PATENT DOCUMENT

Publication Number: US-11483461-B2
Application Number: US-202117399917-A
Country: US
Kind Code: B2

Title: Techniques for forming suspension assemblies for a camera

Abstract:
A suspension assembly of a camera, with electrical traces, may be formed using one or more electroforming processes. The suspension assembly may include one or more flexure arms connecting an inner frame to an outer frame of the camera. The inner frame may be moveable relative to the outer frame to implement autofocus and/or optical image stabilization functions for the camera. The electrical traces may be formed at a first side of a substrate, using one or more electroforming processes. Next, one or more cavities in various shapes may be created in one or more dry film photoresist (DFR) layers at a second side of the substrate by exposing the DFR layers to ultraviolet light. One or more electroforming processes may be used to deposit one or more materials in to the cavities to form one or more components, e.g., a flexure arm, of the suspension assembly.

Claims:
What is claimed is: 
     
       1. A method, comprising:
 forming at least a part of a suspension assembly, wherein:
 the suspension assembly comprises: 
 an inner frame for coupling with an image sensor of a camera; 
 an outer frame; and 
 one or more flexure arms for connecting the inner frame to the outer frame,
 wherein the one or more flexure arms are configured to allow motion of the inner frame, together with the image sensor, in one or more directions relative to the outer frame, 
 
 
 wherein the forming comprises:
 forming one or more electrical traces at a first side of a substrate; and 
 forming the one or more flexure arms at a second side of the substrate,
 wherein the second side faces opposite the first side, and wherein the forming the one or more flexure arms comprises: 
 depositing, using one or more electroforming processes, a first material within one or more cavities defined by at least one layer of at least a second material that is different than the first material, wherein a flexure arm of the one or more flexure arms comprises the first material and is shaped based on a shape of a corresponding cavity within which the first material is deposited; and 
 removing at least a part of the second material that at least partially surrounds the flexure arm. 
 
 
 
     
     
       2. The method of  claim 1 , wherein the substrate comprises copper. 
     
     
       3. The method of  claim 1 , wherein the first material comprises a copper titanium alloy. 
     
     
       4. The method of  claim 1 , wherein the one or more electrical traces comprise a nickel cobalt alloy or a nickel tungsten alloy. 
     
     
       5. The method of  claim 1 , wherein the second material comprises a positive or negative dry film photoresist (DFR). 
     
     
       6. The method of  claim 1 , wherein at least one flexure arm of the one or more flexure arms is formed in a T-shape, an inverse T-shape, or an hourglass shape. 
     
     
       7. The method of  claim 1 , wherein the forming the one or more electrical traces at the first side of the substrate comprises depositing, using the one or more electroforming processes, at least a third material at the first side of the substrate to form the one or more electrical traces. 
     
     
       8. The method of  claim 1 , wherein the outer frame is configured to be foldable with respect to the inner frame to provide an angle between the outer frame and the inner frame. 
     
     
       9. The method of  claim 1 , wherein the one or more cavities in the at least one layer of at least the second material are created by exposing the at least one layer of at least the second material to ultraviolet light of a same or different wavelengths, and wherein subsequent to depositing the first material within the one or more cavities, the forming the one or more flexure arms comprises removing, using one or more etching processes, one or more parts of the substrate such that the one or more flexure arms separate from each other. 
     
     
       10. The method of  claim 1 , wherein the forming the at least a part of the suspension assembly further comprises:
 forming one or more additional electrical traces at the first side of the substrate; and 
 forming the inner frame or outer frame at the second side of the substrate,
 wherein the forming the inner frame or outer frame comprises: 
 depositing, using the one or more electroforming processes, a third material within one or more additional cavities defined by the at least one layer of at least the second material that is different than the third material, wherein the inner frame or outer frame comprises third first material and is shaped based on a shape of a corresponding cavity within which the third material is deposited; and 
 removing at least a part of the second material that at least partially surrounds the inner frame or outer frame. 
 
 
     
     
       11. A camera, comprising:
 at least one optical lens; 
 an image sensor; and 
 a suspension assembly including:
 an inner frame for coupling with the image sensor; 
 an outer frame; 
 one or more electrical traces at a first side of a substrate; and 
 one or more flexure arms at a second side of the substrate facing opposite the first side, wherein the one or more flexure arms are configured to connect the inner frame with the outer frame to allow motion of the inner frame, together with the image sensor, in one or more directions relative to the outer frame, and wherein at least one of the one or more flexure arms includes a first material in a shape defined by one or more cavities created in a second material using one or more electroforming processes. 
 
 
     
     
       12. The camera of  claim 11 , wherein the substrate comprises copper. 
     
     
       13. The camera of  claim 11 , wherein the first material comprises a copper titanium alloy. 
     
     
       14. The camera of  claim 11 , wherein the one or more electrical traces comprise a nickel cobalt alloy or a nickel tungsten alloy. 
     
     
       15. The camera of  claim 11 , wherein the second material comprises a dry film photoresist (DFR). 
     
     
       16. The camera of  claim 15 , wherein the DFR comprises a positive photoresist or a negative photoresist. 
     
     
       17. The camera of  claim 11 , wherein at least one flexure arm of the one or more flexure arms is formed in a T-shape, an inverse T-shape, or an hourglass shape. 
     
     
       18. The camera of  claim 11 , wherein the one or more cavities in the second material are created by exposing the second material to ultraviolet light of a same or different wavelengths, and wherein the at least one of the flexure arms is formed by depositing the first material in the one or more cavities to form the at least one of the flexure arms at the second side of the substrate. 
     
     
       19. The camera of  claim 11 , wherein the outer frame is configured to be foldable with respect to the inner frame to provide an angle between the outer frame and the inner frame. 
     
