Imaging module, endoscope system, and imaging module manufacturing method

An imaging module includes an imager having an optical member on a light receiving surface, an electronic component having a front surface facing the same direction as the one to which an incidence surface of the optical member faces, a resin portion that has a first surface flush with the incidence surface of the optical member and the front surface of the electronic component, and a second surface that is a surface on a side opposite to the first surface while having the imager and the electronic component being embedded therein such that the incidence surface and the front surface are exposed to the first surface, an external connection terminal provided on the second surface, and a through wiring that extends through the resin portion to connect at least one of the imager and the electronic component with the external connection terminal.

BACKGROUND

An imaging module having an image sensor or the like mounted on a mount substrate has been conventionally known. For example, Japanese Patent Laid-Open No. 2010-147200 discloses that the image sensor mounted on the substrate is enclosed with an outer frame, and sealed with a resin material. Japanese Patent Laid-Open No. 2009-240634 discloses the capsule type endoscope in which the camera module derived from those integrally formed in a wafer-like state is mounted on the mount substrate.

SUMMARY

In accordance with one of some aspect, there is provided an imaging module, comprising:an imager having an optical member on a light receiving surface;an electronic component having a front surface, the front surface and an incidence surface of the optical member facing a same direction;a resin portion that has a first surface flush with the incidence surface of the optical member and the front surface of the electronic component, and a second surface that is a surface on a side opposite to the first surface, the imager and the electronic component being embedded in the resin portion such that the incidence surface and the front surface are exposed to the first surface;an external connection terminal provided on the second surface; anda through wiring that extends through the resin portion to connect at least one of the imager and the electronic component with the external connection terminal.

In accordance with one of some aspect, there is provided an endoscope system including an imaging module and a processor that processes image data acquired by the imaging module, wherein:the imaging module includes:an imager having an optical member on a light receiving surface;an electronic component having a front surface, the front surface and an incidence surface of the optical member facing a same direction;a resin portion that has a first surface flush with the incidence surface of the optical member and the front surface of the electronic component, and a second surface that is a surface on a side opposite to the first surface, the imager and the electronic component being embedded in the resin portion such that the incidence surface and the front surface are exposed to the first surface;an external connection terminal provided on the second surface; anda through wiring that extends through the resin portion to connect at least one of the imager and the electronic component with the external connection terminal.

In accordance with one of some aspect, there is provided an imaging module manufacturing method comprising:

a mounting step of mounting an imager and an electronic component on a support substrate such that both an incidence surface of the imager and a front surface of the electronic component face the support substrate;

a sealing step of supplying a resin onto the support substrate to seal the imager and the electronic component to form a resin portion having a first surface and a second surface on a side opposite to the first surface, the first surface being flush with the incidence surface of the imager and the front surface of the electronic component; and

a removing step of removing the support substrate.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

The following disclosure provides many different embodiments, or examples, for implementing different features of the provided subject matter. These are, of course, merely examples and are not intended to be limiting. In addition, the disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. Further, when a first element is described as being “connected” or “coupled” to a second element, such description includes embodiments in which the first and second elements are directly connected or coupled to each other, and also includes embodiments in which the first and second elements are indirectly connected or coupled to each other with one or more other intervening elements in between.

Exemplary embodiments are described below. Note that the following exemplary embodiments do not in any way limit the scope of the content defined by the claims laid out herein. Note also that all of the elements described in the present embodiment should not necessarily be taken as essential elements.

Embodiments will be described below. The embodiments to be described herein are not intended to unreasonably limit the content described in the claims. All configurations to be described in the embodiments are not necessarily regarded as being essential components of the disclosure.

1. Imaging Module

FIG.1is a sectional view of a configuration example of an imaging module3according to an embodiment. More specifically,FIG.1is a sectional view of the imaging module3in a plane parallel to an optical axis of the imaging module3while being orthogonal to a light receiving surface33of an imaging element32of an imager30as described later. This applies to the drawings ofFIGS.2to8B,FIGS.10to14, andFIGS.16A,16Bhereinafter. The imaging module3inFIG.1includes electronic components10A,10B (hereinafter, as appropriate, simply referred to as electronic components10collectively), a resin portion20, the imager30, and external connection terminals40A,40B,40C (hereinafter, as appropriate, simply referred to as external connection terminals40collectively). The imager30includes an optical member34. The electronic components10have front surfaces11A,11B (hereinafter, as appropriate, simply referred to as front surfaces11collectively) each facing the same direction as that of an incidence surface35of the optical member34. The resin portion20has a first surface SF1, and a second surface SF2on the side opposite to the first surface SF1. The imager30and the electronic components10A,10B are embedded in the resin portion20such that the incidence surface35and the front surfaces11A,11B are exposed from the first surface SF1. The first surface SF1is flush with the incidence surface35and the front surfaces11A,11B of the electronic components10A,10B. The external connection terminals40are provided on the second surface SF2.

