PATENT DOCUMENT

Publication Number: US-9891098-B2
Application Number: US-98263710-A
Country: US
Kind Code: B2

Title: Diffuser and filter structures for light sensors

Abstract:
An electronic device may have a display. The display may have a central active area and a peripheral inactive area. A cover layer such as a layer of cover glass may be used to cover the display. The inner surface of the cover layer in the inactive area may be coated with an opaque masking layer such as black ink. Light for an ambient light sensor or other component may pass through an opening in the black ink. A layer of ink or other structures may be mounted within the opening to serve as a filter structure. A light diffusing structure such as a clear member with a textured surface may be used to diffuse light that is passing through the opening in the black ink and the filter to the light sensor. Integral filter-diffuser structures and structures with concave surfaces for focusing incoming light onto the light sensor may be used.

Claims:
What is claimed is: 
     
       1. Apparatus, comprising:
 a transparent planar member having a central region that emits light and a peripheral region that surrounds the central region; 
 an opaque masking layer on the transparent planar member in the peripheral region; 
 a light diffuser attached to the transparent planar member in alignment with at least one opening in the opaque masking layer in the peripheral region; 
 a light sensor aligned with the opening in the opaque masking layer, wherein the light diffuser is interposed between the transparent planar member and the light sensor and is configured to diffuse light that passes through the opening, and wherein the light sensor receives the diffused light; and 
 a layer of filtering ink in the opening, wherein the filtering ink is interposed between the transparent planar member and the light diffuser and wherein the filtering ink is configured to pass at least some light to the light sensor. 
 
     
     
       2. The apparatus defined in  claim 1  wherein the layer of filtering ink is configured to block at least some visible light and wherein the light received through the opening by the light sensor comprises visible light. 
     
     
       3. The apparatus defined in  claim 1  further comprising a display, wherein the transparent planar member comprises a cover layer for the display. 
     
     
       4. The apparatus defined in  claim 3  wherein the cover layer comprises a layer of glass. 
     
     
       5. The apparatus defined in  claim 4  wherein the light diffuser comprises a transparent structure with at least one textured surface. 
     
     
       6. The apparatus defined in  claim 1  wherein the light diffuser comprises a concave surface. 
     
     
       7. The apparatus defined in  claim 6  wherein the light diffuser is part of an integral filter-diffuser structure with a non-flat spectral transmittance characteristic. 
     
     
       8. The apparatus defined in  claim 1  wherein the opening comprises one of a plurality of perforations that are clustered to form a window in the opaque masking layer through which light passes to the light sensor. 
     
     
       9. An electronic device, comprising:
 a housing; 
 a display mounted in the housing, wherein the display has a rectangular active area and a peripheral inactive area, wherein the display has a transparent cover layer, wherein a portion of the transparent cover layer is coated with an opaque masking layer having a hole, and wherein the opaque masking layer is coated on an inner surface of the transparent cover layer in the peripheral inactive area; 
 a layer of visible-light-blocking ink coated on the inner surface of the transparent cover layer in the hole; 
 a light diffuser mounted within the electronic device; 
 a light sensor, wherein the light diffuser is interposed between the layer of visible-light-blocking ink in the hole and the light sensor, and wherein the light diffuser reduces a directionality of the light; and 
 an infrared-light-blocking filter interposed between the light sensor and the light diffuser, wherein the light sensor receives light through the layer of visible light-blocking ink in the hole, the light diffuser, and the infrared-light-blocking filter. 
 
     
     
       10. The electronic device defined in  claim 9  wherein the light diffuser comprises a textured surface. 
     
     
       11. The electronic device defined in  claim 9  further comprising adhesive that attaches the light diffuser to the layer of visible-light-blocking ink. 
     
     
       12. The electronic device defined in  claim 11  wherein the light-diffuser has a planar untextured surface that is attached to the layer of visible-light-blocking ink with the adhesive and wherein the textured surface of the light diffuser faces the light sensor. 
     
     
       13. Apparatus, comprising:
 a display with a cover layer, wherein the display includes an active area and an inactive area; 
 an opaque masking layer on peripheral portions of the cover layer; 
 a light sensor that is mounted under the inactive area on a printed circuit board and that receives light through an opening in the opaque masking layer; 
 a light diffuser interposed between the opening and the light sensor through which the light sensor receives the light; 
 light-blocking structures mounted on the printed circuit board that surround the light sensor, wherein the light blocking structures comprise an opening in which the light sensor is mounted and through which the light sensor receives the light; 
 a first filter layer interposed between the cover layer and the light sensor, wherein the first filter layer blocks infrared light; 
 a second filter layer interposed between the diffuser and the light sensor, wherein the second filter layer blocks infrared light; and 
 a third filter layer interposed between the second filter layer and the light sensor, wherein the third filter layer blocks visible light, and wherein the light sensor receives light through the first, second, and third filter layers. 
 
     
     
       14. The apparatus defined in  claim 13  wherein the light diffuser has a concave surface that faces the light sensor. 
     
     
       15. The apparatus defined in  claim 13 , wherein the light diffuser receives the light and redirects the light onto the light sensor.