     
       20. A device, comprising:
 one or more processors; 
 memory storing program instructions executable by the one or more processors to control operations of a camera; and 
 the camera, comprising:
 at least one optical lens; 
 an image sensor; and 
 a suspension assembly including:
 an inner frame for coupling with the image sensor; 
 an outer frame; 
 one or more electrical traces at a first side of a substrate; and 
 a plurality of flexure arms at a second side of the substrate facing opposite the first side, wherein the plurality of flexure arms are configured to connect the inner frame with the outer frame to allow motion of the inner frame, together with the image sensor, in one or more directions relative to the outer frame, and wherein adjacent flexure arms of the plurality of flexure arms are spaced apart according to an inter-arm spacing less than 180 micrometers.

Description:
This application claims benefit of priority to U.S. Provisional Application Ser. No. 63/064,532, entitled “Techniques for Forming Suspension Assemblies for a Camera,” filed Aug. 12, 2020, and which is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND 
     Technical Field 
     This disclosure relates generally to suspension assemblies for a camera, in particular, techniques for forming a suspension assembly of a camera. 
     Description of the Related Art 
     The advent of mobile multipurpose devices such as smartphones, tablet or pad devices has resulted in a need for bigger lenses such as ultra- or super-wide lenses for integration in cameras of the devices. Some cameras may incorporate optical image stabilization (OIS) mechanisms that may sense and react to external excitation/disturbance by adjusting location of the optical lens on the X and/or Y axis in an attempt to compensate for unwanted motion of the lens. Furthermore, some cameras may incorporate an autofocus (AF) mechanism whereby the object focal distance can be adjusted to focus an object plane in front of the camera at an image plane to be captured by the image sensor. In some such AF mechanisms, the optical lens is moved as a single rigid body along the optical axis of the camera to refocus the camera. 
     In addition, high image quality is easier to achieve in small form factor cameras if lens motion along the optical axis is accompanied by minimal parasitic motion in the other degrees of freedom, for example on the X and Y axes orthogonal to the optical (Z) axis of the camera. Thus, some small form factor cameras that include autofocus mechanisms may also incorporate optical image stabilization (OIS) mechanisms that may sense and react to external excitation/disturbance by adjusting location of the optical lens on the X and/or Y axis in an attempt to compensate for unwanted motion of the lens. In such systems, knowledge of the position of the lens is useful. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates an example camera which may include a suspension assembly having electrical traces, according to some embodiments. 
         FIG. 2A  shows a top view of an example suspension assembly, according to some embodiments. 
         FIG. 2B  shows a cross-sectional view of an example flexure arm of a suspension assembly, according to some embodiments. 
         FIGS. 3A-3L  show an example process to form flexure arms with electrical traces using a negative DFR, according to some embodiments. 
         FIG. 4A  shows one or more example lithography processes to create a T-shape cavity in DFR layers, according to some embodiments. 
         FIG. 4B  shows one or more example lithography processes to create an inverse T-shape cavity in DFR layers, according to some embodiments. 
         FIGS. 5A-5J  show an example process to form flexure arms with electrical traces using both a negative DFR and a positive DFR, according to some embodiments. 
         FIG. 6  shows an example suspension assembly with a foldable outer frame, according to some embodiments. 
         FIG. 7  illustrates a schematic representation of an example device  700  that may include a camera having one or more suspension assemblies, according to some embodiments. 
         FIG. 8  illustrates a schematic block diagram of an example computing device which may include a camera having one or more suspension assemblies, according to some embodiments. 
     
    
    
