PATENT DOCUMENT

Publication Number: US-10090358-B2
Application Number: US-201615234790-A
Country: US
Kind Code: B2

Title: Camera module in a unibody circuit carrier with component embedding

Abstract:
A camera module assembly including a circuit carrier substrate having a first region integrally formed with a second region, the second region being movable with respect to the first region. The camera module assembly may further include an image sensor device positioned within a cavity formed in the first region of the circuit carrier substrate. The image sensor device may have a conductive via and a redistribution layer formed therein. The conductive via and the redistribution layer are electrically connected to the circuit carrier substrate along the side of the image sensor device facing the circuit carrier substrate. The camera module assembly further includes an electronic component positioned within a second cavity formed in the first region, the electronic component being electrically connected to the circuit carrier substrate.

Claims:
What is claimed is: 
     
       1. A camera module assembly comprising:
 a circuit carrier substrate having a first region integrally formed with a second region, the second region being movable with respect to the first region; and 
 an image sensor device positioned within a cavity formed within a portion of the circuit carrier substrate in the first region, the image sensor device having a conductive via and a redistribution layer formed therein, wherein the conductive via and the redistribution layer are electrically connected to the circuit carrier substrate along a side of the image sensor device facing the circuit carrier substrate. 
 
     
     
       2. The camera module assembly of  claim 1  wherein the first region is rigid and the second region is flexible. 
     
     
       3. The camera module assembly of  claim 1  further comprising an electronic component embedded in the first region of the circuit carrier substrate and electrically connected to the circuit carrier substrate. 
     
     
       4. The camera module assembly of  claim 3  wherein the electronic component is an active electronic component partially embedded within the first region of the circuit carrier substrate. 
     
     
       5. The camera module assembly of  claim 3  wherein the electronic component is a passive electronic component completely embedded within the first region of the circuit carrier substrate. 
     
     
       6. The camera module assembly of  claim 1  further comprising a transparent member positioned within a receiving channel in the cavity to enclose the image sensor device within the cavity. 
     
     
       7. The camera module assembly of  claim 1  wherein the conductive via is a through silicon via, the through silicon via being electrically connected to circuitry along the cavity that is within the circuit carrier substrate by the redistribution layer. 
     
     
       8. The camera module assembly of  claim 1  wherein a conductive material is applied between a bottom surface of the cavity and the image sensor device to electrically connect the conductive via to the circuit carrier substrate. 
     
     
       9. The camera module assembly of  claim 1  wherein a bottom surface of the cavity is flat. 
     
     
       10. The camera module assembly of  claim 1  further comprising a voice coil motor assembly positioned over the image sensor device and attached to the first region of the circuit carrier substrate. 
     
     
       11. A camera module assembly comprising:
 a circuit carrier substrate, the circuit carrier substrate having a first cavity and a second cavity formed therein, each of the first cavity and the second cavity having a bottom surface and an opening along a top side of the circuit carrier substrate; 
 an image sensor device positioned within the first cavity formed in the circuit carrier substrate, the image sensor device having an image capture side facing the opening of the first cavity and a connection side facing the bottom surface of the first cavity, and a conductive via extending between the image capture side and the connection side, wherein the conductive via is electrically connected to the circuit carrier substrate at the connection side of the image sensor device; and 
 an electronic component positioned within the second cavity, the electronic component being electrically connected to the circuit carrier substrate. 
 
     
     
       12. The camera module assembly of  claim 11  wherein the first cavity and the second cavity are formed within a first region of the circuit carrier substrate, and the circuit carrier substrate further comprises a second region that is thinner than the first region. 
     
     
       13. The camera module assembly of  claim 12  wherein the first region and the second region are integrally formed as one inseparable carrier structure. 
     
     
       14. The camera module assembly of  claim 11  wherein the circuit carrier substrate comprises a plurality of substrate layers. 
     
     
       15. The camera module assembly of  claim 14  wherein more than at least one of the plurality of substrate layers extends continuously from a first end to a second end of the circuit carrier substrate. 
     
     
       16. The camera module assembly of  claim 11  wherein a z-height of the first cavity is greater than or equal to a z-height of the image sensor device and the image sensor device does not extend through the first cavity opening. 
     
     
       17. The camera module assembly of  claim 11  wherein the electronic component is completely embedded within the second cavity. 
     
     
       18. The camera module assembly of  claim 11  wherein the electronic component is exposed through the opening in the second cavity. 
     
     
       19. A method of producing a camera module assembly, the method comprising:
 providing an integrally formed circuit carrier substrate having a first region and a second region that is movable with respect to the first region, and a first cavity and a second cavity formed within a portion of the circuit carrier substrate within the first region; 
 positioning an image sensor device within the first cavity and an electronic component within the second cavity, the image sensor device having an image capture side exposed through an opening of the first cavity and a connection side facing a bottom surface of the first cavity, a conductive via extending between the image capture side and the connection side, and a redistribution layer formed within the connection side; 
 applying a conductive material between the connection side of the image sensor device and the bottom surface of the first cavity to electrically connect the conductive via and the redistribution layer to the circuit carrier substrate. 
 