Description:
BACKGROUND 
     This relates generally to electronic devices, and more particularly, to light sensor structures for electronic devices. 
     Electronic devices are often provided with light sensors. For example, an electronic device may be provided with an ambient light sensor. An electronic device may use its ambient light sensor to make adjustments to the brightness of a display in real time. If, for example, an electronic device is operated in a bright environment, the brightness of a display in the device may be maximized to allow a user to easily view content on the display. If the electronic device is operated in a dim environment, the brightness level for the display may be set to a lower level to avoid overwhelming the user with an overly bright display. 
     Proper display brightness adjustments rely on accurate ambient light measurements with the ambient light sensor. In a typical light measurement scenario, an electronic device may take an ambient light reading with an ambient light sensor when the device is powered up. If a user happens to be holding the device so that the ambient light sensor is pointed at a bright light source during the power up process, there is a potential for the ambient light sensor to detect an erroneously large amount of ambient light. This can cause the electronic device to set the brightness level of the display at an undesirably high level. Conventional light sensors may also be challenging to fabricate with desired tolerances, particularly in high volume manufacturing scenarios. 
     It would therefore be desirable to be able to provide improved arrangements for light sensors in electronic devices. 
     SUMMARY 
     An electronic device may be provided with a display. The display may be mounted in a device housing. The display may have an active central portion that displays images and an inactive peripheral region. 
     A cover layer may be formed on the display. The cover layer may be formed form a planar transparent member such as a rectangular layer of glass. A layer of opaque masking material such as a layer of black ink may be formed on the inner surface of the cover layer in the inactive region of the display. 
     An opening may be formed in the opaque masking layer to accommodate a light sensor or other optical component. The light sensor may be, for example, an ambient light sensor that makes measurements of ambient lighting conditions during use of the electronic device. 
     The opening in the opaque masking layer may be covered with filter structures and light diffusing structures. A layer of ink or a solid material may be used in forming a filter. Filtering may also be provided by structures associated with a light sensor, by adhesive with filtering properties, by light diffusing structures, by other optical structures, or by combinations of these structures. 
     Light diffusing structures may be formed from a material that scatters light. For example, a diffuser may be implemented using a transparent structure with a textured surface that scatters light. The light diffusing structures may diffuse light that is being received by the light sensor thereby reducing the directionality of the light sensor. 
     Integral filter-diffuser structures may be formed by combining filtering and light diffusing structures into a common unit. A curved surface may be used on a filter, diffuser, or on an integral filter-diffuser to help concentrate incoming light onto the light sensor. 
     Further features of the invention, its nature and various advantages will be more apparent from the accompanying drawings and the following detailed description of the preferred embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an illustrative electronic device with light sensor structures in accordance with an embodiment of the present invention. 
         FIG. 2  is a cross-sectional view of an electronic device of the type shown in  FIG. 1  showing how a light sensor may receive light through a planar transparent member such as a layer of glass or other clear material associated with a display in accordance with an embodiment of the present invention. 
         FIG. 3  is a cross-sectional view of display structures that include an ink layer that serves as a light filter layer and that include a diffuser in accordance with an embodiment of the present invention. 
         FIG. 4A  is a graph showing how the light transmittance of optical structures may vary as a function of wavelength in accordance with an embodiment of the present invention. 
         FIG. 4B  is a graph of an illustrative sensor sensitivity characteristic in accordance with an embodiment of the present invention. 
         FIG. 4C  is a graph of an illustrative photopic light sensor characteristic of the type that may be produced by incorporation of filter structures, diffuser structures, adhesive structures, and sensor structures with appropriate spectral characteristics in accordance with an embodiment of the present invention. 
         FIG. 5  is a top interior view of an electronic device with a light sensor in accordance with an embodiment of the present invention. 
         FIG. 6  is a perspective view of a light-blocking structure such as a black foam structure that may be used to prevent light leakage from adversely affecting light sensor operation in accordance with an embodiment of the present invention. 
         FIG. 7  is a diagram showing how the use of diffuser structures may enhance light sensor performance by reducing sensor directionality in accordance with an embodiment of the present invention. 
         FIG. 8  is a graph showing how a light sensor may accept light rays from a greater range of acceptance angles when a diffuser is used than when a diffuser is not used in accordance with an embodiment of the present invention. 
         FIG. 9  is a cross-sectional side view of illustrative filter and diffuser structures including an ink-based light filter layer that may be used in an electronic device of the type shown in  FIG. 1  in accordance with an embodiment of the present invention. 
         FIG. 10  is a diagram showing how a diffuser of the type shown in  FIG. 9  may be attached to a planar transparent member such as a cover layer associated with a display in an electronic device in accordance with an embodiment of the present invention. 
         FIG. 11  is a flow chart of illustrative steps involved in assembling structures of the type shown in  FIG. 10  into an electronic device during manufacturing operations in accordance with an embodiment of the present invention. 
         FIG. 12  is a cross-sectional side view of an illustrative filter and diffuser arrangement for a light sensor in an electronic device in which the filter is formed from a layer of material that is attached to a cover glass layer or other clear layer using adhesive in accordance with an embodiment of the present invention. 