     This specification includes references to “one embodiment” or “an embodiment.” The appearances of the phrases “in one embodiment” or “in an embodiment” do not necessarily refer to the same embodiment. Particular features, structures, or characteristics may be combined in any suitable manner consistent with this disclosure. 
     “Comprising.” This term is open-ended. As used in the appended claims, this term does not foreclose additional structure or steps. Consider a claim that recites: “An apparatus comprising one or more processor units . . . . ” Such a claim does not foreclose the apparatus from including additional components (e.g., a network interface unit, graphics circuitry, etc.). 
     “Configured To.” Various units, circuits, or other components may be described or claimed as “configured to” perform a task or tasks. In such contexts, “configured to” is used to connote structure by indicating that the units/circuits/components include structure (e.g., circuitry) that performs those task or tasks during operation. As such, the unit/circuit/component can be said to be configured to perform the task even when the specified unit/circuit/component is not currently operational (e.g., is not on). The units/circuits/components used with the “configured to” language include hardware—for example, circuits, memory storing program instructions executable to implement the operation, etc. Reciting that a unit/circuit/component is “configured to” perform one or more tasks is expressly intended not to invoke 35 U.S.C. § 112(f) for that unit/circuit/component. Additionally, “configured to” can include generic structure (e.g., generic circuitry) that is manipulated by software and/or firmware (e.g., an FPGA or a general-purpose processor executing software) to operate in manner that is capable of performing the task(s) at issue. “Configure to” may also include adapting a manufacturing process (e.g., a semiconductor fabrication facility) to fabricate devices (e.g., integrated circuits) that are adapted to implement or perform one or more tasks. 
     “First,” “Second,” etc. As used herein, these terms are used as labels for nouns that they precede, and do not imply any type of ordering (e.g., spatial, temporal, logical, etc.). For example, a buffer circuit may be described herein as performing write operations for “first” and “second” values. The terms “first” and “second” do not necessarily imply that the first value must be written before the second value. 
     “Based On.” As used herein, this term is used to describe one or more factors that affect a determination. This term does not foreclose additional factors that may affect a determination. That is, a determination may be solely based on those factors or based, at least in part, on those factors. Consider the phrase “determine A based on B.” While in this case, B is a factor that affects the determination of A, such a phrase does not foreclose the determination of A from also being based on C. In other instances, A may be determined based solely on B. 
     It will also be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first contact could be termed a second contact, and, similarly, a second contact could be termed a first contact, without departing from the intended scope. The first contact and the second contact are both contacts, but they are not the same contact. 
     The terminology used in the description herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description and the appended claims, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “and/or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms “includes,” “including,” “comprises,” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. 
     As used herein, the term “if” may be construed to mean “when” or “upon” or “in response to determining” or “in response to detecting,” depending on the context. Similarly, the phrase “if it is determined” or “if [a stated condition or event] is detected” may be construed to mean “upon determining” or “in response to determining” or “upon detecting [the stated condition or event]” or “in response to detecting [the stated condition or event],” depending on the context. 
     DETAILED DESCRIPTION 
     In various embodiments, techniques for forming a suspension assembly are disclosed herein. In some embodiments, the suspension assembly may be part of autofocus (AF) and/or optical image stabilization (OIS) systems of a camera, which may allow optical lens(es) and image sensor of the camera to move relative to each other. For instance, the suspension assembly may include an inner frame for coupling with an image sensor of a camera, an outer frame which may be spatially fixed with respect to the camera, and one or more flexure arms for connecting the inner frame to the outer frame. In some embodiments, with the flexure arms, one or more actuators (e.g., voice coil motors) may move the inner frame, together with the image sensor, relative to the optical lens(es) of the camera in one or more directions (e.g., along X and/or Y axes relative to the Z axis or optical axis of the optical lens(es)). The motion of the image sensor relative to the optical lens(es) may be used to implement OIS functions. Similarly, a suspension assembly may be used as part of the AF system, e.g., to provide the movability of the optical lens(es) relative to the image sensor in one or more directions (e.g., along the Z axis or optical axis) to implement autofocus functions. 
     In some embodiments, one or more electrical traces may be added to the suspension assembly. For instance, the electrical traces may be added at one side or both sides of the inner frame, outer frame, and/or flexure arms. Combination of the electrical traces with the suspension assembly may provide a more space-efficient solution for routing electrical traces. In some embodiments, the electrical traces may serve as a power delivery channel (e.g., to supply power to the image sensor) or signal transfer link (e.g., to transfer signals between the image sensor and an “external” processor). 
     In some embodiments, the suspension assembly including the inner frame, outer frame, and flexure arms may be formed using one or more etching processes. For instance, a substrate (e.g., a metal sheet of a few hundred micrometers) may be etched to remove certain parts of the metal sheet to form the inner frame, outer frame, and/or flexure arms of the suspension assembly. In some embodiments, it may be desired for the flexure arms to have a small inter-arm space between individual flexure arms. The decreased inter-arm space can reduce the overall size of the suspension assembly, and/or provide extra space for the other components of the suspension assembly. For instance, when the flexure arms become closer to each other, more space may become available for the inner frame, and thus it may become possible to use a larger image sensor. 