     
     
       20. The method of  claim 19  further introducing an embedding material into the second cavity to embed the electronic component within the second cavity.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of the earlier filing date of U.S. Provisional Patent Application No. 62/203,804, filed Aug. 11, 2015 and incorporated herein by reference. 
    
    
     FIELD 
     Embodiments related to a camera module in a unibody circuit carrier are disclosed. More particularly, an embodiment related to a camera module and electronic component embedded within cavities of a unibody carrier is disclosed. 
     BACKGROUND 
     Camera modules have been incorporated into a variety of consumer electronics devices, including smart phones, mobile audio players, personal digital assistants, and both portable and desktop computers. These devices, however, have a relatively low profile or rise (e.g. height as defined along the z-axis) and therefore components housed within these devices (e.g. camera modules) must also have a relatively low rise. 
     A typical camera module, however, includes several components, which are typically stacked one on top of the other. For example, a camera module generally includes an optical system used to collect and transmit light from an imaged scene to an image sensor. The image sensor is typically mounted on top of an integrated circuit die or substrate. The image sensor is electrically connected to interconnects formed within the substrate by wires bonded between a pixel area side of the image sensor (e.g. a top side) and the substrate. The optical system, which may include a lens barrel having at least one or more lenses and a voice coil motor assembly, is stacked on top of the image sensor. The stacking of each of these components one on top of another, however, adds to the overall z-height of the camera module. In addition, the use of wires to connect the image sensor to the substrate may undesirably increase the overall x, y and z dimensions of the camera module because, for example, additional space may be needed between the image sensor and the substrate to accommodate the wires and bonding of the wires to the substrate surface. 
     SUMMARY 
     A camera module assembly, particularly for use in portable consumer electronics device applications, is disclosed. In one embodiment, the camera module assembly includes a circuit carrier substrate having a first region integrally formed with a second region, the second region being movable with respect to the first region. For example, in one embodiment, the first region is rigid and the second region is flexible. The camera module assembly may further include an image sensor device positioned within a cavity formed in the first region of the circuit carrier substrate. The bottom surface of the cavity may be flat to accommodate the image sensor device. The image sensor device may have a conductive via and a redistribution layer formed therein. The conductive via and the redistribution layer are electrically connected to the circuit carrier substrate along the side of the image sensor device facing the circuit carrier substrate. The conductive via may be a through silicon via electrically connected to the circuit carrier substrate by the redistribution layer. In some aspects, the camera module may further include an electronic component embedded in the first region of the circuit carrier substrate and electrically connected to the circuit carrier substrate. The electronic component may be an active electronic component partially embedded within the first region of the circuit carrier substrate. In other cases, the electronic component is a passive electronic component completely embedded within the first region of the circuit carrier substrate. Additionally, the camera module assembly may include an image sensor device within the cavity. In some embodiments, a conductive material is applied between a bottom surface of the cavity and the image sensor device to electrically connect the conductive via to the circuit carrier substrate. In addition, a voice coil motor assembly may be positioned over the image sensor device and attached to the first region of the circuit carrier substrate. 
     In another embodiment, the camera module assembly includes a circuit carrier substrate having a first cavity and a second cavity, each of the first cavity and the second cavity having a bottom surface and an opening along a top side of the circuit carrier substrate. An image sensor device is positioned within the first cavity of the circuit carrier substrate. The image sensor device includes an image capture side facing the opening of the first cavity and a connection side facing the bottom surface of the first cavity. In addition, the image sensor device includes a conductive via extending between the image capture side and the connection side. The conductive via is electrically connected to the circuit carrier substrate at the connection side of the image sensor device. The assembly may further include an electronic component positioned within a second cavity formed in the first region. The electronic component may be electrically connected to the circuit carrier substrate. In addition, the camera module assembly may further include a redistribution layer to electrically connect the conductive via to the circuit carrier substrate. In one aspect, the first cavity and the second cavity are formed within a first region of the circuit carrier substrate, and the circuit carrier substrate further comprises a second region that is thinner than the first region. The first region and the second region may be integrally formed as one inseparable carrier structure. The circuit carrier substrate may include plurality of substrate layers. In one aspect, more than at least one of the plurality of substrate layers extends continuously from a first end to a second end of the circuit carrier substrate. In addition, a z-height of the first cavity is greater than or equal to a z-height of the image sensor device and the image sensor device does not extend through the first cavity opening. In addition, the electronic component may be completely embedded within the second cavity. In other cases, the electronic component is exposed through the opening in the second cavity. 
     In another embodiment, a process of producing a camera module assembly includes providing an integrally formed circuit carrier substrate having a first region and a second region that is movable with respect to the first region, and a first cavity and a second cavity within the first region. The process further includes positioning an image sensor device within the first cavity and an electronic component within the second cavity. The image sensor device may have an image capture side exposed through an opening of the first cavity and a connection side facing a bottom surface of the first cavity, a conductive via extending between the image capture side and the connection side, and a redistribution layer formed within the connection side. The process further including applying a conductive material between the connection side of the image sensor device and the bottom surface of the first cavity to electrically connect the conductive via and the redistribution layer to the circuit carrier substrate. The process may further include introducing an embedding material into the second cavity to embed the electronic component within the second cavity. 
     The above summary does not include an exhaustive list of all aspects of the present invention. It is contemplated that the invention includes all systems and methods that can be practiced from all suitable combinations of the various aspects summarized above, as well as those disclosed in the Detailed Description below and particularly pointed out in the claims filed with the application. Such combinations have particular advantages not specifically recited in the above summary. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The embodiments are illustrated by way of example and not by way of limitation in the figures of the accompanying drawings in which like references indicate similar elements. It should be noted that references to “an” or “one” embodiment in this disclosure are not necessarily to the same embodiment, and they mean at least one. 
         FIG. 1  is a top plan view of one embodiment of a camera module assembly including a circuit carrier substrate. 
         FIG. 2  is a cross-sectional side view of the camera module assembly and circuit carrier substrate of  FIG. 1  along line  2 - 2 ′. 
         FIG. 3  is a magnified view of section  3 - 3 ′ of the camera module assembly and circuit carrier substrate of  FIG. 3 . 
         FIG. 4  is a pictorial view illustrating an operation for forming a camera module in accordance with one embodiment. 
         FIG. 5  is a pictorial view illustrating an operation for forming a camera module in accordance with one embodiment. 
         FIG. 6  is a pictorial view illustrating an operation for forming a camera module in accordance with one embodiment. 
         FIG. 7  is a pictorial view illustrating an operation for forming a camera module in accordance with one embodiment. 
         FIG. 8  is a pictorial view illustrating an operation for forming a camera module in accordance with one embodiment. 
         FIG. 9  is a pictorial view illustrating an operation for forming a camera module in accordance with one embodiment. 
         FIG. 10  illustrates the further processing step of mounting a voice coil motor and lens barrel assembly to the circuit carrier substrate. 
         FIG. 11  illustrates one embodiment of a simplified schematic view of one embodiment of an electronic device in which a camera module may be implemented. 
         FIG. 12  illustrates a block diagram of some of the constituent components of an embodiment of an electronic device in which an embodiment of the invention may be implemented. 
     