         FIG. 13  is a cross-sectional side view of an illustrative integral filter and diffuser structure for a light sensor in an electronic device in accordance with an embodiment of the present invention. 
         FIG. 14  is a diagram showing how a tool with a roughened surface may be used in forming a diffuser structure such as a diffuser built into an integral filter and diffuser in accordance with an embodiment of the present invention. 
         FIG. 15  is a diagram of an illustrative optical structure such as a filter, diffuser, filter-diffuser, or stand-alone optical element that has been configured to form a light concentrating lens structure for a light sensor in accordance with an embodiment of the present invention. 
         FIG. 16  is a diagram of a window in an opaque masking layer that has been formed using multiple perforations in accordance with an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     Electronic devices may be provided with light sensors. For example, light sensors may be incorporated into electronic devices with displays so that the brightness of the display can be adjusted automatically based on ambient lighting conditions. Light sensors may also be used as part of a proximity sensor, as part of a light meter for a camera, as part of a user input interface device, as part of a light-based communications port, or in other light-sensing applications. 
     An illustrative electronic device of the type that may include a light sensor is shown in  FIG. 1 . Electronic device  10  may be a portable electronic device or other suitable electronic device. For example, electronic device  10  may be a laptop computer, a tablet computer, a somewhat smaller device such as a wrist-watch device, pendant device, headphone device, earpiece device, or other wearable or miniature device, a cellular telephone, a media player, other handheld devices, etc. 
     Device  10  may include a housing such as housing  12 . Housing  12 , which may sometimes be referred to as a case, may be formed of plastic, glass, ceramics, fiber composites, metal (e.g., stainless steel, aluminum, etc.), other suitable materials, or a combination of these materials. In some situations, parts of housing  12  may be formed from dielectric or other low-conductivity material. In other situations, housing  12  or at least some of the structures that make up housing  12  may be formed from metal elements. 
     Device  10  may, if desired, have a display such as display  14 . Display  14  may, for example, be a touch screen that incorporates capacitive touch sensor electrodes. Display  14  may include image pixels formed form light-emitting diodes (LEDs), organic LEDs (OLEDs), plasma cells, electronic ink elements, liquid crystal display (LCD) components, or other suitable image pixel structures. A cover layer may cover the surface of display  14 . The cover layer may be formed from a transparent planar member such as a layer of glass (sometimes referred to as cover glass) or a layer of clear plastic. 
     In a rectangular ring-shaped peripheral region such as peripheral region  20  of display  14 , the underside of the cover layer may be coated with an opaque masking layer such as black ink. Peripheral region  20  may surround central rectangular region  16 . Rectangular dashed line  18  of  FIG. 1  shows the boundary between central region  16  and peripheral region  20  in the example of  FIG. 1 . 
     Central region  16  may sometimes be referred to as the active region of display  14 . Peripheral region  20  may sometimes be referred to as the inactive region of the display. During operation, an array of image pixels in display  14  can produce images within active region  16 . The black ink or other masking layer that is formed under inactive peripheral region  20  may be used to hide internal device structures from view from the exterior of device  10 . 
     The cover layer of display  14  may include openings such as a circular opening for button  28 , openings for speaker ports, openings for other buttons, openings for connectors, etc. 
     The black ink or other opaque masking layer material that is formed on the underside of the cover layer may have openings that coincide with the openings in the cover layer. Additional openings in the black ink or other opaque masking layer material may be formed to allow light to pass through the cover layer. For example, an opening such as black ink layer opening  22  of  FIG. 1  may be formed to allow light to pass from the exterior of device  10  to an internal light sensor. Openings of this type may also be formed in the opaque masking layer to create windows that allow internal light (e.g., light from an infrared light-emitting diode in a proximity sensor or other light source) to pass from the interior of device  10  to the exterior of device  10 . 
     A cross-sectional side view of device  10  of  FIG. 1  taken along line  26 - 26  of  FIG. 1  and viewed in direction  24  is shown in  FIG. 2 . As shown in  FIG. 2 , display  14  of device  10  may have a display module such as display module  14 B and a planar cover layer member such as cover layer  14 A. 
     Display module  14 B may be, for example, a backlit liquid crystal display (LCD), organic light-emitting diode (OLED) display, plasma display, backlit electronic ink display, or other display with an adjustable brightness. Control circuitry in electronic components  36  may be linked to display module  14 B by communications path  40 . During operation, the control circuitry may be used to adjust the brightness of display module  14 B and therefore the brightness of display  14 . Brightness adjustments may be made automatically or in response to user input. In making automatic brightness adjustments, the control circuitry may use measured ambient light data that is gathered using a light sensor such as ambient light sensor  34 . Ambient light measurements may be made using visible light, infrared light, a combination of visible and infrared light, or other suitable ambient light. With one suitable arrangement, which may sometimes be described herein as an example, the optical components in device  10  such as filter structures, adhesive, diffuser structures, and sensor-based filters, may be used to tailor the overall optical response of the ambient light sensor to mimic that of the human eye (e.g., the light sensor stack-up may exhibit a maximum sensitivity at about 555 nm, as with the human eye or may at least be configured to be sensitive at visible wavelengths). An ambient light sensor arrangement of this type may be referred to as exhibiting a photopic response (i.e., a response that mimics the responsivity of the human eye). Ambient light sensor arrangements that exhibit non-photopic responses may also be used in device  10  if desired. 