In the following description, the drawings based on the embodiments are provided for illustrative purpose. Accordingly, it should be noted that the relationship between thickness and width of each component, and a thickness ratio and a relative angle of each component are different from those of the actual component. The dimensional relationship and the ratio in each of the drawings may also be partially different. Illustration of a part of the components may be omitted.

The imager30serves to output a signal indicating image data captured by the imaging element32to be described later to the outside. The imager30includes the imaging element32, the optical member34, and an imager terminal36. The imager30may be formed by executing the process of Chip Size Package, or Wafer Level Chip Size Package (WLCSP), for example. The imager30may be referred to as an image sensor, or a camera module. A structure of the imager30of the imaging module3is not limited to the one as described above, but may be variously modified. For example, the single imaging module3may be constituted by two or more imagers30.

The imaging element32serves to convert information of light incident on the light receiving surface33into image data. The imaging element32is formed as a semiconductor element, for example, a Charge-Coupled Device (CCD), or a Complementary Metal-Oxide-Semiconductor (CMOS) sensor. The imaging element may also be formed as other devices.

The optical member34serves to protect the imaging element32and to guide the light thereto. For example, the imaging element32and the optical member34are bonded using a transparent adhesive38such that the light incident on the incidence surface35of the optical member34is further made incident on the light receiving surface33of the imaging element32. The optical member34may be formed as a cover glass which allows light to travel straight. However, the optical member34may also be formed as a lens for condensing light, a prism for refracting light, or an optical system unit as a combination of multiple kinds of those elements.

The imager terminal36serves to perform electric input/output operations between the imaging element32and an external device. For example, output of a signal from the imaging element32, or input of a control signal from the external device may be performed through the imager terminal36. The signal output from the imaging element32may be a pixel signal, for example. The imager terminal36is formed on a surface opposite to the surface on which the imaging element32is provided. The imager terminal36may be formed as a spherical solder bump, a gold stud bump, a pad using such surface-forming material as Au, Cu, and Al for connection, or the conductive paste. The imager terminal may also be formed using any other material or into any other shape.

The electronic component10serves to assist a function of the imaging module3, for example, and may be formed as a light emitting element for emitting light to an object to be captured by the imager30, for example. The electronic component may also be formed as other elements such as an active element and a passive element. The active element is an element for amplifying and controlling an electric signal based on supplied electric power, for example, a transistor, a diode, or a sensor. The passive element is an element which does not perform the active operations described above, for example, a resistance or a capacitor. The structure of the electric component of the imaging module3is not limited to the one as described above, but may be variously modified. For example, a single unit of the imaging module3may be constituted by a single unit of the electronic component10, or three or more units of the electronic components10.

Electronic component terminals12A,12B (hereinafter, as appropriate, simply referred to as electronic component terminals12collectively) are terminals for performing electric input/output operations between the electronic components10A,10B, and the external device. For example, input of a control signal from the external device, or output of a signal from the electronic component10is performed through the electronic component terminal12. The electronic component terminal12is formed as a spherical solder bump or a gold stud bump. Alternatively, a pad or a terminal of the electronic component itself may be used as it is without adding a new terminal to the electronic component10. The electronic component terminal may be formed using any other material or into any other shape.

The resin portion20is a part to be packaged by sealing the imager30and the electronic components10using a resin material. The resin portion20is produced by executing the process of pouring a thermosetting resin into a prescribed mold, for example. The resin portion may also be produced by executing any other process. The thermosetting resin is produced using epoxy resin, for example, as a main material. The thermosetting resin may also be produced using any other resin as the main material. The resin portion20may be produced by adding the material other than the resin. This allows the resin portion20to protect the imager30and the electronic components10from the external environment. For example, the external environment may be temperature, humidity, impact or light. For example, addition of the high light shielding material to the main material of the resin portion20makes it possible to protect the imager30from stray light.

The front surfaces11A,11B of the electronic components10A,10B face the same direction as that of the incidence surface35of the optical member34in the imaging module3. In other words, those surfaces face the same direction as the one orthogonal to those surfaces. The state of facing the same direction includes the state of facing substantially the same direction. The first surface SF1of the resin portion20, from which the optical member34and the electronic components10A,10B are exposed is flush with the incidence surface35and the front surfaces11A,11B. The flush state represents that no level distance exists between two surfaces. The flush state includes substantially the flush state. The use of a flat support substrate60to be described later attains the state where the first surface SF1, the incidence surface35, and the front surfaces11are flush with one another. Such term as flat represents the state in which flatness is within a predetermined range of the predetermined area. For example, the flatness of the support substrate60in the area equal to that of the 8-inch wafer (φ200 millimeters) is one micrometer or smaller. As the first surface SF1including the incidence surface35is flat, it is possible to attain mass production of the imaging modules3each with high accuracy in an optical axis direction.