    
    
     DETAILED DESCRIPTION 
     Embodiments describe camera module assemblies, particularly for use in portable consumer electronics device applications. However, while some embodiments are described with specific regard to integration within mobile electronics devices, the embodiments are not so limited and certain embodiments may also be applicable to other uses. For example, a camera module assembly as disclosed herein may be incorporated into an electronic device that remains at fixed locations, or used in relatively stationary applications, e.g., as a lens in a multimedia disc player or desk top device having a display. 
     In various embodiments, description is made with reference to the figures. However, certain embodiments may be practiced without one or more of these specific details, or in combination with other known methods and configurations. In the following description, numerous specific details are set forth, such as specific configurations, dimensions, and processes, in order to provide a thorough understanding of the embodiments. In other instances, well-known processes and manufacturing techniques have not been described in particular detail in order to not unnecessarily obscure the description. Reference throughout this specification to “one embodiment,” “an embodiment”, or the like, means that a particular feature, structure, configuration, or characteristic described is included in at least one embodiment. Thus, the appearance of the phrase “one embodiment,” “an embodiment,” or the like, in various places throughout this specification are not necessarily referring to the same embodiment. Furthermore, the particular features, structures, configurations, or characteristics may be combined in any suitable manner in one or more embodiments. 
     The use of relative terms throughout the description, such as “top” and “bottom” may denote a relative position or direction. For example, a “top edge”, “top end” or “top side” may be directed in a first axial direction and a “bottom edge”, “bottom end” or “bottom side” may be directed in a second direction opposite to the first axial direction. However, such terms are not intended to limit the use of the camera module disclosed herein to a specific configuration described in the various embodiments below. For example, a top side of a camera module or its components (e.g. an image sensor) may be directed in any direction with respect to an external environment. 
       FIG. 1  is a top plan view of one embodiment of a camera module assembly including a circuit carrier substrate. The camera module assembly  100  is shown in  FIG. 1  with the voice coil motor and lens assembly removed so that the relationship between the image sensor  102  and circuit carrier substrate  104  can be more clearly shown. In particular, from this view, it can be seen that image sensor  102  is positioned within a cavity  106  formed in circuit carrier substrate  104 . In this aspect, a low overall profile of the camera module assembly  100  can be maintained. Cavity  106  includes an opening  108  through the top side  110  of circuit carrier substrate  104  such that when the image sensor  102  is positioned within cavity  106 , the image capture side  112  (i.e. the active side having an array of pixel sensors) of image sensor  102  is exposed and a connection side (not shown) faces the bottom of the cavity  106 . 
     In still further embodiments, additional electronic components, for example electronic components  114 ,  116  may be positioned within additional cavities  118 ,  120 , respectively, within circuit carrier substrate  104 . For example, in one embodiment, electronic component  114  may be a passive component positioned within cavity  118  and electronic component  116  may be an active component positioned within cavity  120 . Representative passive components may include any electronic component that consumes (but does not produce) energy, or a component that is incapable of power gain, for example, a capacitor or resistor. Representative active components may include any electronic component that is capable of power gain, for example, a transistor or integrated circuit. Positioning of electronic components  114 ,  116  within their respective cavities  118 ,  120  further helps to maintain an overall low profile of camera module assembly  100 . In addition, in some embodiments, electronic components  114 ,  116  may be partially or fully embedded within their respective cavities  118 ,  120  as will be described in more detail in reference to  FIG. 8 - FIG. 9 . For example, where electronic component  114  is a passive component, whose functionality does not require it to be exposed outside of circuit carrier substrate  104 , it may be fully embedded (i.e. completely covered with an embedding material) within cavity  118 . In other embodiments, where electronic component  116  is an active component, whose functionality requires it to be exposed outside of circuit carrier substrate  104 , it may be partially embedded within cavity  118  such that it is not completely covered by an embedding material. It should further be understood that although two additional electronic components  114 ,  116  and corresponding cavities  118 ,  120  are shown, any number of cavities having electronic components therein may be formed within circuit carrier substrate  104 . 