     Electronic components  36  may include integrated circuits, connectors, switches, batteries, discrete components such as resistors, inductors, and capacitors, sensors, input-output devices, memory, processor circuitry, and other electronic devices. Electronic components  36  and sensor  34  may be interconnected using conductive lines in printed circuit boards, traces on flexible cables such as flex circuit cables, coaxial cables, wires, and other electrical communications paths. In the example of  FIG. 2 , light sensor  34  and components  36  have been mounted on substrate  38 . Substrate  38  may be formed from a rigid printed circuit board (e.g., a printed circuit board formed form fiberglass-filled epoxy), a flexible printed circuit board (e.g., a flex circuit formed from a thin layer of flexible polymer such as a sheet of polyimide), a rigid flex (e.g., a substrate with a rigid printed circuit board portion and flex circuit tails), more than one printed circuit board structure, substrates formed from molded plastic, ceramic, or glass, or other suitable substrate structures. 
     Cover layer  14 A of  FIG. 2  is formed from a material that is transparent to visible light. This allows light  42  from display module  14 B to be viewed by a user of device  10 . Examples of suitable materials that may be used for cover layer  14 A include glass, ceramic, polymers, laminated stacks of glass, ceramic, polymer, or other clear materials, or combinations of these materials. If desired, cover layer  14 A may be formed from part of display module  14 B. For example, cover layer  14 A may serve as a color filter layer, polarizer layer, touch sensor substrate layer, antireflection layer, or other layer in display module  14 B as well as serving as a protective outer layer for display  14 . 
     To hide internal portions of device  10  from view from the exterior of device  10 , inactive portions of display  14  may be provided with an opaque masking structure. In the illustrative configuration of  FIG. 2 , an opaque masking structure has been formed using a layer of opaque material such as black ink on the inner surface of cover layer  14 A in inactive display region  20 . As shown in  FIG. 2 , black ink  30  may be provided with an opening such as opening  22  to allow light  32  to pass between the exterior of device  10  and the interior of device  10 . Opening  22  may form a light sensor window in layer  30  that allows light  32  to pass to sensor  34 . In configurations in which device  10  has internal components that generate light, windows such as opening  22  may be formed to allow light to pass through cover layer  14 A from the interior to the exterior of device  10 . 
     Opening  22  in ink layer  30  may be free of any additional materials (i.e., cover layer  14 A may be bare within opening  22 ). If desired, a layer of ink or other structures may be formed on the underside of cover layer  14 A within opening  22 . As an example, a layer of infrared (IR) ink may be placed within opening  22  to serve as a visible-light-blocking and infrared-light-transmitting filter. Filter structures of this type may help block the interior of device  10  from view by a user, because the user&#39;s eyes are only sensitive to visible light. At the same time, the infrared-light-transmitting qualities of the IR ink may allow ambient light  32  (e.g., light in the near infrared spectrum) to reach light sensor  34 . Filter structures may also be associated with light sensor  34 . For example, an IR-cut filter may be included in the packaging for sensor  34  or may be otherwise interposed within the incoming light path for sensor  34 . Adhesive layers, diffuser structures, lens structures and other optical structures may also be provided with filtering capabilities (e.g., by using stacked dielectric layers with appropriate indicies of refraction, by incorporating dyes or other filter materials into appropriate optical structures, etc.). The net spectral response of the light sensor and associated optical structures in the incoming light path for the sensor may, if desired, be tailored to mimic the response of the human eye or may be used to implement other desired spectral response curves. 
       FIG. 3  is a cross-sectional side view of a portion of an illustrative device in which a light filter has been formed in opening  22  using a layer of light filtering ink. As shown in  FIG. 3 , device  10  may have a cover layer such as cover layer  14 A on which opaque masking layer  30  has been formed. Opaque masking layer  30  may be, for example, black ink or other material that is opaque in the visible portion of the spectrum. Filter layer  42  may be formed from a layer of ink or other material with a desired spectral characteristic. As an example, layer  42  may be formed from a layer of ink that blocks visible light and that is transparent to infrared light (i.e., IR ink). This type of arrangement allows infrared light  32  to pass through opening  22  to sensor  34  without allowing a user to view internal device components such as sensor  34  from the exterior of device  10 . Sensor  34  may have associated filters such as illustrative internal filter  35 . The spectral response of semiconductor sensor  56  (which may, for example, be more sensitive in the infrared than the visible) may be adjusted using filter structures such as internal filter  35 , filter layer  42 , and filtering structures that are integrated into one or more other optical component in the light path leading to sensor  34  (e.g., filtering structures integrated into a diffuser, filtering structures integrated into adhesive, filtering structures integrated into other optical components, etc.). 
     Display cover layer  14 A may be attached to internal device structures (e.g., a frame, mounting structures, support structures, and other internal components). For example, cover layer  14 A may be attached to metal bracket  62 . Metal bracket  62  may have an opening that is approximately the same size as opening  22  in black ink layer  30 . Diffuser  46  may be mounted in the opening in bracket  62  over opening  22  in black ink layer  30 . 
     Sensor  34  may have a glass cover such as cover  52 . Cover  52  may be mounted on sensor package  54 . Semiconductor light sensor  56  (e.g., a photodiode or other light sensor component) may be mounted within package  54 . Internal filter  35 , cover  52 , or other structures associated with sensor  34  may serve as light filters that adjust the spectral response of the ambient light sensor for device  10 . For example, internal filter  35  may be an infrared cut filter that helps reduce excessive sensitivity of semiconductor sensor  56  in the infrared, thereby enhancing the visible response of sensor  34  relative to the infrared response of sensor  34 . 