The external connection terminal40allows connection from outside the resin portion20subsequent to formation of the resin portion20. After being packaged, the imager30and the electronic components10may be electrically connected to the external device through the external connection terminals40. The external connection terminal40includes a dummy terminal used for an operation other than input/output of electric signals. The external connection terminal40is exposed from the second surface SF2opposite to the first surface SF1of the resin portion20. The external connection terminal40is formed as the solder bump or the gold stud bump. However, it may be formed using any other material, or into any other shape. The second surface SF2includes a pattern using the solder resist SR. However, it needs not include such pattern.

Referring to the imaging module3inFIG.1, a distance between the second surface SF2of the resin portion20and a surface37of the imager30which faces the second surface SF2is defined as LA, and a distance between the second surface SF2of the resin portion20and each of surfaces13A,13B (hereinafter, as appropriate, referred to as surfaces13collectively) of the electronic components10A,10B which face the second surface SF2is defined as LB. In this case as illustrated inFIG.1, the relationship of LB>LA is established. That is, asFIG.1illustrates, the distance from the second surface SF2of the resin portion20to each surface of the electronic components10which faces the second surface SF2is longer than the distance from the second surface SF2to the surface of the imager30which faces the second surface SF2. Meanwhile, it is possible to establish the relationship of LA>LB as illustrated inFIG.2. Specifically, referring toFIG.2, the distance from the second surface SF2of the resin portion20to the surface of the imager30which faces the second surface SF2is longer than the distance from the second surface SF2to each surface of the electronic components10which faces the second surface SF2.

As described above, the imaging module3according to the embodiment includes the imager30, the electronic components10, the resin portion20, and the external connection terminals40. The imager30includes the optical member34. The electronic component10has the front surface11which faces the same direction as that of the incidence surface35of the optical member34. The resin portion20includes the first surface SF1, and the second surface SF2on a side opposite to the first surface SF1. The imager30and the electronic components10are embedded in the resin portion20such that the incidence surface35and the front surfaces11are exposed to the first surface SF1. The first surface SF1is flush with the incidence surface35and the front surfaces11of the electronic components. The external connection terminals40are provided on the second surface SF2.

The imaging module3allows the imager30and the electronic components10to be packaged with no need of mount substrate nor outer frame. This allows the imaging module3to be compact, and optimized for application to a leading end of the endoscope. The imaging module3according to the embodiment is applicable to the microscope, for example, as well as the endoscope.

The device disclosed in Japanese Patent Laid-Open No. 2009-240634 is configured to simply mount the camera module and the LED on the mount substrate, resulting in the problem of durability against the external environment. The imaging module3of the embodiment has the imager30and the electronic components10sealed and packaged. This makes it possible to improve durability against the external environment.

Furthermore, there may be a problem that a sophisticated technique is necessary for assembly of the imager30and the electronic components10with a housing at the leading end of the endoscope. As the imaging module3of the embodiment has the imager30and the electronic components10firmly packaged with the resin portion20, those components may be assembled with the housing in the simplified process.

The dummy electronic component may be included in the electronic component10. The dummy electronic component is used for operations non-related to the function of the imaging module3. For example, the dummy electronic component is used in an alignment process as described later.

The first surface SF1of the imaging module3may be differently colored, or have the color density variable to discriminate the resin portion20, the incidence surface35, the front surfaces11, a through wiring50to be described later, and a rewiring52to be described later from one another. This allows the alignment step to be easily executed.

The imaging module3of the embodiment may be provided with through wirings50A,50B,50C (hereinafter, as appropriate, simply referred to as the through wirings50collectively), each of which extends through the resin portion20to connect the external connection terminal40to at least one of the imager30and the electronic components10.

The through wiring50serves to electrically connect the external connection terminal40to the imager terminal36and the electronic component terminals12, both of which are embedded in the resin portion20. The through wiring50is formed using a conductive material, for example, copper. The through wiring may be formed using other materials, for example, nickel, gold, aluminum, or a solder. The imaging module3of the embodiment may be formed even in the case where all terminals of the imager terminal36and the electronic component terminals12are not connected to the external connection terminals40.

According to the imaging module3having the above-structured through wirings50, even in the case where the imager30, the electronic components10, and the resin portion20have different thicknesses, the imager30and the electronic components10may be packaged collectively conforming to the thickness of the resin portion20.

The through wiring50of the imaging module3according to the embodiment may be configured to connect the external connection terminal40to the imager30or the electronic components10selectively in accordance with a distance (LA, LB) from the second surface SF2to each surface of the imager30and the electronic components10on a side opposite to the second surface SF2, whichever is longer. For example, as illustrated inFIG.2, if the distance LA is longer than the distance LB, the imager terminal36of the imager30and the external connection terminal40C are connected via the through wiring50C to form the imaging module3. As illustrated inFIG.1, if the distance LB is longer than the distance LA, the electronic component terminals12A,12B of the electronic components10A,10B, and the external connection terminals40A,40B are connected via the through wirings50A,50B, respectively to form the imaging module3. The distance LB in the case of the electronic component10A may be different from the distance LB in the case of the electronic component10B. That is, the thickness of the electronic component10A may be different from the thickness of the electronic component10B in the thickness direction of the resin portion20.