     There may be a minimum space restriction for an etching process to maintain an access to the part(s) of the substrate that need to be etched for creating the suspension assembly. Therefore, the techniques disclosed herein may form the suspension assembly using a different approach—e.g., based on one or more electroforming (or electroplating) processes. The electroforming processes may form the suspension assembly based on a thin substrate (e.g., a thin metal foil of a few tens of micrometers). In some embodiments, one or more electrical traces may first be formed at one side of the substrate. For instance, a first electrically conductive material (e.g., including a nickel cobalt alloy or a nickel tungsten alloy) may be deposited at a first side of the substrate using the electroforming processes to form the electrical traces. In some embodiments, one or more layers of dry film photoresist (DFR) may be used to coat the substrate. The DFR may include either a negative photoresist or a positive photoresist. In some embodiments, one or more cavities may be created in the DFR layers at a second side of the substrate facing opposite the first side according to one or more patterns for forming various components of the suspension assembly, e.g., one or more flexure arms. For instance, the cavities may be generated by exposing the DFR layers to ultraviolet (UV) light of the same or different wavelengths to create the cavities in various shapes, e.g., a T-shape, an inverse T-shape, or an hourglass shape, for the flexure arms. In some embodiments, a second electrically conductive material (e.g., a copper titanium alloy) may be deposited in to the cavities to form the flexure arms whose shape may be defined by the cavities generated according to the patterns. Note that the disclosed techniques may be used to form various components of the suspension assembly, including the inner frame, outer frame, and/or flexure arms. The disclosed techniques can alleviate the minimum space restriction as seen in the etching processes (by using the electroforming processes to form the suspension assembly components), and reduce the size of the suspension assembly. For instance, the inter-arm spacing may be reduced from hundreds of micrometers (e.g., ˜180 μm or higher) to tens of micrometers (e.g., ˜25-40 μm or even lower), e.g., depending on the thickness of the DFR layers. In some embodiments, the outer frame may be further designed to be foldable relative to the inner frame to an angle to further reduce the size of the suspension assembly in one or more directions, e.g., in X and/or Y axes. 
     In some embodiments, a relatively thicker substrate (e.g., a metal sheet of a few hundred micrometers) other than a thin foil may be used to form the suspension assembly with the disclosed techniques. For instance, one or more parts of the substrate may first be etched to create a thin foil (e.g., a thin foil of a few tens of micrometers). Next, one or more electroforming processes (similar to those described above) may be applied to the thin foil to form electrical traces, together with components of the suspension assembly (e.g., one or more flexure arms). In some embodiments, one or more remaining parts of the substrate which were not etched may be used directly to form an inner frame and/or an outer frame. This may be suitable especially for scenarios where the substrate may be used directly (without electroforming) to create the inner frame and/or outer frame. 
       FIG. 1  illustrates an example camera which may include a suspension assembly having electrical traces, according to some embodiments. In the example as shown in  FIG. 1 , camera  100  may include optical lens  102  inside lens assembly  104  which may be packaged in lens carrier  106 . In some embodiments, camera  100  may include image sensor  108  for producing image data (e.g., represented by electrical signals) based on light captured by and transmitted from optical lens  102 . In some embodiments, camera  100  may include axial motion voice coil motor  110 . Axial motion voice coil motor  110  may include a suspension assembly having one or more flexure arms  112  for moveably mounting optical lens carrier  104  to base  114 , where base  114  may be mechanically fixed to enclosure  138  of camera  100 . In some embodiments, axial motion voice coil motor  110  may include one or more magnets  116  mounted to base  114 , and one or more focusing coils  118  fixedly mounted to lens carrier  106  and mounted to base  114  through flexure arms  112 . In some embodiments, focusing coils  118  may carry currents which may interact with the magnetic field of magnets  116  to generate motive forces (e.g., Lorentz forces). With flexure arms  112 , the motive forces may allow lens assembly  104  containing optical lens  102  to move relative to image sensor  108 , e.g., along an optical axis or Z axis of optical lens  102 , thus implementing autofocus (AF) functions for camera  100 . 
     In some embodiments, camera  100  may further include transverse motion voice coil motor  120 . Transverse motion voice coil motor  120  may include image sensor inner frame  122  (which may be a dynamic platform), a suspension assembly including one or more flexure arms  124  for mechanically connecting image sensor inner frame  122  to image sensor outer frame  126  (which may be a static platform) of transverse motion voice coil motor  120 , and one or more optical image stabilization (OIS) coils  132  moveably mounted to image sensor inner frame  122  (e.g., through flexible printed circuit  134 ). In some embodiments, OIS coils  132  may be positioned within the magnetic fields of magnets  116 , and thus may cause the production of motive forces (e.g., Lorentz forces). In some embodiments, camera  100  may include bearing surface end stop  136  mounted to base  114  for restricting motion of image sensor inner frame  122  (and image sensor  108 ) along an optical axis of optical lens  102  (e.g., Z axis). Thus, with flexure arms  124 , the motive forces caused by OIS coils  132  may move image sensor inner frame  122 , together with image sensor  108 , relative to optical lens  102  in one or more directions (e.g., along X and/or Y axes) orthogonal to the optical axis of optical lens  102  (e.g., Z axis), thus implementing OIS functions for camera  100 . 
     In some embodiments, besides serving as mechanical connections, flexure arms  112  (of axial motion voice coil motor  110 ) and/or  124  (of transverse motion voice coil motor  120 ) and other components of the suspension assembly (e.g., the inner frame and/or the outer frame) may also be attached with electrical traces for purpose of power and/or signal transfers. For example, one or more electrical traces  130  may be added at one or both sides of flexure arms  124  to ( 1 ) deliver power from a power supply to image sensor  108  (and/or OIS coils  132 ) and/or ( 2 ) transfer signals between image sensor  108  and a processor, where the power supply and/or processor may be located inside or external of camera  100 . 
       FIG. 2A  shows a top view of an example suspension assembly, according to some embodiments. In some embodiments, suspension assembly  200  may include inner frame  202 , outer frame  204 , two of which may be connected through flexure arms  206  along a perimeter of inner frame  202 . In this example, inner frame  202  may include one or more obtrusions  203  (e.g., towards outer frame  204 ), whilst outer frame may include one or more obtrusions  205  (e.g., towards inner frame  202 ). Flexure arms  206  may be coupled to obtrusions  203  (of inner frame  202 ) to obtrusions  205  (of outer frame  204 ) and thus implement the connection between inner frame  202  and outer frame  205 , as shown in  FIG. 2A . In some embodiments, flexure arms  206  may be spaced apart from each other substantially evenly according to an inter-arm spacing. As described above, with techniques disclosed here, the inter-arm spacing between flexure arms  206  may be greatly reduced, e.g., from hundreds of micrometers (e.g., 200 μm) to tends of micrometers (e.g., 50 μm). In some embodiments, inner frame  202  and outer frame  204  may each include one or more conductor pads  208  and pads  210 . Conductor pads  208  and  210  may serve as electrical connecting points for inner frame  202  and outer frame  204 , respectively. For instance, an image sensor may rest on inner frame  202 , where input/output (I/O) ports of the image sensor may be surface mounted to conductor pads  208 . Conductor pads  208  may further be connected to electrical traces attached to flexure arms  206 , and the electrical traces may extend and connect to conductor pads  210  of outer frame  204 . 
