Patent ID: 7564629

Claim:
A method for aligning a microlens array in a sensor die, comprising: (a) performing a pre-simulation to simulate a microlens array alignment in a silicon die and to determine a shrink-factor; (b) designing a new photo-mask for the microlens array based on the shrink-factor; (c) producing a sample silicon die using the new photo-mask; (d) capturing an image of a collimated white light source using the sample silicon die; (e) evaluating uniformity of brightness distribution of the image; and in case of unsatisfactory brightness distribution; (f) calculating error in alignment of the sample silicon die and a de-centering value; (g) performing a post-simulation based on the error to tune the shrink-factor and the de-centering value; (h) designing a new photo-mask for the microlens array based on the shrink-factor and the de-centering value; and (i) repeating the steps (c)-(h) until a satisfactory brightness distribution is obtained.