The above-configured imaging module3allows the component located at a long distance from the second surface SF2to be brought into conduction with the external connection terminal40. The through wiring50may be formed by executing the plating process.

The imaging module3of the embodiment allows at least one of the imager terminal36and the electronic component terminals12to be exposed to the second surface SF2to serve as the external connection terminal40. In other words, the imaging module3may be configured to make the distance LA or LB zero (that is, the surface13of the electronic component10or the surface37of the imager30becomes flush with the second surface SF2). The imaging module3may also be configured to allow the surface13of the electronic component10or the surface37of the imager30to protrude from the second surface SF2. In this case, the external connection terminal40may be connected to the imager terminal36or the electronic component terminal12, which is not exposed to the second surface SF2, via the through wiring50. The through wiring50needs not be provided for the imager terminal36or the electronic component terminal12, which is exposed from the second surface SF2.

For example, as illustrated inFIG.3, the imaging module3is configured to expose the imager terminal36from the second surface SF2to serve as the external connection terminal40. The imaging module3as illustrated inFIG.3makes the distance LA zero. Although not shown in the drawing, the imaging module3may be configured to expose the electronic component terminal12from the second surface SF2to serve as the external connection terminal40. In this case, the imaging module3makes the distance LB zero.

AsFIG.4illustrates, for example, the imaging module3may be configured to expose the imager terminal36, and the electronic component terminals12A,12B from the second surface SF2to serve as the external connection terminals40, respectively. The imaging module3as illustrated inFIG.4makes each of the distances LA and LB zero.

The imaging module3allows the resin portion20to have the same thickness as that of the component with the largest thickness. Accordingly, the imaging module3may be manufactured to have the minimum possible thickness, and to omit formation of the through wiring50.

As the sectional view inFIG.5schematically illustrates, the imaging module3of the embodiment may be configured to include rewirings52A,52B,52C (hereinafter, as appropriate, simply referred to as rewirings52collectively) formed in the second surface SF2for connecting the external connection terminal40to at least one of the imager terminal36, the electronic component terminals12, and the through wirings50. The rewiring52is formed to have a predetermined wiring pattern in a planar view of the second surface SF2seen from below inFIG.5. The rewiring52C formed as illustrated inFIG.5allows the external connection terminal40C to be formed at a position different from that of the imager terminal36in the planar view of the second surface SF2. Similarly, the rewiring52A formed as illustrated inFIG.5allows the external connection terminal40A to be formed at a position different from that of the electronic component terminal12A in the planar view of the second surface SF2. The position different from that of the electronic component terminal12A refers to the different position in a direction orthogonal to the drawing plane inFIG.5, for example. This makes it possible to place the external connection terminal40on the second surface SF2at a position which allows easy connection with the signal wiring or the like, resulting in easy mounting. Change in the position of the external connection terminal40C to the one to which the smaller mechanical load is applied ensures to improve package reliability of the imaging module3. The imaging module3of the embodiment may be configured by forming the rewiring52without changing arrangement of the external connection terminal40. In this case, the layer of the rewiring52is formed on the through wiring50, and the external connection terminal40is further provided on the rewiring52. An insulating layer53is formed in the same layer as the rewiring52. This applies to the configuration to be described later referring toFIGS.8A and8B.

2. Method of Manufacturing Imaging Module

Next, a method of manufacturing the imaging module3of the embodiment will be described. The imaging module3of the embodiment is manufactured by executing the respective steps as illustrated inFIGS.6A,6B,7A,7B,8A, and8B.

Each ofFIGS.6A to8Bis a sectional view illustrating the method of manufacturing the imaging module3. In the embodiment, multiple imaging modules3are arrayed to form the shape like the semiconductor wafer. The substrate may be formed into a polygonal shape such as a quadrangle besides the disc-like shape of the semiconductor wafer. Each ofFIGS.6A to8Btypically illustrates a single unit of module after singulation, and illustration of other modules is omitted. Codes and explanations given to structures and terms similar to those of the above-described imaging module3will be omitted.

In the first step, as illustrated inFIG.6A, the imager30and the electronic components10are mounted onto a temporary bonding member62on the support substrate60. Specifically, the first step is executed by the method as illustrated inFIG.6A. The first step may be called a mounting step. The first step may be executed by placing the imager30and the electronic components10A,10B such that the incidence surface35of the optical member34of the imager30, and the front surfaces11A,11B of the electronic components10A,10B come in contact with the temporary bonding member62. The first step is executed by a component mounter, or may be executed by other devices.FIG.6Aillustrates a configuration example that the single unit of the imaging module3is formed by combining the single imager30and the two electronic components10A,10B. However, the imaging module3may be configured by other combinations. The first step may be executed by adding the active element, the passive element, or the dummy electronic component.

The support substrate60is an auxiliary member for manufacturing the imaging module3. In the embodiment, the shape and size of the support substrate60are the same as those of a generally employed semiconductor wafer. Executing the wafer dicing process as described later allows collective mass production of the imaging modules3. The use of the material with high flatness allows production of the support substrate60. For example, the support substrate60is made of glass, or may be made of other materials like silicon.