       FIG. 2B  shows a cross-sectional view of an example flexure arm of a suspension assembly, according to some embodiments. As shown in  FIG. 2A , the cross-sectional view in  FIG. 2B  corresponds to a position indicated by the line and two arrows. For purposes of illustration, only one single flexure arm  206  is shown in  FIG. 2B , although the cross-sectional view at the position indicated in  FIG. 2A  may include multiple flexure arms. In this example, flexure arm  206  may be in a T-shape attached to substrate  222 . In some embodiments, both flexure arm  206  and substrate  222  may comprise metal. For instance, flexure arm  206  may be made from copper titanium, whilst substrate  222  may include copper. In some embodiments, there may be insulator layer  224  and seed layer  226  between substrate  222  and electrical trace  220   d . Insulator layer  224  may include at least one dielectric material, e.g., polyamide, ajinomoto build-up film (ABF), and/or other dielectric materials, to provide electrical insulation between substrate  222  and electrical trace  220 , whilst seed layer  226  may include metal and be used to facilitate deposition of electrical trace  220  on to substrate  222 , in one or more electroforming processes as described below. In some embodiments, there may be a cover layer  228 , e.g., an insulator layer, to provide protection for electrical trace  220 . Note that, besides a T-shape, flexure arm  206  may be in various shapes as needed. For instance, flexure arm  206  may have an inverse T-shape, an hourglass shape, etc. 
       FIGS. 3A-3L  show an example process to form flexure arms with electrical traces using a negative DFR, according to some embodiments. The example process illustrated may include three sections: lithography (e.g., as shown in  FIGS. 3A-3F ), electroforming (e.g., as shown in  FIGS. 3G-3I ), and etching (e.g., as shown in  FIGS. 3J-3L ). For purposes of illustration, two electrical traces and two flexure arms are illustrated to be formed at different sides of a substrate. In some embodiments, the example process may be used to form less or more electrical traces and flexure arms, and/or other components (e.g., an inner frame and/or an outer frame) of a suspension assembly. As shown in  FIG. 3A , the lithography section may start with forming one or more electrical traces  320  at a first side of substrate  305 . In some embodiments, substrate  305  may be a thin metal foil, e.g., a copper foil with a thickness of a few tens of micrometers. Insulator layer  310 , e.g., an insulator layer including polyamide, ABF, and/or other dielectric materials, may be used to coat one or more regions at the first side of substrate  305  to isolate later-formed electrical traces  320  from substrate  305 . Next, seed layer  315  may be applied on top of insulator layer  310 . In some embodiments, seed layer  315  may comprise an electrically conductive material, e.g., copper. A photoresist layer may then be used to cover seed layer  315 . Next, the photoresist layer may be exposed to UV light through a patterned photomask, and the regions that were exposed (e.g., in cases where a positive DFR is used) or unexposed (e.g., in cases where a negative DFR is used) may be removed by dissolving the exposed or exposed photoresist with a solvent (also called developer). The result may be substrate  305  with a patterned photoresist layer which may expose seed layer  315  on the bottom of the pattern. Next, an additive manufacturing process may be used where a voltage may be applied across an anode and seed layer  315  to deposit an electrically conductive material on to exposed seed layer  315  to form electrical traces  320  at a first side of substrate  305 . In some embodiments, the electrically conductive material for forming electrical traces  320  may include a nickel cobalt alloy or a nickel tungsten alloy. In some embodiments, cover layer  325 , which may include at least one dielectric material, may be applied to cover electrical traces  320  at the first side of substrate  305  to provide a protection of electrical traces  320 . 
     Referring to  FIG. 3B , after the forming of electrical traces  320  at the first side of substrate  305 , a first dry film photoresist (DFR) layer  330 , e.g., including a negative photoresist, may be added at the first side and a second side (which may be opposite to the first side) of substrate  305 . Next, as shown in  FIG. 3C , DFR layer  330  at the second side of substrate  305  may be exposed to UV light through a patterned photomask to create one or more patterns  335  in DFR layer  330 . In this example as shown in  FIG. 3C , patterns  335  may include a rectangular shape. Next, as shown in  FIG. 3D , a second DFR layer  340  may be applied to coat the second side of substrate  305 , e.g., on top of the first DFR layer  330  at the second side. In some embodiments, DFR layer  340  may include a negative photoresist which may be the same as or different from the negative photoresist of DFR layer  330 . Referring back to  FIG. 3E , the second DFR layer  340  may then be exposed to UV light to create one or more patterns  345  in the second DFR layer  340 . In this example as shown in  FIG. 3E , patterns  345  may include a rectangular shape connected to patterns  335  but having a different size from patterns  335  such that patterns  335  and  355  together may form one or more T-shapes in DFR layers  330  and  340 . Next, referring to  FIG. 3F , one or more parts of DFR layers  330  and  340  corresponding to patterns  335  and  345  may be dissolved away using a solvent to thus create T-shape cavities  350  at the second side of substrate  305 . Also, note that one or more parts of DFR layer  330  between electrical traces  320  at the first side of substrate  305  may also be removed, thus exposing substrate  305  between electrical traces  320 . 
       FIGS. 3G-3I  show the next section—an electroforming section—of the example process, according to some embodiments. As shown in  FIG. 3G , after the lithography section, circuit protection layer  355  may be applied to the first side of substrate  305  to further protect electrical traces  320 . Next, as shown in  FIG. 3H , one or more electroforming processes may be used to form flexure arms  360  in DFR layers  330  and  340  at the second side of substrate  305 . For instance, the electroforming processes may include an additive manufacturing process, where a voltage may be applied across an anode and substrate  305  exposed at the bottom of cavities  350  to deposit an electrically conductive material within cavities  350  to form flexure arms  360 . In some embodiments, the electrically conductive material for forming flexure arms  360  may include a copper titanium alloy. In this example as shown in  FIG. 3H , flexure arms  360  may be formed in a T-shape. Referring back to  FIG. 3I , after the forming of flexure arms  360  at the second side of substrate  305 , circuit protection layer  355  may be removed. 
       FIGS. 3J-3L  show the next section—an etching section—of the example process, according to some embodiments. As shown in  FIG. 3J , after the electroforming section, a third DFR layer  365  may be applied at the second side of substrate  305  to cover exposed flexure arms  360 . Next, as shown in  FIG. 3K , one or more etching processes may be used to remove one or more exposed parts of substrate  305  in between electrical traces  320  such that flexure arms  360  may separate from each other. Finally, as shown in  FIG. 3L , residual DFR layers  330 ,  340 , and  365  may be stripped away. 
     As described, the example process described above may also be used to form other components of a suspension assembly, e.g., an inner frame and/or an outer frame, with electrical traces. For instance, one or more electrical traces may be formed at a first side of a thin foil substrate, e.g., as described above with regards to  FIG. 3A . Next, depending on the size and shape of an inner frame (and/or outer frame), one or more cavities  350  may be created in one or more DFR layers at a second side of the substrate, e.g., as described above with regards to  FIGS. 3B-3F . For instance, the cavities at the second side of the substrate may have a rectangular shape (not a T-shape) for the inner frame (and/or outer frame). Next, one or more electroforming processes, e.g., as described above in  FIGS. 3G-3I , may be used to deposit a material (e.g., a copper titanium alloy and/or other metal materials) within the cavities to form the inner frame. Finally, residual photoresists may be removed, e.g., as described above in  FIG. 3L . 