     Each of cavities  106 ,  118 ,  120  may be formed within a first region  122  of circuit carrier substrate  104 . First region  122  is considered to be the portion of circuit carrier substrate  104 , which is near, or extends from, a first end  124  of circuit carrier substrate  104 . Circuit carrier substrate  104  may further include a second region  126 , which is near, or extends from, a second end  128  of circuit carrier substrate  104  toward the first region  122 . The first region  122  is different from the second region  126  in that the first region  122  is considered rigid and the second region  126  is considered flexible. As used herein, the term “rigid” means a structure with two-dimensional and/or three-dimensional stability allowing no deformation, bending or an otherwise change in shape or profile of the structure upon application of an external force. In other words, first region  122  of circuit carrier substrate  104  is considered stiff, non-pliant, non-compliant or otherwise does not bend upon application of a bending force. Rather, application of a bending force to first region  122  of circuit carrier substrate  104  would cause first region  122  to break. The term “flexible” as used herein means providing a structure with no considerable resistance against deformation or change in shape or profile of the structure. In other words, second region  126  of circuit carrier substrate  104  is pliant, compliant or bendable without breaking upon application of a bending force. Said another way, first region  122  is considered less pliant, less compliant, less flexible, or less bendable than second region  126 . Similarly, second region  126  is more pliant, more compliant, more flexible or more bendable than first region  122 . In this aspect, while first region  122  is considered to have a fixed or stiff configuration and cannot conform to the dimensions of a device within which the camera module assembly  100  is mounted, second region  126  is modifiable and may be bent so that it can conform to (e.g., bend around) the device dimensions. In other words, second region  126  is movable, or can be bent, with respect to first region  122 . 
     Although first region  122  is less pliant (i.e. first region  122  is rigid) than second region  126  (i.e. second region  126  is flexible), it should be understood that both regions of circuit carrier substrate  104  are integrally formed as one continuous piece such that circuit carrier substrate  104  is considered a uniform or unibody circuit carrier substrate. Said another way, circuit carrier substrate  104  is a homogenous circuit carrier substrate in that both the rigid and flexible regions (e.g. first and second regions  122 ,  126 ) are formed by a stack up of a number of the same substrate layers. For example, circuit carrier substrate  104  may include one or more substrate layers (e.g. dielectric layers) extending continuously from first end  124  to second end  128 . A number of patterned circuit layers may be sandwiched between the substrate layers. In one embodiment, circuit carrier substrate  104  may include more substrate layers in the first region  122  than the second region  126  such that first region  122  is less pliant, or rigid, in comparison to second region  126 . First region  122  and second region  126  are, however, formed by at least one or more of the same continuous substrate layers such that circuit carrier substrate  104  has a uniform or homogenous structure. This is in contrast to, for example, flex-rigid circuit boards which are formed by two separately formed pieces, for example, a flexible circuit and a printed circuit board, that are attached as two separate pieces to one another (e.g. soldered). 
       FIG. 2  is a cross-sectional side view of the camera module assembly and circuit carrier substrate of  FIG. 1  along line  2 - 2 ′. From this view, the relatively low profile or z-height (i.e. thickness) of camera module assembly  100  can be seen. In particular, because the image sensor  102  and other electronic components  114 ,  116  are mounted within respective cavities  108 ,  118 ,  120  within circuit carrier substrate  104 , the overall z-height of the image sensor assembly, identified as Z in  FIG. 2 , is determined by the z-height or thickness of the circuit carrier substrate  104  alone, and is not increased due to the image sensor or other electronic components electrically connected to circuit carrier substrate  104 . In addition, the voice coil motor assembly  202  and the lens barrel  204  can be mounted directly on the top side  110  of circuit carrier substrate  104  thereby further reducing the overall z-height of the camera module assembly  100 , identified as Z′ in  FIG. 2 . This is in contrast to a camera module assembly having an image sensor mounted to a top side of the carrier substrate, and then the voice coil motor assembly and lens barrel mounted above the image sensor, for example, to a separate casing around the image sensor and carrier. 
     Referring to cavity  106  in more detail, it can be seen from  FIG. 2  that a z-height of cavity  106 , represented by Z″ in  FIG. 2 , is greater than a z-height of image sensor  102 , represented by Z′″. As such, image sensor  102  does not extend through the cavity opening  108  or otherwise above the top side  110  of circuit carrier substrate  104 . The z-height of cavity  106  (i.e. Z″) with respect to the z-height of image sensor  102  (i.e. Z′″) further helps to maintain a low profile module in that it allows image sensor  102  to be completely confined to a thickness of cavity  106  and not extend above top side  110  of cavity  106 . It should be understood, however, that although Z″ of cavity  106  is shown as being greater than Z′″ of image sensor  102 , they may also be substantially equal. 
     In addition, cavity  106  includes a substantially flat bottom surface  206 . Said another way, bottom surface  206  of cavity  106  may be planar, and in some cases, form a ninety degree angle with sidewalls  224  of cavity  106 . It should be understood that because image sensor  102  is electrically connected to circuit carrier substrate  104  through the bottom side  212 , it is important that the bottom surface  206  of cavity  106  be flat or planar. In particular, the bottom side  212  of image sensor  102  is also relatively flat. Therefore, in order to maintain a close proximity between contact points (e.g. pads) at the bottom side  212  of image sensor  102  and contact points at the bottom surface  206  of cavity  106 , these interfacing surfaces should be complementary, or otherwise substantially the same (i.e. flat). A cavity  106  having an uneven or sloping bottom surface  206  may not allow for proper electrical connection between image sensor  102  and circuit carrier substrate  104 . 