The temporary bonding member62serves to temporarily fix the support substrate60and the imaging module3in the process of manufacturing the imaging module3. The temporary bonding member62is formed to be as flat as the support substrate60. For example, a prescribed resin is applied onto the support substrate60by a spin coating method to form the temporary bonding member62. The temporary bonding member62may be formed by laminating the sheet material onto the support substrate60. The material which allows the imaging module3to be easily peeled off is used for forming the temporary bonding member62.

In the second step, as illustrated inFIG.6B, the resin portion20is formed on the temporary bonding member62. The second step may be called a sealing step. The second step is executed by the mold resin sealing method, or may be executed by other methods. In the second step, the resin portion20may be formed to allow any one or all of the imager terminal36and the electronic component terminals12A,12B to serve as the external connection terminal40. The terminal which serves as the external connection terminal40does not have to be subjected to the third, fourth, and the fifth steps as described later. The resin portion20has the first surface SF1which comes in contact with the temporary bonding member62, and is flush with the incidence surface35and the front surfaces11. The surface on the side opposite to the first surface SF1is the second surface SF2.

In the third step, as illustrated inFIG.7A, through holes54A,54B,54C (hereinafter, as appropriate, simply referred to as through holes54collectively) are formed in the resin portion20. The third step is executed by forming the through holes54from the side of the second surface SF2. The third step is executed by forming the through holes54by laser machining. The through holes54may also be formed by the etching technique, for example.

The third step may be executed only when any one or all of the imager terminal36, and the electronic component terminals12A,12B are not exposed to the second surface SF2.

In the fourth step, as illustrated inFIG.7B, the through wirings50A,50B,50C are formed in the through holes54as illustrated inFIG.7A, respectively. The fourth step by itself, or together with the third step may be called a through wiring forming step. The fourth step is executed by filling the through holes54with a conductive material. The fourth step may be executed together with the step of forming the pad on which the external connection terminal40is mounted. The fourth step is executed by the electroplating method, or may be executed by other methods. For example, the fourth step may be executed by filling with the conductive paste, or by connecting and mounting a thin and long columnar pin onto the imager terminal36, and the electronic component terminals12A,12B. The fourth step may be executed by the Molded Interconnect Device (MID) technique. The MID technique is utilized for forming the wiring only on the section of the molded resin member irradiated with the prescribed laser light. The MID technique is implemented using the resin forming material which contains a prescribed additive. The fourth step may be executed only in the case where the third step has been executed.

In the fifth step, as illustrated inFIG.8A, the external connection terminals40A,40B,40C are formed. The fifth step is executed by the solder bump forming method, for example, or may be executed by other methods. The solder bump forming method is implemented by the printing technique, or may be implemented by a plating technique or a micro soldering ball mounting technique. The fifth step may be executed together with the step of forming the rewirings52A,52B,52C. If the external connection terminals40A,40B,40C are located at the same positions as the imager terminal36and the electronic component terminals12A,12B, the step of forming the rewirings52A,52B,52C needs not be executed in the fifth step. The fifth step may be executed together with the step of forming a solder resist SR pattern on the second surface SF2. The fifth step may be executed only in the case where the third and fourth steps have been executed.

In the sixth step, as illustrated inFIG.8B, the support substrate60and the temporary bonding member62are removed from the imaging module3. The sixth step may be called a removing step. The sixth step is executed by the mechanical peeling-off method, or may be executed by other methods. The step of applying ultraviolet rays and heat to the temporary bonding member62may be added to the sixth step.

The sixth step may be executed by generating bubbles from the temporary bonding member62to cause self-peeling of the imaging module3.

A temporary flattening step of temporarily flattening the second surface SF2may be added to the sixth step. The temporary flattening step may be executed by utilizing a dedicated protective sheet, and a soluble resin. This makes it possible to improve adsorption to the prescribed device at the side on the second surface SF2to suitably allow peeling of the temporary bonding member62.

The sixth step is executed by the dedicated device, or may be executed by the same device as the one used in a singulation step to be described later.

As described above, the method of manufacturing the imaging module3of the embodiment includes the mounting step, the sealing step, and the removing step. In the mounting step, as illustrated inFIG.6A, the imager30and the electronic components10are mounted on the support substrate60such that the incidence surface35of the imager30and the front surfaces11of the electronic components10face the support substrate60. In the sealing step, as illustrated inFIG.6B, the resin is applied onto the support substrate to seal the imager30and the electronic components10. The resultant resin portion20has the first surface SF1flush with the incidence surface35and the front surfaces11, and the second surface SF2on the side opposite to the first surface SF1. In the removing step, as illustrated inFIG.8B, the support substrate60is removed.

The method of manufacturing the imaging module3of the embodiment using no substrate nor outer frame allows the imaging module3to be more compact than the one manufactured through the generally employed method. The method allows mass production of the imaging modules3in the wafer-like state, each of which has the first surface SF1flush with the incidence surface35and the front surfaces11.