     Package  54  may be, for example, a surface mount technology (SMT) component that is mounted to printed circuit board  38  or other suitable substrate. In the illustrative configuration shown in  FIG. 3 , light sensor package  54  has been mounted to substrate  38  using solder  58 . If desired, conductive adhesive, fasteners, or other attachment mechanisms may be used in electrically and mechanically attaching light sensor  34  to substrate  38 . 
     In a typical configuration, sensor  34  may be separated from layer  42  by about 1 mm. The height of sensor  34  may be about 0.6 mm. The lateral dimensions of sensor  34  (i.e., the dimensions of sensor  34  in dimensions X and Y of  FIG. 3 ) may be about 0.9 mm and 1.6 mm. The thickness of glass  52  may be about 0.4 mm. The lateral dimensions of opening  22  may be about 2 mm. Bracket  62  and diffuser  46  may be about 0.3 mm thick. Diffuser  46  may have lateral dimensions of about 2.6 mm (matching the lateral dimensions of the corresponding opening in bracket  62 ). 
     Diffuser  46  may help reduce the directionality of sensor  34 . In some operating environments, light hotspots may pose challenges that make it difficult to obtain accurate ambient light readings. Consider, as an example, a scenario in which an electronic device makes an ambient light reading upon power up and makes corresponding display brightness adjustments without taking further ambient light readings. In this type of scenario, use of an ambient light sensor that is too directionally specific, may sometimes cause the ambient light reading to be too high or too low. If, as an example, a user powers up a device when the ambient light sensor is pointed at an unusually bright region in the user&#39;s environment such as a spotlight, the device may erroneously conclude that the user&#39;s environment is bright. On the other hand, if the user powers of the device when the ambient light sensor is pointed at a particularly dark area, the device may erroneously conclude that the user&#39;s environment is dark. The user of ambient light sensor arrangements that are overly directional may therefore cause an electronic device to take inappropriate actions, such as making inaccurate display brightness adjustments. 
     To reduce that directional specificity of light sensor  34  of  FIG. 3 , device  10  of  FIG. 3  has been provided with diffuser  46 . Diffuser  46  may diffuse incoming light  32 , so that ambient light readings taken with ambient light sensor  34  are not overly sensitive to the orientation of sensor  34  and device  10 . 
     Diffuser  46  may be formed from polymer, glass, ceramic, other materials, or combinations of these materials. In some configurations, diffuser  46  and filter  42  may be formed as a unitary structure. In other configurations, diffuser  46  and filter  42  may be formed as separate parts. Layers of adhesive may, if desired, be used in connecting light sensor structures such as a filter and/or diffuser structure. In the arrangement of  FIG. 3 , for example, diffuser  46  may be attached to ink layer  42  using adhesive  44 . Adhesive  44  may be formed, for example, from an optically clear adhesive (OCA). Adhesives such as adhesive  44  and the other adhesives used in device  10  may, in general, be formed from liquids (e.g., thermally cured or ultraviolet-light-cured epoxy or other liquid adhesives), pressure sensitive adhesive (PSA), adhesive on tape, or other suitable adhesive materials. Light filter materials (e.g., dyes that absorb light at particular wavelengths) may, if desired, be incorporated into adhesive  44  and other adhesives in the light path for sensor  34  to adjust the spectral response of sensor  34  (i.e., one or more layers of adhesive may be used in implementing spectral filter structures). Adhesive  44  and other layers of adhesive in the light path for sensor  34  may also be provided with diffusing capabilities (i.e., adhesive may be formed using translucent materials that help to scatter light). 
     Diffuser  46  may be formed from a material that incorporates internal light-scattering structures and/or from a structure that includes one or more surfaces that assist in light scattering. Examples of internal structures that may help scatter light include bubbles (e.g., air bubbles, voids filled with other gases, voids filled with vacuum, particles such as spheres or other pieces of polymer, glass, or ceramic that have an index or refraction that is different than the primary structural material from which diffuser  46  is formed, dye structures, pigment-based structures, etc. These approaches may be used to provide a stand-alone diffuser element with diffusing properties and/or may be used in providing other optical material in the incoming light path for sensor  34  (e.g., adhesive, window material, lens structures, filters, etc.) with diffusing properties. As shown in the example of  FIG. 3 , diffuser  46  may have one a flat surface such as flat upper surface  48  and a textured surface such as surface  50 . The flat upper surface of diffuser  46  in  FIG. 3  may help in forming a smooth optical interface that receives incoming light  32  without undue reflection. Textured lower surface  50  may help scatter light  32  as light  32  exits diffuser  46  towards the interior of device  10 . 
     Any suitable type of texture may be used in forming lower surface  50 . For example, surface  50  may include multiple ridges (e.g., to form a corrugated surface pattern), may include bumps, may include other types of surface texture patterns, and may include combinations of these patterns. In configurations in which the light diffusing properties of diffuser  46  are based at least partly on the texture present on textured surface  50 , it may be desirable to ensure that textured surface  50  is not covered with adhesive. Diffuser  46  may, for example, be mounted to filter layer  42  using adhesive  44 , so that only smooth upper surface  48  of diffuser  46  is exposed to the adhesive and not textured lower surface  50 . If adhesive is placed in contact with textured surface  50 , the adhesive may tend to serve as an index-of-refraction-matching material that tends to reduce scattering and therefore reduces the light diffusing properties of diffuser  46 . 
       FIG. 4A  is a graph showing how optical structures in the light path for sensor  34  such as filter structures and other structure may have various spectral characteristics. In the graph of  FIG. 4A , the transmittance T of three illustrative filters has been plotted as a function of wavelength λ. In the visible light portion of the spectrum (VIS), the filter associated with illustrative transmittance curve T 1  transmits relatively small amounts of light (i.e., the filter is essentially opaque to visible light). In the infrared portion of the spectrum (IR), the value of transmittance T 1  is high (i.e., this filter is transparent at infrared wavelengths). The boundary between the visible and infrared portions of the light spectrum is at about 760 to 780 nm and is denoted by the label VIS-IR on the wavelength axis of the graph of  FIG. 4A . Transmittance curve T 2  corresponds to illustrative filter structures that pass visible light and that block infrared light. Transmittance curve T 3  corresponds to an illustrative filter structures that cut both visible and infrared light and that allows somewhat more visible light to pass at a wavelength of about 555 nm (e.g., to help implement a photopic response for the ambient light sensor). 