     Cavity  106  may also, in some embodiments, include a receiving channel  208  formed within the top portion of sidewalls  224  of cavity  106 . Receiving channel  208  is dimensioned to receive and support a transparent member  214  over image sensor  102 . In this aspect, receiving channel  208  may form a step like structure in sidewalls  224  upon which transparent member  214  may be positioned so that it is within cavity  106  and held above image sensor  102 . Transparent member  214  may, for example, be a glass cover or similar transparent structure, which can enclose image sensor  102  within cavity  106  without blocking light transmission to image sensor  102 . It is further noted that receiving channel  208  may have a z-height substantially similar to, or greater than, the thickness of transparent member  214  so that transparent member  214  does not protrude above top side  110  of circuit carrier substrate  104 , thereby further maintaining a relatively low z-height of the overall system. 
     Further details of the image sensor  102  will now be described in reference to  FIG. 3 , which is a magnified view of section  3 - 3 ′ of  FIG. 2 . From this view, it can be seen that image sensor  102  includes a stack up of an image capture side or layer  302 , a silicon layer  304  and a redistribution layer  306 . The image capture layer  302  (which faces opening  108  of cavity  106 ) may include a color filter layer  312 , pixel sensors  310  positioned along a top side of the filter layer  312  and microlenses  308  positioned over the pixel sensors  310 . A support layer  314  may further be provided between the filter layer  312  and silicon layer  304  to, for example, space, and in some cases insulate, the components of the image capture layer  302  from components within the silicon layer  304 . For example, support layer  314  may be, for example, an insulating layer, which insulates conductive components in image capture layer  302  from those within silicon layer  304 . 
     Silicon layer  304  may include one or more of a conductive via  316 , which extends entirely through a thickness of silicon layer  304 . Representatively, conductive via  316  may be considered a through silicon via (TSV) which extends from the top side to the bottom side of silicon layer  304 . Conductive via  316  may have a conductive interconnect pad  324  electrically connected to the top end (e.g. at a top side of silicon layer  304 ) and a conductive interconnect pad  328  electrically connected to the bottom end of conductive via  316  (e.g. at a bottom side of silicon layer  304 ). Conductive interconnect pad  324  may be used to electrically connect conductive via  316  to one or more components of image capture layer  302  (e.g. pixel sensors  310  or filter  312 ) using one or more of a conductive traces or tracks  326  formed through the support layer  314 . Conductive interconnect pad  328  at the bottom end of conductive via  316  may, in turn, be used to electrically connect conductive via  316  and any electrically connected components at the top side of image sensor  102  (e.g. pixel sensors  310  or filter  312 ) to circuit carrier substrate  104 . In this aspect, the electrical connection between components along the top side of image sensor  102  and the circuit carrier substrate  104  are made at the bottom side of image sensor  102  instead of the top side (e.g. image capture layer  302 ). This, in turn, helps to maintain a relatively low profile of the image sensor module and camera module assembly overall because it eliminates the need for additional space along the top side of the image sensor to accommodate wiring between the top side of the image sensor and the circuit carrier substrate, which can increase the z-height. 
     Image sensor  102  may further include a redistribution layer  306  below silicon layer  304 . Redistribution layer  306  may, in one aspect, serve to distribute and reduce, for example, the number of external pad connections (e.g. input/output pad connections), which further reduces z-height because fewer signal lines are routed internally to image sensor  102 . In one embodiment, redistribution layer  306  may include redistribution layer traces or tracks  318  formed within a layer of insulating material. One or more of the redistribution layer tracks  318  may be electrically connected to the image sensor components along the top side of image sensor  102  (e.g. pixel sensors  310  or filter  312 ) through a conductive via  316 . For example, one or more of redistribution layer tracks  318  may be electrically connected at one end to a conductive interconnect pad  328  at the bottom end of conductive via  316  (which is connected to image capture layer  302  at its top end) and at another end to circuitry  334  within circuit carrier substrate  104 . In this aspect, redistribution layer  306  may also be considered a connection side of image sensor  102  which faces the bottom surface  206  of cavity  106  when positioned therein. In one embodiment, a conductive micro bump  320  (e.g. a solder micro bump) on the bottom side (i.e. connection side) of image sensor  102  may be used to electrically connect redistribution layer tracks  318  to circuit carrier substrate  104 . Although a micro bump  320  is shown, it is further contemplated that any conductive adhesive may be used to establish an electrical connection between image sensor  102  and circuit carrier substrate  104 , for example, a solder paste. 
     In still further embodiments, an underfill layer  322  may be applied around each of micro bump  320  to protect the micro bump connections. The underfill layer  322  may be made up of, for example, an electrically insulating material (e.g. a glass or polymer). 
