Abstract:
Optical sensors containing reduced amounts of cross talk, as well as methods for making and using such sensors are described. The sensors contain a light absorption coating that is placed on a portion of the external surface of the optical sensor near the detector. This absorption coating reduces the amount of cross talk by reducing the amount of light reflected inside a transparent package of the sensor. As well, the coating can also reduce the amount of ambient and/or stray light that enters the sensor. The coating adds little cost or complexity to the manufacturing process for the sensors, yet reduces the cross talk without substantially increasing the size of the sensor or without increasing any reliability risks. Other embodiments are also described.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This patent application claims priority of U.S. Application Ser. No. 60/941,455, filed Jun. 1, 2007, the entire disclosure of which is hereby incorporated by reference. 
     
    
     FIELD 
       [0002]    This application generally relates to optical sensors and method for making and using such optical sensors. More specifically, this application relates to reflective optical sensors containing reduced amounts of cross talk. 
       BACKGROUND 
       [0003]    Optical sensors are used in a wide variety of applications. One application where optical sensors are of particular use is to detect the presence and/or absence of an object. Two types of optical sensors that detect the presence and absence of an object are interrupt optical sensors and reflective optical sensors. 
         [0004]    Interrupt optical sensors (also known as transmissive sensors) include an optical emitter and an optical detector located on opposite sides of an object to be sensed. The presence of the object is detected when the object breaks the optical path between the emitter and the receiver. The absence of the object is shown when the optical path between the emitter and of the receiver remains undisturbed (i.e., since the object does not break that optical path). 
         [0005]    Reflective optical sensors, on the other hand, contain an optical emitter and an optical detector that are located on the same side of the object to be sensed. The object is detected when an optical emission from the optical emitter is reflected from a surface of that object and then received by the optical detector. Reflective optical sensors typically contain a light emitting diode (“LED”) as the optical emitter and a photodiode or phototransistor as the optical detector. These two components are mounted in a side-by-side relationship in the housing of the optical sensor. The LEDs can have a broad angular emission window projected in a large undefined angular range (i.e., similar to a conventional light bulb). 
         [0006]    The performance of optical reflective sensors can be measured, in part, by the contrast provided when scanning an object that contains alternating reflective and non-reflective surfaces. This contrast is typically determined by the reflectance of those surfaces, the resolution of the sensor compared to the dimensions of the object, and the amount of cross talk that contributes to the photocurrent between the optical emitter and the optical receive detector. This cross talk is the portion of emitted light that it internally reflected, scattered, or channeled to the optical detector (as opposed to that external light which is reflected by the object), as well as any direct illumination from the LED. Generally, the smaller the cross-talk, the better the operation of the optical reflective sensor. 
         [0007]    There are currently two methods to minimize the problems associated with cross talk. As shown in  FIG. 1 , the first method places an opaque barrier  116  between the emitter (located in a first cavity  112 ) and the detector (located in a second cavity  114 ) in the sensor  100 , and so is often called a packaging solution. This first method, while somewhat effective in preventing cross talk, requires a complex assembly process and does not allow for sophisticated optics. 
         [0008]    The second method for minimizing cross talk processes the light signal in a differential manner by using a dual photodiode and a comparator. This method is therefore often called a die design solution. The die design solution is not very effective since the light is not evenly spread over the 2 photodiodes, does not work for analog output, and is expensive as it doubles the size of the photosensitive area. 
       SUMMARY 
       [0009]    This application describes reflective optical sensors containing reduced amounts of cross talk, as well as methods for making and using such sensors. The sensors contain a light absorption coating that is placed on a portion of the external surface of the optical sensor near the detector. This absorption coating reduces the amount of cross talk by reducing the amount of light reflected inside a transparent package of the sensor. As well, the coating can also reduce the amount of ambient and/or stray light that enters the sensor. The coating adds little cost or complexity to the manufacturing process for the sensors, yet reduces the cross talk without substantially increasing the size of the sensor or without increasing any reliability risks. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    The following description can be better understood in light of Figures, in which: 
           [0011]      FIG. 1  depicts a conventional reflective optical sensor; 
           [0012]      FIGS. 2   a  through  2   c  show different views of some embodiments of a reflective optical sensor containing an absorption coating; 
           [0013]      FIG. 3  shows other embodiments of a reflective optical sensor containing an absorption coating; and 
           [0014]      FIG. 4  depicts yet other embodiments of the operation of a reflective optical sensor containing an absorption coating. 