       FIG. 4A  shows one or more example lithography processes to create a T-shape cavity in DFR layers, according to some embodiments. As shown in  FIG. 4A , at  410 , a first DFR layer  404  and a second DFR layer  406  may cover substrate  402  at one side of substrate  402 . In some embodiments, DFR layer  404  and DFR layer  406  may include the same or different photoresists. At  410 , DFR layers  404  and  406  may be exposed to UV light, e.g., UV light of 405 nm wavelength, through a photomask to create a first pattern  408  in DFR layers  404  and  406 . In this example shown in  FIG. 4A , pattern  408  may include a rectangular shape. Next, at  420  in  FIG. 4A , another lithography process may be applied with UV light through another photomask to create a second pattern  410  in DFR layer  406 . By using laser direct imaging (LDI) techniques, UV light of different wavelengths may be used in the example lithography processes. For instance, the second pattern  410  may be created by exposing DFR layer  406  to UV light of 375 nm wavelength. In some embodiments, pattern  410  may have the same or different shape and/or size as pattern  408 . In this example, pattern  410  may also include a rectangular shape having a different size from pattern  408 , thus patterns  408  and  410  together may form a T-shape. Referring back to  FIG. 4A , at  430 , DFR layers  404  and  406  may be subject to a solvent to dissolve one or more parts of DFR layers  404  and  406 , according to patterns  408  and  410 , to thus generate T-shape cavity  412  in DFR layers  404  and  406 . As described above, e.g., with regards to  FIG. 3H , one or more electroforming processes may next be used to deposit material in to cavity  412  to form part of a suspension assembly, e.g., a T-shape flexure arm. 
       FIG. 4B  shows one or more example lithography processes to create an inverse T-shape cavity in DFR layers, according to some embodiments. As shown in  FIG. 4B , at  440 , a first DFR layer  474  may be applied to coat substrate  472  at one side of substrate  472 . At  440 , DFR layer  474  may be subject to UV light exposure, e.g., UV light of 405 nm wavelength, through a photomask to create pattern  478  in DFR layer  474 . Next, at  450 , a second DFR layer  476  may be applied on top of the first DFR layer  474  and exposed to UV light, e.g., the same UV light as  440  (e.g., UV light of 405 nm wavelength) or UV light of a different wavelength (e.g., UV light of 375 nm wavelength), through another photomask to create pattern  480  in DFR layer  476 . In this example as shown in  FIG. 4B , patterns  478  and  480  together may form an inverse T-shape. Next, at  460 , one or more parts of DFR layers  474  and  476  corresponding to patterns  478  and  480  may be dissolved away to create inverse T-shape civility  482 . 
       FIGS. 5A-5J  show an example process to form flexure arms with electrical traces using both a negative DFR and a positive DFR, according to some embodiments. Similar to the example process illustrated in  FIG. 3 , the example process in  FIG. 5  may be also divided into three sections: lithography (e.g., as shown in  FIGS. 5A-3D ), electroforming (e.g., as shown in  FIGS. 5E-5G ), and etching (e.g., as shown in  FIGS. 5H-5J ). As shown in  FIG. 5A , electrical traces  520  may be formed at a first side of substrate  505 , using one or more electroforming processes as described above with regards to  FIG. 3A . Note that there may be insulator layer  510 , seed layer  515 , and cover layer  525  at the first side of substrate  505 , as shown in  FIG. 5A . Next, as shown in  FIG. 5B , a first DFR layer  530  (including a negative DFR) and a second DFR layer  535  (including a positive DFR) may be applied at the first side and a second side of substrate  505 , where the second side may face opposite the first side. One difference between the negative and positive DFRs may be associated with the photosensitive characteristics of the negative and positive photoresists. For instance, in the case of a positive photoresist, the positive photoresist may become degraded by light and a solvent may dissolve away the regions that were exposed to light, leaving behind a coating where the mask was placed. By comparison, in the case of a negative photoresist, the negative photoresist may become strengthened (either polymerized or cross-linked) by light, and the solvent may dissolve away only the regions that were not exposed to light, leaving behind a coating in areas where the mask was not placed. In addition, a positive photoresist may be able to maintain its size and pattern because the solvent may not easily permeate the regions that have not been exposed to the UV light. By comparison, the solvent may permeate both exposed and unexposed regions of a negative photoresist which may lead to pattern distortions. Thus, in some embodiments, the positive DFR may be used to achieve better resolution requirements, especially for creating complicated patterns or shapes. Note that, in some embodiments, a positive DFR may be applied to both sides of substrate  505 , e.g., in order to maintain process stability. 
     Referring back to  FIG. 5C , both negative DFR layer  530  and positive DFR layer  535  may be exposed to UV light to create pattern  545  in negative DFR layer  530  (at the first side of substrate  505 ) and pattern  540  in positive DFR layer  535  (at the second side of substrate  505 ). In this example, pattern  445  may have a rectangular shape which may be less complicated than the hourglass shape of pattern  540  (thus it may be chosen to use positive DFR  535 ). Next, as shown in  FIG. 5D , one or more parts of DFR layer  430  and  535  may be removed, e.g., using a solvent, to create one or more hourglass-shape cavities  550  in positive DFR layer  535  at the second side of substrate  505  as well as remove negative DFR layer  530  between electrical traces  520  at the first side of substrate  505 . 
       FIGS. 5E-5G  show the next section—an electroforming section—of the example process, according to some embodiments. As shown in  FIG. 5E , after the lithography section, circuit protection layer  555  may be applied to the first side of substrate  305  to further protect electrical traces  520 . Next, as shown in  FIG. 5F , one or more electroforming processes may be used to form one or more parts of a suspension assembly, e.g., flexure arms  560 , in the hourglass shape at the second side of substrate  505 . For instance, the electroforming processes may include an additive manufacturing process to deposit an electrically conductive material (e.g., a copper titanium alloy) within cavities  550  to form flexure arms  560 . Referring back to  FIG. 5G , after the forming of flexure arms  560  at the second side of substrate  505 , circuit protection layer  555  may be removed. 
       FIGS. 5H-5I  show the next section—an etching section—of the example process, according to some embodiments. As shown in  FIG. 5H , after the electroforming section, a third DFR layer  565  may be applied at the second side of substrate  505  to cover exposed flexure arms  560 . Next, as shown in  FIG. 5I , one or more etching processed may be applied to remove substrate  505  between electrical traces  520 . Finally, as shown in  FIG. 5J , residual DFR layers  530 ,  535 , and  565  may be stripped away. 