       FIG. 4 - FIG. 9  are pictorial views illustrating operations in forming a camera module in accordance with an embodiment. Referring to  FIG. 4 ,  FIG. 4  illustrates one embodiment of a circuit carrier substrate  402  having a first region  404  and a second region  406 . The first region  404  may be rigid and the second region  406  may be flexible as previously discussed in reference to  FIG. 1 . Circuit carrier substrate  402  may further include a number of substrate layers  408 A,  408 B,  408 C,  408 D,  408 E and  408 F (e.g. insulating layers) stacked on top of one another and extending between the first region  404  and second region  406 . Conductive layers  412 A and  412 B are formed between any one or more of the substrate layers  408 A- 408 F, in this case, layers  408 A- 408 B and layers  408 B- 408 C, respectively. Conductive layers  412 A and  412 B are, for example, metallic layers that form the circuitry within circuit carrier substrate  402  and allow for transmission of electrical signals through circuit carrier substrate  402 . 
     At least one or more of the substrate layers  408 A- 408 F may extend continuously between the first region  404  and the second region  406  such that both regions may be formed by, for example, two or more of the same substrate layers  408 A- 408 F. For example, in the embodiment shown in  FIG. 4 , layers  408 A- 408 C extend continuously between the first region  404  and the second region  406 . In this aspect, circuit carrier substrate  402  is considered to be a unibody or homogenous carrier as previously discussed in reference to  FIG. 1 . Although first region  404  and second region  406  may be made of the same materials, the rigidity of first region  404  and flexibility of second region  406  may be achieved, in one embodiment, due to the different thicknesses (or z-heights) of first region  404  with respect to second region  406 . For example, first region  404  may have a thickness (T) (or z-height) that is greater than a thickness (t) (or z-height) of second region  406 . In other words, first region  404  includes more of substrate layers  408 A- 408 F than second region  406  such that first region  404  is rigid, or more rigid, than second region  406 . Said another way, first region  404  may include a stack up of enough of substrate layers  408 A- 408 F that, in combination, result in a rigid structure or region. Second region  406 , in turn, may include fewer of substrate layers  408 A- 408 F such that it is flexible or can otherwise be bent upon application of a bending force. Said another way, second region  406  is thinner than first region  404 . 
     In addition, as can be seen from  FIG. 4 , cavities  416 ,  418 ,  420  are formed through one or more of substrate layers  408 A- 408 F. For example, cavities  416 ,  418 ,  420  may be formed by cutting, or punching, an opening through one or more of substrate layers  408 A- 408 F until a desired cavity depth suitable for embedding an electronic device within the cavity is reached. Representatively, cavities  416 ,  418 ,  420  may be formed by cutting openings through substrate layers  408 D- 408 F and removing unwanted portions of the substrate layers  408 A- 408 F. It is further noted that it is important that the bottom surfaces  410  of each of cavities  416 ,  418 ,  420  are flat, or otherwise planar. Said another way, the top side of the substrate layer, in this case substrate layer  408 C, forming the bottom surfaces  410  of cavities  416 ,  418 ,  420  should be flat or planar. It is important that the bottom surfaces  410  of cavities  416 ,  418 ,  420  be flat so that electrical connections can be made between the bottom side of the electronic device (e.g. an image sensor) placed within the cavity and the circuit carrier substrate  402  with minimal z-height impact. 
     Cavities  416 ,  418 ,  420  are formed along the top side  424  of circuit carrier substrate  402 . Cavity  418  may further include a receiving channel  422 , which forms a step like structure within the top of cavity  418  to accommodate, for example, the insertion of a transparent member or cover as will be discussed in more detail in reference to  FIG. 7 . In addition, circuitry  426  may be formed between the bottom of one or more of cavity  416 ,  418 ,  420  such that an electronic device or component positioned within the cavity can be electrically connected to conductive layers  412 ,  414  within circuit carrier substrate  402  from a bottom side of the device as previously discussed. 
       FIG. 5  illustrates the further processing step of positioning an image sensor  502  within cavity  418 . Image sensor  502  may be substantially the same as image sensor  102  discussed in reference to  FIG. 1 - FIG. 3 . Image sensor  502  is placed within cavity  418  by inserting it through the opening  506  at the top side  424  of circuit carrier substrate  402 . From this view, it can be seen that each of the micro bumps  504  attached to the bottom of the image sensor  502  as previously discussed, align with, and are electrically connected to, circuitry  426  within circuit carrier substrate  402 . 
       FIG. 6  illustrates the further processing step of forming an underfill layer  602  around micro bumps  504 . The underfill layer  602  may be formed by, for example, applying an underfill material (e.g. an electrically insulating material) into cavity  418  until it surrounds micro bumps  504 . The underfill layer  602  therefore provides a protective layer around the electrical micro bump connections. 
       FIG. 7  illustrates the further processing step of mounting a transparent member  702  within the receiving channel  422  of cavity  418 . Transparent member  702  may be substantially the same as transparent member  214  described in reference to  FIG. 2 . Transparent member  702  may be mounted within receiving channel  422  using, for example an epoxy material applied between interfacing surfaces of the transparent member  214  and receiving channel  422 . 
