integral lens holder
extension 3 is a one-piece molded part. A raw lead frame with wire leads 5 is partially
embedded within the base section 6 of the molded housing in such a manner that leaves inner portions 5a and outer portions 5b of the wire leads exposed. The lens
holder extension 3 includes an interior cylindrical surface 7 that defines a lens opening 8. The lens opening 8 is located above the base section 6 of the molded housing.
FIG. 2 shows the cross-sectional view of an image sensing module that
incorporates the premolded package described in FIG. 1. An image sensor 10 is
attached to die pad 12 on the interior bottom surface of the molded housing 2, directly
below the lens opening 8. Wire bonds 1 1 attach the image sensor 10 to the inner
portions 5a of the wire leads. A lens barrel 13, which supports lens 9, is fitted inside the
lens holder extension 3. As shown in FIG. 2, the image sensor 10 is enclosed by the
molded housing 3 and the lens 9. In the preferred embodiment, a lens barrel 13 having
a threaded exterior surface is provided for supporting the optical lens 9 as shown in
FIG. 2. The lens holder extension is provided with an interior cylindrical surface that is
also threaded so as to engage the lens barrel. The lens barrel 13 is attached to the
lens holder extension 3 by rotating the lens barrel 13 while it is being inserted into the
lens opening 8. By this threading arrangement, the position of the lens can be readily
adjustable for focusing the lens. Alternatively, other conventional means may be
employed for attaching and supporting the optical lens 9 inside the lens holder
extension 3. For example, the lens 9 may be attached to the lens holder extension 3 by
the use of adhesives, or by snap-on lens assembly etc.
One advantage of the image sensing module of the present invention is that it is not necessary to have a separate glass cover (or transparent lid) between the image
sensor and the lens to protect the image sensor. In addition, unlike prior art modules,
no separate substrate for supporting the image sensor is required because the die pad
can be attached directly to the molded housing. Thus, the image sensing module of the
invention has the most simple design as compared to prior art modules.
FIG. 3 illustrates the flow chart of a method for constructing the imaging sensor module according to the preferred embodiment of the present invention. A raw
stamped frame is provided in stage 100. The raw lead frame to be used in the present
invention is formed by etching or stamping a thin metal strip to provide the wire leads.
The lead frame can be made of copper or copper alloys. Alternatively, the lead frame
can be made of copper plated with other metals. In the next stage 200, the raw lead
frame is inserted into a molding tool (or die), and then injection molding is performed so
as to produce a plastic molded housing having a lead frame embedded within the
bottom portion of the housing and a lens holder extension as shown in Fig. 1. The
plastic molding material encapsulates the lead frame in such a manner that exposes
inner lead portions 5a and outer lead portions 5b of the wire leads 5. The plastic
molding material is preferably a thermoplastic material with a high melting point in the
range of 300-400 SC; e.g. liquid crystal polymers. The molding tool can be any
conventional molding tool capable of producing the molded housing having the
configuration as described above. In the next stage 300, an image sensor is placed
inside the housing, and a die attachment step and a wire bonding step are then
performed. The die attachment step involves attaching the image sensor chip to the
interior bottom surface of the molded housing, directly below the lens opening, as shown in FIG. 2. Conventional attaching techniques can be used for die attachment;
e.g., using an adhesive. The wire bonding step involves electrically connecting the
active portion of the chip to the exposed inner lead portions of the lead frame. The
image sensor chip to be used in the image sensor package includes Charge Coupled
Device (CCD) and Complementary Metal-Oxide Semiconductor (CMOS), but is not limited thereto.
After the premolded package with an image sensor chip therein is constructed, an optical lens assembly is then fitted into the lens holder in stage 400 to provide an
imaging sensing module. In the final stage 500, calibration is performed to determine
the proper focal distance of the lens to the image sensor chip and the lens assembly is
then fixed into position. Calibration involves adjusting the lens position until radiation
passing through the lens is properly focused.
In the prior art, it is typical to provide a separate substrate on which the die pad is
to be attached. After the image sensor package is fabricated, the package is joined
with the substrate by adhesive. The method of the invention eliminates this
conventional joining step by eliminating the need for a separate substrate. In addition,
the conventional step of providing a transparent cover or window between the lens and
the image sensor is also eliminated. Thus, the method of the present invention requires
minimal manufacturing steps for constructing an image sensing module as compared to
prior art methods.
In order to increase production volume and to minimize the cost of an individual premolded package, a plurality of image sensor packages can be fabricated by
simultaneously forming a plurality of molded housing directly on an array of raw lead
frames. An array of connecting raw lead frames is inserted into a molding tool and
injection molding is carried out to form an array of molded housings with lead frames
embedded therein, as shown in FIG. 4. Next, an image sensor is placed inside each of
the molded housings, and die attachment and wire bonding are then performed as
previously described for FIG. 3. Subsequently, the array of premolded packages with
image sensors therein can be separated into individual packages by conventional means.
Although the invention has been described in relation to the preferred embodiments, it is to be understood that many modifications and variations of the
described embodiments are possible without departing from the spirit and scope of the
invention as claimed here after.