The through wiring forming process of forming the through wirings50in the resin portion20may be included for connection with at least one of the imager30and the electronic components10from the second surface SF2.

Even in the case where each thickness of the imager30, the electronic components10, and the resin portion20is different, although the thickness of the resin portion20is variable depending on the location, the method of manufacturing the imaging module3allows those elements to be packaged in the wafer-like state conforming to the thickness of the resin portion20, which has been set to be the largest.

In the sealing step, as illustrated inFIG.3or4, the resin portion20may be formed such that at least one of the imager terminal36and the electronic component terminals12is exposed from the second surface SF2to serve as the external connection terminal40.

The method of manufacturing the imaging module3allows the thickness of the resin portion20to be set in accordance with that of the component having the largest thickness. This makes it possible to manufacture the imaging module3with very small thickness, and to reduce the number of points at which the through wirings50are formed, and frequency of forming the through wirings50.

A step of grinding the resin portion20to be executed at arbitrary timing may be included in the method of manufacturing the imaging module3of the embodiment.

A step of forming an alignment pattern to be executed at arbitrary timing may be included in the method of manufacturing the imaging module3of the embodiment.

A groove forming step of forming a half-cut groove for dicing to be executed at arbitrary timing may be included in the method of manufacturing the imaging module3of the embodiment.

The method of manufacturing the imaging module3of the embodiment may be implemented by forming the external connection terminal40after execution of the singulation step to be described later.

The method of manufacturing the imaging module3of the embodiment may be implemented by executing the mounting step, the sealing step, and the removing step to form multiple imaging modules3in the wafer-like state collectively, and further executing the additional singulation step for singulation of the multiple imaging modules3by the wafer dicing process. Specifically, the singulation step is executed by the method as illustrated inFIGS.9A and9B.

Each ofFIGS.9A and9Bis a perspective view illustrating the singulation step for singulation of the imaging modules3in the wafer-like state, which have been produced as illustrated inFIGS.6A to8Bby the wafer dicing process. The singulation step includes an attachment step of attaching the wafer-like imaging modules3to a dicing tape200, and a dicing step of dicing the wafer-like imaging modules3.

As illustrated inFIG.9A, the attachment step is executed by attachment of the wafer-like imaging modules3to a position around the center of the dicing tape200. A dicing ring frame210used for transportation or the like is attached to a circumference of the dicing tape200. The attachment step is executed by the wafer dicing processing device. The attachment step is executed by attachment of the dicing tape200to the side of the first surface SF1of the wafer-like imaging modules3. The attachment step may also be executed by attachment of the dicing tape200to the side of the second surface SF2.

Referring toFIG.9B, although partially omitted, the dicing step is executed using a dicing blade220rotating at high speeds for singulation of the imaging modules3. The dicing step includes an alignment step of determining a processing position and a processing direction using a prescribed camera.

The alignment step may be executed by recognizing images of alignment marks on the respective points of the imager30. The alignment step, however, may be executed using other patterns. The alignment step may be executed using a pattern which has been formed based on images of the incidence surface35and the front surfaces11, for example. The alignment step may be executed using a pattern which has been formed based on an image of a surface of the dummy component, for example. The alignment step may be executed using a pattern which has been formed in the fourth step or the fifth step as described above, for example.

The singulation step may be executed by the additional laser machining and expansion for expanding the dicing tape200, or by combining those techniques.

The singulation step may be executed by the process except the singulation step as illustrated inFIGS.9A and9B. For example, the singulation step may be executed by adding the groove forming step to the third step, and further adding a pre-dicing grinding step of grinding until the groove is exposed from the side of the first surface SF1. This makes it possible to clean the incidence surfaces of many imaging modules3collectively, and to make the imaging module3further thinner.

Japanese Patent Laid-Open No. 2009-240634 discloses manufacturing of wafer-level camera modules. As the camera modules are mounted on the mount substrate one by one, the manufacturing cost cannot be reduced. The method of manufacturing imaging modules3according to the embodiment allows formation of the packaged imaging modules in the wafer-like state. This makes it possible to further reduce the manufacturing cost.

The method of manufacturing imaging modules of the embodiment is not limited to the one as described above, but is applicable to the method of manufacturing the imaging modules3as described below.

The wafer-like imaging modules3bonded to the support substrate60described above may be diced.

3. Imaging Module Including Light Guiding Optical Member

The imaging module3of the embodiment may be provided with light guiding optical members70A,70B (hereinafter, as appropriate, simply referred to as light guiding optical members70collectively) each disposed on the incidence surface35of the imager30for guiding the incident light toward the incidence surface35, as illustrated by the sectional views ofFIGS.10and11. The incident light refers to the one emitted from an object. Codes and explanations given to the structures similar to those described above will be omitted.