       
    
    
       [0015]    Together with the following description, the Figures demonstrate and explain the principles of the reflective optical sensors and methods for making and using such sensors. In the Figures, the configuration of components may be exaggerated or simplified for clarity. In the drawings, the thickness of layers and regions are exaggerated for clarity. It will also be understood that when a layer, component, or substrate is referred to as being “on” another layer, component, or substrate, it can be directly on the other layer, component, or substrate, or intervening layers may also be present. The same reference numerals in different drawings represent the same element, and thus their descriptions will not be repeated. 
       DETAILED DESCRIPTION 
       [0016]    The following description supplies specific details in order to provide a thorough understanding. Nevertheless, the skilled artisan would understand that the optical sensors and methods for making and using such sensors can be implemented and used without employing these specific details. For example, while the description focuses on reflective optical sensors, it can be modified to be used in other optical sensors such as optical encoders and bar code readers heads. Indeed, the description can be used in numerous end uses, such as numerous printer, motion control, position control, and bar code applications. 
         [0017]    The reflective optical sensors described in this application contain a coating that partially or completely absorbs the internally reflected light that can cause cross talk. As well, the coating can also reduce the amount of ambient and/or stray light that can enter the sensor. Some examples of such reflective optical sensors are depicted in the Figures and described herein. 
         [0018]    Referring to the devices illustrated in  FIGS. 2   a  through  2   c ,  FIG. 2   a  contains a top view of the reflective optical sensor  1 ,  FIG. 2   b  contains a side view of the sensor  1 , and  FIG. 2   c  contains an end view of the sensor  1 . The optical sensor  1  comprises a light emitting element (or emitter)  31  and a light detecting element (or detector)  32 . The light emitting element  31  has a broad emission window  33  that projects the light in a large angular range so that the maximum amount of light can be reflected off of the desired object which the sensor is measuring. 
         [0019]    The light that can be emitted from the light emitting element  31  can be any known light that can be reflected off the desired object and then detected by light detecting element  32 , whether that light exists in the visible spectrum or not. Examples of such light include infrared, monocolor visible, white, and combinations thereof. In some embodiments, the light used comprises red light. In some embodiments, the wavelength of the light can range anywhere from about 400 nm to about 1000 nm. In other embodiments, the wavelength of the light is about 630 nm. 
         [0020]    The light emitting element  31  comprises any light source known in the art. Examples of known light sources include vertical cavity surface emitting lasers (VCSEL), resonant cavity light emitting diodes (RCLED), light emitting diodes (LEDs), and combinations thereof. In some embodiments, the light source comprises a light emitting diode. While any number of light sources can be combined to create the light emitting element, typically only a single light source is used as the light emitting element  31 . 
         [0021]    The light detecting element  32  comprises any known electronic component that can detect the light emitted form the emitter  31  and then reflected from the measured object. Examples of light detecting elements that can be used include a photodiode array, a charge coupled device (CCD), a phototransistor, a photodiode, a photodiode followed with a transimpedance amplifier, a transimpedance amplifier, or combinations thereof. In some embodiments, the light detecting element comprises a phototransistor. While any number of these components can be combined to create the light detecting element, typically only a single component is used as the light detecting element  32 . 
         [0022]    The light emitting and detecting elements are sealed in a packaging material (or package)  2 . The package  2  encloses the light emitting element  31  and light detecting element  32 , insulates them from the environment, and also protects them. In some embodiments, the package  2  is made of a partially or completely optically transparent material so that the light can pass partially or completely though it. The package can be made of any material consistent with these functions, such as silicone, glass, a transparent epoxy resin, or combinations of these materials. In some embodiments, the material used for the package comprises a transparent epoxy resin. 
         [0023]    The light emitting element  31  and the light detecting element  32  are electrically connected to leads  5 . The leads  5  extend out of the protective package  2  to connect the sensor  1  to an external electrical component or device, such as a printed circuit board which connects the optical sensor to a control circuit. Any lead known in the art can be used in the reflective optical sensor  1 , including any conductive metal or metal alloy, such as steel or copper. In some embodiments, the leads  5  comprise steel. As depicted, the outer portions of the leads  5  are bent substantially in a shape of L to form horizontally extending end portions that can be easily mounted to a printed circuit board. Any other known configuration for the leads  5  can also be used. And while six leads are shown in the Figures, the optical sensor could contain any number of leads  5 , including from 4 to 8. 