       FIG. 8  illustrates the further processing step of mounting electronic components  802 ,  804  within cavities  416 ,  420 , respectively. Representatively, electronic components  802 ,  804  may be passive or active electronic components such as components  114 ,  116  previously discussed in reference to  FIG. 2 . Each of electronic components  802 ,  804  may be placed within their respective cavities  416 ,  420  by inserting them through their respective openings in the top side  424  of circuit carrier substrate  402 . 
       FIG. 9  illustrates the further processing step of embedding one or more of electronic components  802 ,  804  within cavities  416 ,  420 , respectively. In one embodiment, electronic component  802  is completely embedded within cavity  416  by applying an embedding material  902  entirely around electronic component  802 . In other words, embedding material  902  completely fills cavity  416  such that electronic component  802  is not exposed through the opening of cavity  416 . Electronic component  804  is shown partially embedded within cavity  420  by the embedding material  902  such that the top side of electronic component  804  is exposed through the opening in cavity  420 . The embedding material  902 ,  904  may be, for example, a polymer, an epoxy resin or any other material suitable for embedding electronic components or devices within a circuit carrier substrate. It can further be seen from this view that because each of the electronic components (e.g. image sensor  502 , electronic component  802  and electronic component  804 ) are within cavities and therefore do not extend above the top side  424  of circuit carrier substrate  402 , the z-height of the overall image sensor module is relatively low and does not need to be increased in order to accommodate any electronic components mounted thereto. In other words, the overall z-height of the image sensor module is the same as, or otherwise defined by, the z-height or thickness of the circuit carrier substrate  402 . In addition, since, as previously discussed, electrical connections between the image sensor  502  and circuit carrier substrate  402  are made at the bottom side of the image sensor  502  using internal conductive vias and redistribution layers within the image sensor  502 , external wiring and the space need for such wiring is eliminated. This, in turn, further helps to reduce an x, y and/or z dimension of the image sensor module and the camera module overall. 
       FIG. 10  illustrates the further processing step of mounting a voice coil motor and lens barrel assembly to the circuit carrier substrate. Representatively, voice coil motor  1002  within lens barrel  1004  therein may be positioned over image sensor  502 . The voice coil motor  1002  may then be mounted directly to the top side  424  of circuit carrier substrate  402  using any suitable mounting material (e.g. an epoxy) to complete the camera module assembly. 
       FIG. 11  illustrates one embodiment of a simplified schematic view of one embodiment of an electronic device in which a camera module may be implemented. As seen in  FIG. 11 , the camera module may be integrated within a consumer electronic device  1102  such as a smart phone with which a user can conduct a call with a far-end user of a communications device  1104  over a wireless communications network; in another example, the camera module may be integrated within the housing of a tablet computer  1102 . These are just two examples of where the camera module described herein may be used, it is contemplated, however, that the camera module may be used with any type of electronic device in which a camera module is desired, for example, a desk top computing device or other display device. 
       FIG. 12  illustrates a block diagram of some of the constituent components of an embodiment of an electronic device in which an embodiment of the invention may be implemented. Device  1200  may be any one of several different types of consumer electronic devices. For example, the device  1200  may be any camera-equipped mobile device, such as a cellular phone, a smart phone, a media player, or a tablet-like portable computer. 
     In this aspect, electronic device  1200  includes a processor  1212  that interacts with camera circuitry  1206 , motion sensor  1204 , storage  1208 , memory  1214 , display  1222 , and user input interface  1224 . Main processor  1212  may also interact with communications circuitry  1202 , primary power source  1210 , speaker  1218 , and microphone  1220 . The various components of the electronic device  1200  may be digitally interconnected and used or managed by a software stack being executed by the processor  1212 . Many of the components shown or described here may be implemented as one or more dedicated hardware units and/or a programmed processor (software being executed by a processor, e.g., the processor  1212 ). 
     The processor  1212  controls the overall operation of the device  1200  by performing some or all of the operations of one or more applications or operating system programs implemented on the device  1200 , by executing instructions for it (software code and data) that may be found in the storage  1208 . The processor  1212  may, for example, drive the display  1222  and receive user inputs through the user input interface  1224  (which may be integrated with the display  1222  as part of a single, touch sensitive display panel). In addition, processor  1212  may send an audio signal to speaker  1218  to facilitate operation of speaker  1218 . 
     Storage  1208  provides a relatively large amount of “permanent” data storage, using nonvolatile solid state memory (e.g., flash storage) and/or a kinetic nonvolatile storage device (e.g., rotating magnetic disk drive). Storage  1208  may include both local storage and storage space on a remote server. Storage  1208  may store data as well as software components that control and manage, at a higher level, the different functions of the device  1200 . 