Referring to the imaging module3inFIG.10, the light guiding optical member70A is bonded to the incidence surface35of the imager30using a not shown transparent adhesive. The light guiding optical member70A is formed as a lens unit, for example. Referring to the imaging module3inFIG.10, a cable80is connected with one of the external connection terminals40. However, the cable80may be connected to the arbitrary number of external connection terminals40. Referring to the imaging module3inFIG.10, an optical axis of the light guiding optical member70A is aligned with a direction orthogonal to the light receiving surface33of the imaging element32.

Referring toFIG.11, the imaging module3is provided with the light guiding optical member70B which bends the incident light to be guided toward the incidence surface35. That is,FIG.10illustrates that an optical axis of the light guiding optical member70A is aligned with the direction orthogonal to the light receiving surface33of the imaging element32. Meanwhile,FIG.11illustrates that an optical axis of the light guiding optical member70B extends parallel to the first surface SF1. Specifically, the imaging module3as illustrated inFIG.11has the light guiding optical member70B including a prism71, which is disposed on the incidence surface35. The imaging module3may be configured by connecting the cable80to the external connection terminal40. The process for connection between the external connection terminal40and the cable80may be variously modified.

Referring toFIGS.10and11, the imaging module3has the light guiding optical member70for guiding the incident light toward the incidence surface35, which is disposed on the incidence surface35of the imager30. The use of the light guiding optical member70allows the incident light from the object to be guided toward the incidence surface35of the imager30, and the imager30to capture an image of the object. The imaging module3thus can be incorporated into the endoscope system or the like. The imaging module3may be incorporated into the microscope system.

4. Imaging Module Including Multi-Layered Body

Referring to the imaging module3of the embodiment in each sectional view ofFIGS.12A,12B, a multi-layered body100formed by stacking multiple semiconductor elements may be provided on a surface opposite to the light receiving surface33of the imager30. Codes and explanations given to the structures similar to those described above will be partially omitted. The explanation with respect to the electronic components10will be omitted.

The multi-layered body100is formed by stacking multiple semiconductor elements. The multi-layered body100is manufactured by singulation of not shown stacked semiconductor wafer. That is, the multi-layered body100is formed by executing the semiconductor wafer process.

Provision of the compact multi-layered body100to the packaged imager30compact in size synergistically allows the imaging module3to be easily incorporated into the endoscope system.

The multi-layered body100as illustrated inFIG.12Ais constituted as a double-layered structure including a first semiconductor layer110and a second semiconductor layer120. It may also be constituted by three or more layers of semiconductor elements.

The multi-layered body100is connected to the cable80which intervenes between the multi-layered body100and the external device. However, the connection may be attained in various modifications. For example, as illustrated inFIG.12A, the multi-layered body100and the cable80may be connected via a flexible printed board81on a surface100SF1opposite to a surface100SF2of the multi-layered body100to be connected with the external connection terminal40.

FIG.12Billustrates a detailed configuration of the multi-layered body100. In the description below, a code D1denotes a direction toward the light receiving surface33from a back surface thereof, and a code D2denotes a direction opposite to the direction D1. For example, as illustrated inFIG.12B, the first semiconductor layer110, the second semiconductor layer120, and the imager30are stacked in this order along the direction D1.

The first semiconductor layer110and the second semiconductor layer120are stacked via a sealing resin layer130. The first semiconductor layer110and the second semiconductor layer120have through-vias114and124, respectively. The first semiconductor layer110and the second semiconductor layer120are connected with a layer adjacent to the multi-layered body100or the imager30via the through vias114,124, and bumps116,126, respectively. For example, referring to an example illustrated inFIG.12B, the second semiconductor layer120is connected with the imager30, and the first semiconductor layer110is connected to the second semiconductor layer120. A first semiconductor element112is disposed on a surface of the first semiconductor layer110at the side D1. A second semiconductor element122is disposed on a surface of the second semiconductor layer120at the side D1. The first semiconductor element112may be disposed on a surface of the first semiconductor layer110at the side D2, or both sides. Correspondingly, the second semiconductor element122may be disposed on a surface of the second semiconductor layer120at the side D2, or both sides.

The configuration of the imaging module3including the multi-layered body100is not limited to those illustrated inFIGS.12A,12B. The configuration may be variously modified by omitting a part of those components or adding other components.

The imaging module3of the embodiment may be configured to embed the imager30and the multi-layered body100in the resin portion20as the sectional view inFIG.13illustrates. Codes and explanations given to the structures similar to those described above will be partially omitted. The explanation with respect to the electronic components10will be omitted.

The imaging module3has the imager30and the multi-layered body100firmly fixed with the resin portion20to allow improvement in reliability. It is also possible to simplify the process of manufacturing the endoscope or the like.

5. Imaging Module Containing Light Guiding Optical Member in Resin Portion

As the sectional view inFIG.14illustrates, the imaging module3of the embodiment may be provided with a light guiding optical member70C inside the resin portion20. Codes and explanations given to the structures similar to those described above will be omitted. The explanation with respect to the electronic components10will be omitted. Referring toFIGS.10and11, the light guiding optical members70A,70B are disposed on the incidence surface35exposed to the first surface SF1of the resin portion, respectively. Referring toFIG.14, the light guiding optical member70C bonded to the optical member34is sealed with resin so that a light guiding incidence surface72of the light guiding optical member70C is exposed to the first surface SF1.