         [0024]    As depicted in  FIG. 2   a , the sensor  1  contains a coating  15  that is located on the section of the sensor  1  containing the light detecting element  32 . The coating  15  can be located over any desired part of this section of the sensor. In the embodiments illustrated in the Figures, the coverage area of the coating  15  in this section is maximized. 
         [0025]    The coating  15  absorbs the light that is internally reflected in the sensor  1  that would otherwise eventually impinge on the light detecting element  32 . This internally reflected light contributes the cross talk phenomenon in the sensor, as described above, and so when it reduces this light, it also reduces the cross talk. The coating  15  can also reduce the amount of ambient and/or stray light that enters the sensor. This ambient and/or stray light can also interfere with the operation of the optical sensor  1  since it can also be detected by the light detecting element  32 . 
         [0026]    The coating  15  can have any thickness that absorbs the internally reflected light and/or the ambient/stray external light. The actual thickness may also depend on the material(s) which is used to make the coating and the material used in the package  2 . In some embodiments, the thickness of the coating  15  can range from about 20 μm to about 100 μm. 
         [0027]    In some embodiments, the coating  15  contains a single layer. In other embodiments, though, the coating  15  can contain a plurality of layers, such as where one of the layers absorbs a certain type/wavelength of light. Another layer can then be used to absorb a different type/wavelength of light. 
         [0028]    In some embodiments, the coating  15  does not completely cover the entire section of the sensor  1  containing the light detecting element  32 . In these embodiments, the coating  15  contains an opening  17  at the location where the light reflected from the measured object will enter the sensor  1  and be detected. Thus, the useful light is allowed to enter through opening  17  and be detected by the light detecting element  32 , while at the same time the coating  15  reduces the internally reflected light and the ambient/stray external light. 
         [0029]    The size of the opening  17  will therefore depend, in part, on the size of the light detecting element  32 . In some embodiments, such as where the detector is in the shape of a rectangle or square, the size of the opening can range from about 0.25 mm 2  to about 4 mm 2 . 
         [0030]    The opening  17  can have any shape that will maximize the amount of light reflected from the measured object while minimizing the internally reflected light and/or the ambient/stray external light. The shape used will also depend on the expected use of the sensor  1 . Examples of the shapes that can be used include substantially rectangular, square, circular, oblong, triangular, elliptical, and trapezoidal shapes. In some configurations, the shape of opening  17  can be modified by providing the sidewalls of the opening  17  with an incline to allow more reflected light from the measured object to enter the sensor  1 . 
         [0031]    In some embodiments, the coating  15  and the opening  17  are configured as depicted in  FIG. 3 . In the sensor depicted in this Figure, the sensor  1  contains a coating  15  covering the section of the sensor  1  that contains the light detecting element  32  (which is depicted in this Figure as being substantially circular in shape). The section of the sensor  1  containing the light emitting element  31  does not contain a coating  15 . The sensor  1  contains a substantially rectangular-shaped opening  17  in coating  15  that allows the light reflected from the measured object to pass though it and impinge on the detector. 
         [0032]    Different configurations for the coating  15  can be used in the optical sensors. In some configurations, the coating  15  can be located under—rather than over—the outer surface of the sensor, even though such a configuration might complicate the manufacturing process. In other configurations, an air cavity can be included between the active area of the sensor  1  and the surface of the coating, whether the coating is on the inside or the outside of the outer surface. In yet other configurations, the coating  15  can be extended to cover the sides and bottom of the sensor. And still in other configurations, the coating  15  can even cover the entire surface of the sensor except for the emitter dome  33  and the opening  17 . 
         [0033]    The coating  15  can be made from any material, or combination of materials, that absorbs the internally reflected light and the ambient/stray external light. As well, the material(s) used in the coating should be resistant to water and any cleaning solvents that might be used with the sensor during manufacture or during operation, should be compatible with the material it is coated on (i.e., wettability and adherence), and should be compatible with the process used in dispensing the materials so that the formed thickness is uniform and consistent from lot to lot. Examples of the materials that can be used include inks, paints, and combinations thereof. In some embodiments, black ink can be used as the material for the coating  15 . In other embodiments, inks that are used for semiconductor device marking can be used. In yet other embodiments, carbon-loaded inks that optimize the light absorbed can be used as the coating. 