     In addition to storage  1208 , there may be memory  1214 , also referred to as main memory or program memory, which provides relatively fast access to stored code and data that is being executed by the processor  1212 . Memory  1214  may include solid state random access memory (RAM), e.g., static RAM or dynamic RAM. There may be one or more processors, e.g., processor  1212 , that run or execute various software programs, modules, or sets of instructions (e.g., applications) that, while stored permanently in the storage  1208 , have been transferred to the memory  1214  for execution, to perform the various functions described above. 
     The device  1200  may include communications circuitry  1202 . Communications circuitry  1202  may include components used for wired or wireless communications, such as two-way conversations and data transfers. For example, communications circuitry  1202  may include RF communications circuitry that is coupled to an antenna, so that the user of the device  1200  can place or receive a call through a wireless communications network. The RF communications circuitry may include a RF transceiver and a cellular baseband processor to enable the call through a cellular network. For example, communications circuitry  1202  may include Wi-Fi communications circuitry so that the user of the device  1200  may place or initiate a call using voice over Internet Protocol (VOIP) connection, transfer data through a wireless local area network. 
     The device may include a microphone  1220 . In this aspect, microphone  1220  may be an acoustic-to-electric transducer or sensor that converts sound in air into an electrical signal. The microphone circuitry may be electrically connected to processor  1212  and power source  1210  to facilitate the microphone operation (e.g. tilting). 
     The device  1200  may include a motion sensor  1204 , also referred to as an inertial sensor, that may be used to detect movement of the device  1200 . The motion sensor  1204  may include a position, orientation, or movement (POM) sensor, such as an accelerometer, a gyroscope, a light sensor, an infrared (IR) sensor, a proximity sensor, a capacitive proximity sensor, an acoustic sensor, a sonic or sonar sensor, a radar sensor, an image sensor, a video sensor, a global positioning (GPS) detector, an RF or acoustic doppler detector, a compass, a magnetometer, or other like sensor. For example, the motion sensor  1204  may be a light sensor that detects movement or absence of movement of the device  1200 , by detecting the intensity of ambient light or a sudden change in the intensity of ambient light. The motion sensor  1204  generates a signal based on at least one of a position, orientation, and movement of the device  1200 . The signal may include the character of the motion, such as acceleration, velocity, direction, directional change, duration, amplitude, frequency, or any other characterization of movement. The processor  1212  receives the sensor signal and controls one or more operations of the device  1200  based in part on the sensor signal. 
     The device  1200  also includes camera circuitry  1206  that implements the digital camera functionality of the device  1200 . One or more camera modules having image sensors (e.g. camera module assembly  100 ) are built into the device  1200 , and each may be located at a focal plane of an optical system that includes a respective lens. An optical image of a scene within the camera&#39;s field of view is formed on the image sensor, and the sensor responds by capturing the scene in the form of a digital image or picture consisting of pixels that may then be stored in storage  1208 . The camera circuitry  1206  may also be used to capture video images of a scene. 
     Device  1200  also includes primary power source  1210 , such as a built in battery, as a primary power supply. 
     In the foregoing specification, the invention has been described with reference to specific exemplary embodiments thereof. It will be evident that various modifications may be made thereto without departing from the broader spirit and scope of the invention as set forth in the following claims. The specification and drawings are, accordingly, to be regarded in an illustrative sense rather than a restrictive sense.

Metadata:
Filing Date: 20160811
Publication Date: 20181002
Grant Date: 20181002
Priority Date: 20150811
Inventors: YANG, ANNABELLE Q.
WEBSTER, STEVEN
STA AGUEDA, REYNALDO VINCENT H.
HUNAT, CHRISTOPHER
Assignee: APPLE INC
CPC Classifications: [{"code": "H04N23/57", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04N23/57", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04N23/54", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04N23/54", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01L2224/73204", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2224/16225", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L27/14687", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04N5/2253", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01L27/14645", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04N5/2257", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01L27/14618", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01L27/14636", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01L27/14632", "inventive": true, "first": false, "tree": "[]"}, {"code": "H10F39/811", "inventive": true, "first": false, "tree": "[]"}, {"code": "H10F39/809", "inventive": true, "first": false, "tree": "[]"}, {"code": "H10F39/804", "inventive": true, "first": false, "tree": "[]"}, {"code": "H10F39/182", "inventive": true, "first": false, "tree": "[]"}, {"code": "H10F39/026", "inventive": true, "first": true, "tree": "[]"}, {"code": "H10F39/809", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01L2224/73204", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2224/16225", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2224/73204", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2224/16225", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 57996265