The imaging module3has the imager30and the light guiding optical member70C firmly fixed to allow improvement in reliability. It is also possible to simplify the process of manufacturing the endoscope or the like.

6. Imaging Module Including Shielding Member

The imaging module3of the embodiment may be provided with a shielding member300for enclosing at least the imager30.FIGS.15A,15Bare plan views each illustrating a configuration example of the imaging module3including the shielding member300in a planar view in the direction vertical to the first surface SF1. Codes and explanations given to the structures similar to those described above will be omitted.

As illustrated inFIGS.15A,15B, the shielding member300may be formed to extend from the first surface SF1to the second surface SF2, or extend from either the first surface SF1or the second surface SF2to the middle of the depth. That is, the shielding member300may be formed to positionally overlap at least with the imager30in a side view from the direction orthogonal to the vertical direction of the first surface SF1.

Referring to the imaging module3inFIG.15A, the shielding member300is formed to enclose only the imager30. Like the imaging module3inFIG.15B, the shielding member300may be formed to enclose the imager30and the electronic components10. Although not shown, the shielding member300may be formed to enclose the imager30and an arbitrary one of the electronic components10.

The shielding member300may be formed using the same material as the one for forming the through wiring50, or using the different material from the one for forming the through wiring50. The shielding member300is produced in the step other than the third and the fourth steps as described above. However, it may be formed along with the third and the fourth steps. Accordingly, those manufacturing steps can be integrated.

The foregoing imaging module3allows the imager30and the electronic components10to be shielded from noise and stray light.

7. Imaging Module Including Opening

As the sectional view inFIG.16Billustrates, the imaging module3of the embodiment may be configured to form an opening400in the resin portion20, which extends from the first surface SF1to the second surface SF2. Codes and explanations given to the structures similar to those described above will be omitted. For example, the opening400is formed by laser machining, or may be formed by etching. The through hole54as illustrated inFIG.7Ais formed for conduction by the through wiring50. Meanwhile, the opening400is formed to serve as a water feed hole or a forceps hole for the endoscope. The opening400is formed by executing the process separately from the third step as described above. However, it may be formed along with the third step. Accordingly, those manufacturing steps can be integrated. The imaging module3as illustrated inFIGS.16A,16Bincludes the multi-layered body100as described above. The imaging module3may also be manufactured without including the multi-layered body100.

The method according to the embodiment is applicable to an endoscope system. An endoscope system2includes the above-described imaging module3, and a processor75A for processing image data acquired by the imaging module3. The imaging module3includes the imager30, the electronic components10, the resin portion20, and the external connection terminals40. As the imager30, the electronic components10, the resin portion20, and the external connection terminals40have been described above in detail, explanations thereof thus will be omitted. Specifically, the endoscope system2is configured as illustrated inFIG.17.

The endoscope system2includes an endoscope1including the imaging module3, and the processor75A for processing the image data acquired by the imaging module3. Specifically, the endoscope1includes an insertion portion73, a grip portion74disposed at a base end of the insertion portion73, a universal code74B extending from the grip portion74, and a connector74C disposed at a base end of the universal code74B. The insertion portion73includes a rigid top end portion73A to which the imaging module3is attached, a bending portion73B extending from a base end of the top end portion73A, which is bendable for changing the direction of the top end portion73A, and a flexible portion73C extending from a base end of the bending portion73B. The grip portion74includes a rotatable angle knob74A as an operation portion which allows an operator to operate the bending portion73B. The endoscope system2may be configured to include a display device75B for displaying the image processed by the processor75A.

In the embodiment, the top end portion73A includes the imaging module3and a housing. However, the top end portion73A may be constituted only by the imaging module3.

The endoscope system2of the embodiment is not limited to the one as illustrated inFIG.17, but is applicable to various types of endoscope systems. For example, like the capsule type endoscope, the endoscope system may be configured to attain wireless communication between the top end portion73A and the processor75A. The endoscope system2of the embodiment may also be configured to allow the external server or the like to control the endoscope1, or allow AI to operate the endoscope1.

Although the embodiments to which the present disclosure is applied and the modifications thereof have been described in detail above, the present disclosure is not limited to the embodiments and the modifications thereof, and various modifications and variations in components may be made in implementation without departing from the spirit and scope of the present disclosure. The plurality of elements disclosed in the embodiments and the modifications described above may be combined as appropriate to implement the present disclosure in various ways. For example, some of all the elements described in the embodiments and the modifications may be deleted. Furthermore, elements in different embodiments and modifications may be combined as appropriate. Thus, various modifications and applications can be made without departing from the spirit and scope of the present disclosure. Any term cited with a different term having a broader meaning or the same meaning at least once in the specification and the drawings can be replaced by the different term in any place in the specification and the drawings.