     Any one, two, three, or more than three of the optical structures in the incoming light path for sensor  34  and/or the semiconductor sensor within sensor  34  (e.g., sensor element  56  of  FIG. 3 ) may be implemented using structures and materials that tailor their spectral response curves to provide a desired overall response for the ambient light sensor. Examples of structures within device  10  that can be configured to provide desired transmittances as a function of wavelength so as to adjust the overall response of the ambient light sensor include: cover glass layers or other display layers that form windows for receiving incoming light, adhesive layers that hold components together such as adhesive  44  of  FIG. 3 , diffuser structures such as structure  46  of  FIG. 3 , filter layers such as filtering ink layer  42 , filter structures such as filter structure  35 , sensor cover structures such as sensor cover layer  52 , additional filter elements (e.g., lens shaped or planar filters), other filter structures, and combinations of these structures. 
       FIG. 4B  shows how semiconductor sensor  56  in sensor  34  may be more sensitive at infrared wavelengths than at visible wavelengths (as an example). In  FIG. 4B , the sensitivity S 1  of sensor  56  has been plotted as a function of wavelength λ. 
       FIG. 4C  shows how the net spectral response of all of the structures interposed between the exterior of device  10  and sensor  56  may, in combination with the inherent spectral response of sensor  56 , produce a photopic response curve. As shown in  FIG. 4C , the overall spectral response of the sensor structures in device  10  may be tailored to mimic that of the human eye (e.g., so that overall sensitivity S 2  peaks at a wavelength of about 555 nm or other visible wavelength) or may at least be adjusted so that the sensor is responsive to changes in ambient light within the visible part of the spectrum. One way that a photopic response may be obtained is by forming layer  42  of  FIG. 3  from an ink that blocks all but 2% of incoming visible light (e.g., to block sensor  34  from view from the exterior of device  10  and to help ensure that the sensor is not saturated during normal use), by using spectrally neutral diffuser and adhesive layers, and by providing sensor  34  with an IR cut filter (e.g., internally using filter  35  or externally in layer  42  or another structure) to help compensate for the inherent IR sensitivity of sensor  56  and to thereby ensure that the sensor does not become saturated. If desired, sensor responses of the type shown in  FIG. 4C  may be accommodated without using IR blocking filters such as filter  35  of  FIG. 3  by ensuring that other structures with spectral filtering capabilities (e.g., filter layer  42 , adhesive  44 , diffuser  46 , and/or other material in the optical stack) block IR light while allowing an appropriate amount of light at visible wavelengths to be sensed. For example, the response of  FIG. 4C  or other visible-light-sensitive response may be implemented by using only filter ink  42  and the inherent response of sensor  56  (as an example). 
     The shapes of the optical structure transmittance curves of  FIG. 4A , the semiconductor sensor response curve of  FIG. 4B , and the overall ambient light sensor sensitivity curve of  FIG. 4C  are examples. If desired, other filter transmittance curves may be associated with filter structures for device  10 , the semiconductor sensor element associated with sensor  34 , and the overall response for the ambient light sensor. For example, one or more optical structures in the light path for sensor  34  may have a bandpass characteristic (e.g., at a visible or infrared wavelength), may have a high-pass characteristic, may have a low-pass characteristic, may have a notch filter characteristic, may have steeper or more gradual shapes, may exhibit one or more peaks or valleys as a function of wavelength, or may have other non-flat spectral transmittance characteristics in the visible and IR portions of the light spectrum. The curves of  FIGS. 4A, 4B, and 4C  are merely illustrative. 
     Device  10  may include light sources such as light-emitting diodes in a backlight portion of display module  14 B. To prevent stray light from display module light-emitting diodes or other internal sources, light sensor  34  may be surrounded by light-blocking structures  60 , as shown in  FIG. 3 . Light-blocking structures  60  may be formed from black foam or other material that helps ensure that stray light from light-emitting diodes or other internal light sources does not reach light sensor  34 . 
     As shown in the top view of the interior of device  10  in  FIG. 5 , light-blocking structures  60  may have a rectangular central hole  62  into which light sensor  34  is placed. During operation of device  10 , light-emitting diodes  64  that are mounted on flex circuit substrate  66  may launch light  68  into light guide plate  70  to serve as backlight for display  14 . Light guide plate  70  may be used to horizontally distribute the backlight from light-emitting diodes  64  under the image pixel structures of display module  14 B. Some of light  68  may leak in direction  72  towards sensor  34 , but this leaked light will tend to be blocked by light-blocking structures  60 . 
       FIG. 6  shows an illustrative shape that may be used for light-blocking structures  60 . Other shapes may be used if desired (e.g., circular shapes, shapes with curved and straight edges, shapes having openings  62  with curved and/or straight sides, etc.). 
     The ability of light-diffusing structures such as diffuser  46  to decrease the directionality of the ambient light sensor or other optical component in device  10  may be understood with reference to  FIG. 7 . As shown in  FIG. 7 , incoming light rays that pass through opening  22  may take paths such as paths  32 A and  32 B. Light rays along paths such as path  32 A may be oriented at angle θ 1  with respect to vertical axis  74 . Light rays following paths such path  32 B may be oriented at angle θ 2  with respect to vertical axis  74 . In this example, angle θ 1  is smaller than angle θ 2 . Light rays that are oriented at angles of θ 1  or less with respect to vertical axis  74  will generally pass through opening  22  and will be detected by light sensor  34 . 