         [0034]    One measure of the effectiveness of the coating  15  is I FT , the amount of LED current necessary to turn the detector on when no light is reflected from outside. The larger the I FT  amount, the lower the cross talk of the sensor. In some instances, for the reflective optical sensors that do not contain a coating  15  and are configured as shown in  FIG. 2   a  (but without a coating  15 ), the I FT  can range from 2.3 mA to 7.9 mA. But by using a coating  15 , the I FT  can be increased anywhere from about 15.6 mA to about 25.9 mA. Thus, by using the coating  15 , the cross talk can be reduced by about 50% to about 80% with less dispersion (i.e., a standard deviation of 7.3 mA). 
         [0035]    The sensors described above can be made by any process which provides the structures described and illustrated. In some embodiments, the process described below is used to manufacture the sensors. First, a lead frame is prepared as known in the art. In some instances, the lead frame can be produced by pressing or stamping a thin metal plate into the desired shape. Next, the light emitting element  31  is bonded or attached to one portion of the lead frame and the light detecting element  32  is attached or bonded to another portion of the lead frame. The light emitting element  31  and the light detecting element  32  can be attached in the same process or in separate processes. While any attachment process known in the art can be used, a die attach process in a strip or matrix form can be used in some embodiments. Then, the material used in the die attach process is cured by any method known in the art. 
         [0036]    Next, the light emitting element  31  and the light detecting element  32  are electrically connected to the lead frame. In some embodiments, this process is performed by using any known wire bonding process. Then the package  2  is formed around the light emitting element  31 , the light detecting element  32 , and most of the lead frame except for external leads  5 . The package  2  can be formed by, for example, a transfer molding method in a strip form. The molded plastic material used in the transfer molding process provides the final shape of the package  2  with a dome shape above the emitter side of the sensor  1 . 
         [0037]    Next, the coating  15  is provided on the outside of the package  2  using any known process that leaves the opening  17  in the coating  15 . In some instances, such as where an ink is used, the coating can be just applied selectively to the desired areas of the exterior surface of the package  2 . In other instances, a layer of the coating material can applied over the entire detector section of the sensor and then the opening  17  can be formed by, for example, any known removal process for that coating material used. 
         [0038]    Next, the molded plastic material of the package  2  is cured by any known process. Then, the sensors are singulated and tested, the leads extending from the lead frame are bent into the desired shape (such as shown in the Figures), and taping is performed as known in the art. 
         [0039]    The reflective optical sensor  1  can operate as illustrated in  FIG. 4 . Light  55  is emitted from the light emitting element  31 , passes through the emission window  33 , and impinges on the object  50  that is desired to be detected and/or measured. The reflected light from the object  50  then either impinges as light  59  on the coating  15  (and is absorbed) or passes through opening  17  in the coating  15  as light  57  and is detected by the light detecting element  32 . As well, a certain amount of light  56  that is emitted from the emitting element  31  does not exit the package. A fraction of this light (now light  58 ) travels inside the package until it hits the inner side of the coating  15  where it is absorbed. 
         [0040]    The ability to reduce the cross talk in the reflective optical sensors described above can also be applied in other optical sensors, including any other types of reflective sensors, whether they are non-surface mount, focused, or non-focused reflective optical sensors, as well as proximity sensors. As well, this ability could be incorporated into other optoelectronic devices where any internally reflected or scattered light needs to be reduced, such as bar code scanners, label scanners, light curtains, touchscreens, and transmitter/receiver modules, whether IrDA or not. 
         [0041]    In addition to any previously indicated modification, numerous other variations and alternative arrangements may be devised by those skilled in the art without departing from the spirit and scope of this description, and appended claims are intended to cover such modifications and arrangements. Thus, while the information has been described above with particularity and detail in connection with what is presently deemed to be the most practical and preferred aspects, it will be apparent to those of ordinary skill in the art that numerous modifications, including, but not limited to, form, function, manner of operation and use may be made without departing from the principles and concepts set forth herein. Also, as used herein, examples are meant to be illustrative only and should not be construed to be limiting in any manner.