     As described above, the example processes in  FIGS. 3 and 5  may be implemented based on a thin substrate (e.g., substrate  305  and  505 ), such as a thin copper foil of a few tens of micrometers thickness. In some embodiments, a suspension assembly, together with electrical traces, may also be formed based on a relatively thicker substrate, e.g., a copper titanium sheet of a few hundred micrometers. This example process may include one or more steps similar to those of the example processes illustrated above in  FIGS. 3 and 5 . For instance, the example process may start with etching one or more parts of the copper titanium sheet to generate a thin foil in a few tens of micrometers thickness. The thin foil may be similar to the substrate, e.g., substrate  305  and  505  described above with regards to  FIGS. 3 and 5 . Next, the lithography, electroforming, and etching processes such as those illustrated above in  FIGS. 3A-3L and 5A-5J  may be used to form electrical traces and one or more components of the suspension assembly, e.g., one or more flexure arms, from the thin foil created out of the copper titanium sheet. The rest of the copper titanium sheet which were not etched at the beginning of this example process may be used directly as the inner frame and/or outer frame for the suspension assembly. This example process may be suitable especially in scenarios where the substrate may be used directly (without electroforming) to create the inner frame and/or outer frame. 
       FIG. 6  shows an example suspension assembly with a foldable outer frame, according to some embodiments. In this example, suspension assembly  600  may include inner frame  602 , which may be mechanically coupled to outer frame  604  through one or more flexure arms  606 . In this example, suspension assembly  600  may be designed such that outer frame  604  may be folded to an angle relative to inner frame  602 . For instance, outer frame  604  may be folded along a perimeter between inner frame  602  and  604 , as indicated by dashed lines  610 , along the Z axis up to an angle ranging from, e.g., −180° to 180°, with respect to inner frame  602 . This may allow the size of suspension assembly  600  to further reduce in one or more direction, e.g., in the X and Y axes as shown in  FIG. 6 . Moreover, this may provide additional flexibilities as to the connections of electrical traces and/or image sensor to outer frame  604  and/or inner frame  602 . For instance, by folding outer frame  604  from zero to 90° relative to inner frame  602 , one or more electrical traces may now be able to be attached to corresponding conductor pad(s) of outer frame  604  in a vertical position (rather than in a horizontal position). 
       FIG. 7  illustrates a schematic representation of an example device  700  that may include a camera having one or more suspension assemblies, as described herein with reference to  FIGS. 1-6 , according to some embodiments. In some embodiments, the device  700  may be a mobile device and/or a multifunction device. In various embodiments, the device  700  may be any of various types of devices, including, but not limited to, a personal computer system, desktop computer, laptop, notebook, tablet, slate, pad, or netbook computer, mainframe computer system, handheld computer, workstation, network computer, a camera, a set top box, a mobile device, an augmented reality (AR) and/or virtual reality (VR) headset, a consumer device, video game console, handheld video game device, application server, storage device, a television, a video recording device, a peripheral device such as a switch, modem, router, or in general any type of computing or electronic device. 
     In some embodiments, the device  700  may include a display system  702  (e.g., comprising a display and/or a touch-sensitive surface) and/or one or more cameras  704 . In some non-limiting embodiments, the display system  702  and/or one or more front-facing cameras  704   a  may be provided at a front side of the device  700 , e.g., as indicated in  FIG. 7 . Additionally, or alternatively, one or more rear-facing cameras  704   b  may be provided at a rear side of the device  700 . In some embodiments comprising multiple cameras  704 , some or all of the cameras may be the same as, or similar to, each other. Additionally, or alternatively, some or all of the cameras may be different from each other. In various embodiments, the location(s) and/or arrangement(s) of the camera(s)  704  may be different than those indicated in  FIG. 7 . 
     Among other things, the device  700  may include memory  706  (e.g., comprising an operating system  708  and/or application(s)/program instructions  710 ), one or more processors and/or controllers  712  (e.g., comprising CPU(s), memory controller(s), display controller(s), and/or camera controller(s), etc.), and/or one or more sensors  716  (e.g., orientation sensor(s), proximity sensor(s), and/or position sensor(s), etc.). In some embodiments, the device  700  may communicate with one or more other devices and/or services, such as computing device(s)  718 , cloud service(s)  720 , etc., via one or more networks  722 . For example, the device  700  may include a network interface (e.g., network interface  810 ) that enables the device  700  to transmit data to, and receive data from, the network(s)  722 . Additionally, or alternatively, the device  700  may be capable of communicating with other devices via wireless communication using any of a variety of communications standards, protocols, and/or technologies. 
       FIG. 8  illustrates a schematic block diagram of an example computing device which may include a camera having one or more suspension assemblies, e.g., as described herein with reference to  FIGS. 1-7 , according to some embodiments. In addition, computer system  800  may implement methods for controlling operations of the camera and/or for performing image processing images captured with the camera. In some embodiments, the device  700  (described herein with reference to  FIG. 7 ) may additionally, or alternatively, include some or all of the functional components of the computer system  800  described herein. 
     The computer system  800  may be configured to execute any or all of the embodiments described above. In different embodiments, computer system  800  may be any of various types of devices, including, but not limited to, a personal computer system, desktop computer, laptop, notebook, tablet, slate, pad, or netbook computer, mainframe computer system, handheld computer, workstation, network computer, a camera, a set top box, a mobile device, an augmented reality (AR) and/or virtual reality (VR) headset, a consumer device, video game console, handheld video game device, application server, storage device, a television, a video recording device, a peripheral device such as a switch, modem, router, or in general any type of computing or electronic device. 
     In the illustrated embodiment, computer system  800  includes one or more processors  802  coupled to a system memory  804  via an input/output (I/O) interface  806 . Computer system  800  further includes one or more cameras  808  coupled to the I/O interface  806 . Computer system  800  further includes a network interface  810  coupled to I/O interface  806 , and one or more input/output devices  812 , such as cursor control device  814 , keyboard  816 , and display(s)  818 . In some cases, it is contemplated that embodiments may be implemented using a single instance of computer system  800 , while in other embodiments multiple such systems, or multiple nodes making up computer system  800 , may be configured to host different portions or instances of embodiments. For example, in one embodiment some elements may be implemented via one or more nodes of computer system  800  that are distinct from those nodes implementing other elements. 
     In various embodiments, computer system  800  may be a uniprocessor system including one processor  802 , or a multiprocessor system including several processors  802  (e.g., two, four, eight, or another suitable number). Processors  802  may be any suitable processor capable of executing instructions. For example, in various embodiments processors  802  may be general-purpose or embedded processors implementing any of a variety of instruction set architectures (ISAs), such as the x86, PowerPC, SPARC, or MIPS ISAs, or any other suitable ISA. In multiprocessor systems, each of processors  802  may commonly, but not necessarily, implement the same ISA. 