     The behavior of light rays that are oriented at larger angles such as light rays following path  32 B at angle θ 2  with respect to vertical axis  74  depends on whether or not a diffusing structure is present in position  78  within opening  22 . In situations in which no diffuser is present in position  78 , light rays along path  32 B will tend to miss light sensor  34  and will not be detected, as indicated by portion  75  of light ray path  32 B. When a diffuser such as diffuser  46  of  FIG. 3  is present in position  78 , however, the diffuser may scatter the incoming light from path  32 B towards sensor  34 , as indicated by light ray  76  of  FIG. 7 . 
     The absence of a diffuser in opening  22  therefore tends to make sensor  34  more directional. The presence of a diffuser in opening  22  has the effect of scattering light and reducing sensor directionality. Sensor arrangements that are less directional may exhibit improved performance during operation, because less directional sensor schemes help avoid undesired responses of the type that might otherwise arise when device  10  and sensor  34  are pointed at localized sources of light (or locally dark regions). The use of diffusers may also ease alignment tolerance requirements during manufacturing, thereby improving manufacturing yields. 
     The graph of  FIG. 8  illustrates how the presence of diffuser structures within opening  22  may decrease the directionality of the light sensor in device  10 . In the graph of  FIG. 8 , sensor sensitivity S has been plotted as a function of the angle θ of incoming light. Curve  80  corresponds to the response of the light sensor structures of  FIG. 7  in the absence of light diffusing structures in region  78 . Curve  82  corresponds to the response of the light sensor structures of  FIG. 7  in the presence of light diffusing structures in region  78 . As the graph of  FIG. 8  demonstrates, curve  80  has a narrower shape than curve  82 . This indicates that sensor directionality is reduced as desired when including a diffuser in opening  22 . 
       FIG. 9  is a cross-sectional side view of opening  22  in a configuration that includes a filter formed from filtering ink and in which opening  22  has been covered with a diffuser. As shown in  FIG. 9 , filtering ink  42 , which may forms a visible-light-blocking and IR-passing filter (e.g., IR ink), a filter that blocks IR light to compensate for the infrared-biased sensitivity S 1  of sensor  56 , or other suitable spectral filter, may be mounted over opening  22  so as to overlap slightly with the edges of opaque masking layer  30 . Adhesive  44  may be used to attach diffuser  46  to filter  42 . Adhesive  44  be a liquid adhesive (e.g., an adhesive material without a substrate) or may be implemented using two-sided adhesive tape such as optically clear adhesive (OCA) tape. Adhesive tape for forming adhesive layer  42  may include a thin polymer substrate. Adhesive material may be formed on both sides of the substrate. The polymer substrate may be formed from a sheet of clear plastic such as polypropylene, polyethylene, polyimide, polyethylene terephthalate (PET), polyester, or other flexible materials. The polymer substrate and/or the adhesive may be formed from translucent material (e.g., material that incorporates additives or bubbles that help scatter light). This allows the adhesive structures to serve as diffuser structures or to assist other diffuser structures in scattering light. 
       FIG. 10  shows how filter and diffuser structures of the type shown in  FIG. 9  may be attached to opening  22 . As shown in  FIG. 10 , a light box such as light box  102  may produce light  100 . Light  100  may travel upwards through cover layer  14 A. In the regions of cover layer  14 A that are covered with opaque masking layer  30 , light  100  is blocked from view by operator  104 . In opening  22 , however, at least some of light  100  may pass through infrared filter layer  42 . Although filter layer  42  may be nominally opaque in the visible spectrum (e.g., in the illustrative arrangement in which filter layer  42  is formed from IR ink), sufficient visible light may pass through filter layer  42  to be viewed by user  104  of the system of  FIG. 10 . 
     Assembly  90  may include a layer of polymer film such as layer  92 . Diffuser  46  may initially be attached to film  92  by releasable adhesive layer  88 . Optically clear adhesive (OCA) tape  44  may be attached to the smooth surface of diffuser  46 . While observing the location of opening  22  by viewing light  100  that has passed through opening  22 , the user may push assembly  90  into opening  22  by pressing tool  84  downwards onto film  92  in direction  86 . This presses adhesive  44  onto ink layer  42 , as indicated by line  106 . Tool  84  may be a flexible polymer rod or other suitable structure that is sufficiently soft to prevent scratches from forming in ink layer  42  when assembly  90  is pressed onto cover layer  14 A. Once adhesive  44  has attached diffuser  46  to layer  42  in opening  22 , tab  96  of film  92  may be peeled upwards in direction  98 , releasing diffuser  46  from adhesive  88  and film  92 . 
     To prevent situations in which film  92  is inadvertently left in place during manufacturing, film  92  may be provided with one or more visual indicators. Visual indicators for film  92  may take the form of patterns (e.g., a dot such as dot  94 ), distinguishable colors or other visually identifiable features. A visual indicator helps make it apparent whether or not film  92  is present on diffuser  46  and layer  14 A. 
     A flow chart of illustrative operations involved in attaching diffuser  46  to cover layer  14 A using an arrangement of the type shown in  FIG. 10  is shown in  FIG. 11 . At step  108 , tool  84  may be used to press assembly  90  onto cover layer  14 A. Once adhesive  44  has been pressed against cover layer  14 A, tab  96  of flexible polymer layer  92  may be pulled upwards to remove layer  92  and adhesive  88  from diffuser  46  (step  110 ). 
     Following step  110 , a user may inspect opening  22  to determine whether layer  92  is still present. If layer  92  has not been properly removed, a visual indicator such as indicator  94  of  FIG. 10  will be visible. As indicated by line  116 , the assembly process may then return to step  110  to remove layer  92  properly. If, however, visual inspection of hole  22  at step  112  reveals that layer  92  has been successfully removed, the technician performing the inspection can conclude that device  10  has passed inspection (line  114 ) and subsequent manufacturing operations may be performed. 
     If desired, filter structures and diffuser structures may be formed using solid filters (e.g., filters formed from solid pieces of plastic, glass, ceramic, etc.), integral filter and diffuser arrangements (e.g., filter-diffuser structures formed using solid pieces of plastic, glass, ceramic, etc.), filter-diffuser or diffuser structures that are molded into place on cover layer  14  (e.g., using liquid precursors that cure or using solid pieces of plastic or other material that can be thermally molded to cover layer  14 ), and/or lens-shaped structures (e.g., stand-alone lenses, integral lens-filter structures, integral lens-diffuser structures, integral lens-filter-diffuser structures, etc.). Arrangements such as these are shown in  FIGS. 12, 13, 14, and 15 . 