     System memory  804  may be configured to store program instructions  820  accessible by processor  802 . In various embodiments, system memory  804  may be implemented using any suitable memory technology, such as static random access memory (SRAM), synchronous dynamic RAM (SDRAM), nonvolatile/Flash-type memory, or any other type of memory. Additionally, existing camera control data  822  of memory  804  may include any of the information or data structures described above. In some embodiments, program instructions  820  and/or data  822  may be received, sent or stored upon different types of computer-accessible media or on similar media separate from system memory  804  or computer system  800 . In various embodiments, some or all of the functionality described herein may be implemented via such a computer system  800 . 
     In one embodiment, I/O interface  806  may be configured to coordinate I/O traffic between processor  802 , system memory  804 , and any peripheral devices in the device, including network interface  810  or other peripheral interfaces, such as input/output devices  812 . In some embodiments, I/O interface  806  may perform any necessary protocol, timing or other data transformations to convert data signals from one component (e.g., system memory  804 ) into a format suitable for use by another component (e.g., processor  802 ). In some embodiments, I/O interface  806  may include support for devices attached through various types of peripheral buses, such as a variant of the Peripheral Component Interconnect (PCI) bus standard or the Universal Serial Bus (USB) standard, for example. In some embodiments, the function of I/O interface  806  may be split into two or more separate components, such as a north bridge and a south bridge, for example. Also, in some embodiments some or all of the functionality of I/O interface  806 , such as an interface to system memory  804 , may be incorporated directly into processor  802 . 
     Network interface  810  may be configured to allow data to be exchanged between computer system  800  and other devices attached to a network  824  (e.g., carrier or agent devices) or between nodes of computer system  800 . Network  824  may in various embodiments include one or more networks including but not limited to Local Area Networks (LANs) (e.g., an Ethernet or corporate network), Wide Area Networks (WANs) (e.g., the Internet), wireless data networks, some other electronic data network, or some combination thereof. In various embodiments, network interface  810  may support communication via wired or wireless general data networks, such as any suitable type of Ethernet network, for example; via telecommunications/telephony networks such as analog voice networks or digital fiber communications networks; via storage area networks such as Fibre Channel SANs, or via any other suitable type of network and/or protocol. 
     Input/output devices  812  may, in some embodiments, include one or more display terminals, keyboards, keypads, touchpads, scanning devices, voice or optical recognition devices, or any other devices suitable for entering or accessing data by one or more computer systems  800 . Multiple input/output devices  812  may be present in computer system  800  or may be distributed on various nodes of computer system  800 . In some embodiments, similar input/output devices may be separate from computer system  800  and may interact with one or more nodes of computer system  800  through a wired or wireless connection, such as over network interface  810 . 
     Those skilled in the art will appreciate that computer system  900  is merely illustrative and is not intended to limit the scope of embodiments. In particular, the computer system and devices may include any combination of hardware or software that can perform the indicated functions, including computers, network devices, Internet appliances, PDAs, wireless phones, pagers, etc. Computer system  900  may also be connected to other devices that are not illustrated, or instead may operate as a stand-alone system. In addition, the functionality provided by the illustrated components may in some embodiments be combined in fewer components or distributed in additional components. Similarly, in some embodiments, the functionality of some of the illustrated components may not be provided and/or other additional functionality may be available. 
     Those skilled in the art will also appreciate that, while various items are illustrated as being stored in memory or on storage while being used, these items or portions of them may be transferred between memory and other storage devices for purposes of memory management and data integrity. Alternatively, in other embodiments some or all of the software components may execute in memory on another device and communicate with the illustrated computer system via inter-computer communication. Some or all of the system components or data structures may also be stored (e.g., as instructions or structured data) on a computer-accessible medium or a portable article to be read by an appropriate drive, various examples of which are described above. In some embodiments, instructions stored on a computer-accessible medium separate from computer system  900  may be transmitted to computer system  900  via transmission media or signals such as electrical, electromagnetic, or digital signals, conveyed via a communication medium such as a network and/or a wireless link. Various embodiments may further include receiving, sending or storing instructions and/or data implemented in accordance with the foregoing description upon a computer-accessible medium. Generally speaking, a computer-accessible medium may include a non-transitory, computer-readable storage medium or memory medium such as magnetic or optical media, e.g., disk or DVD/CD-ROM, volatile or non-volatile media such as RAM (e.g. SDRAM, DDR, RDRAM, SRAM, etc.), ROM, etc. In some embodiments, a computer-accessible medium may include transmission media or signals such as electrical, electromagnetic, or digital signals, conveyed via a communication medium such as network and/or a wireless link. 
     The methods described herein may be implemented in software, hardware, or a combination thereof, in different embodiments. In addition, the order of the blocks of the methods may be changed, and various elements may be added, reordered, combined, omitted, modified, etc. Various modifications and changes may be made as would be obvious to a person skilled in the art having the benefit of this disclosure. The various embodiments described herein are meant to be illustrative and not limiting. Many variations, modifications, additions, and improvements are possible. Accordingly, plural instances may be provided for components described herein as a single instance. Boundaries between various components, operations and data stores are somewhat arbitrary, and particular operations are illustrated in the context of specific illustrative configurations. Other allocations of functionality are envisioned and may fall within the scope of claims that follow. Finally, structures and functionality presented as discrete components in the example configurations may be implemented as a combined structure or component. These and other variations, modifications, additions, and improvements may fall within the scope of embodiments as defined in the claims that follow.

Metadata:
Filing Date: 20210811
Publication Date: 20221025
Grant Date: 20221025
Priority Date: 20200812
Inventors: SOMMER, PHILLIP R.
KOREN, MORAN
MAGEN, ADAR
Assignee: APPLE INC
CPC Classifications: [{"code": "H04N23/55", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04N23/54", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04N23/687", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04N23/67", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04N23/54", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04N23/50", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04N23/55", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04N5/2254", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 80223200