     As shown in  FIG. 12 , filter  120  may be attached to cover layer  14 A in opening  22  using adhesive  118 . Diffuser  46  may be attached to filter  120  using adhesive  118 ′. If filter  120  is formed from a sticky material (e.g., optically clear adhesive with filter additives), adhesives such as adhesive  118  and/or adhesive  118 ′ may be omitted. Filter  120  and diffuser  46  may be formed from solid materials such as solid polymers, glass, ceramic, or other suitable materials. 
       FIG. 13  shows how filter structures and diffuser structures may be combined into a single unitary filter-diffuser structure (filter-diffuser  124 ). Filter-diffuser  124  may be formed from solid polymer, glass, ceramic, or other suitable materials. Filter-diffuser  124  may be attached to cover layer  14 A using adhesive  122 . Filter-diffuser may be provided with light filtering capabilities by incorporating dye into filter-diffuser  124 . Light diffusing capabilities may be provided by forming a textured surface (e.g., surface  50 ) on the inner surface of filter-diffuser. 
       FIG. 14  shows how an integral filter-diffuser may be formed from a liquid or moldable polymer or other structure that can be molded into place on cover layer  14 A. As shown in  FIG. 14 , material for filter-diffuser (e.g., a polymer with filter dye) may be pressed against cover layer  14 A in opening  22  using tool  128 . Tool  128  may first press inward in direction  136 . After filter-diffuser  126  has solidified (e.g., by cooling, by chemically curing, by curing through application of ultraviolet light, etc.), tool  128  may be removed in direction  134 . Tool  128  may be formed from a polymer, metal, glass, ceramic, or other material with a textured surface (textured surface  130 ). When removed from filter-diffuser  126  in direction  134 , the texture from surface  130  may be mirrored in the texture of surface  132 . Filter-diffuser  126  of  FIG. 14  may also be provided with diffusing properties by including voids or other light-scattering structures within filter-diffuser  126 . 
     If desired, filter and diffuser structures and stand-alone optical elements associated with opening  22  and sensor  34  may be provided with lens shapes to help concentrate incoming light onto the active portion of sensor  34 . An illustrative optical structure with a lens shape of this type is shown in  FIG. 15 . As shown in  FIG. 15 , optical structure  138  may be provided with a planar upper surface such as surface  140  and a concave lower surface  142  (as an example). The concave shape of lower surface  142  may help focus light onto sensor  34 , as indicated by the trajectory of illustrative light ray  32  of  FIG. 15 . The lens shape of optical structure  138  of  FIG. 15  may be used for a sensor filter (e.g., a visible-light-blocking and infrared-light passing filter), for a light diffuser, for an integral filter-diffuser, or for a stand-alone optical element that is stacked in series with other optical elements in opening  22 . 
     When used as a diffuser or integral filter-diffuser, diffusing properties can be provided by incorporating voids or other light-scattering structures within structure  138  or may be provided by including a texture on one or both surfaces of structure  138 . To preserve the focusing capabilities of structure  138  when a textured surface is used, it may be desirable to form the texture on upper planar surface  140 . This may help avoid situations in which light is scattered from lower surface  142  instead of being focused. When the textured surface is located on the upper surface of structure  138 , any adhesive that is used in attaching the textured surface to cover layer  14 A may be restricted to the periphery of structure  138  (if desired) to help ensure that the presence of the adhesive does not interfere with the light-scattering properties of the textured surface. Structures of the type shown in  FIG. 15  may be attached to cover layer  14 A using one or more layers of adhesive. 
     To avoid saturating sensor  56 , a layer such as layer  42  of  FIG. 3  may be provided that reduces the intensity of incoming light without completely blocking all incoming light present in opening  22 . Visible light intensity may, for example, be reduced in intensity so that only 2% of incoming light in opening  22  passes through layer  42  to sensor  56 . Sensor filter  35 , IR-absorbing material in layer  42 , or other filter structures may similarly be used to reduce infrared light intensity. 
     If desired, the intensity of the light that is received by sensor  56  can be controlled by adjusting the size of opening  22 . For example, the size of opening  22  may be limited to a relatively small size (e.g., to a diameter of less than 1 mm, less than 0.5 mm, less than 0.2 mm, less than 0.1 mm, etc.). Light intensity may also be controlled by forming opening  22  from multiple smaller openings rather than one larger opening. 
     Light intensity control structures that have been implemented by incorporating patterned opening features such as these into opaque masking layer  30  are shown in  FIG. 16 .  FIG. 16  is view of opening  22  along the Z-axis of  FIG. 3 . As shown in  FIG. 16 , window  22  may be implemented by grouping multiple smaller openings  22 ′ together. In the example of  FIG. 16 , there are numerous smaller openings  22 ′ (e.g., perforations) in layer  30  that are organized in a circular cluster to form a circular-shaped window for device  10 . As shown by the dashed line in  FIG. 16 , diffuser  46  may be aligned so as to overlap openings  22 ′. There may be two or more openings  22 ′. Because openings  22 ′ in the example of  FIG. 16  are collectively smaller than the single large opening  22  of  FIG. 3 , less light will pass through the multi-perforation opening  22  of  FIG. 16  than opening  22  of  FIG. 3 . By selection of an appropriate number of openings  22 ′, the amount of light that passes to sensor  56  may be adjusted to avoid sensor saturation. Light intensity may also be controlled by reducing the size of opening  22  of  FIG. 3  (e.g., to form a single smaller-diameter opening such as opening  22 ″ of  FIG. 16 ). 
     Light-intensity control schemes that are based on controlling the aperture of opening  22  (as with illustrative opening  22 ″ of  FIG. 16 ) or that are based on using multiple openings  22 ′ to form window opening  22  (as with illustrative openings  22 ′ of  FIG. 16 ) may be used with or without the use of filter structures such as structure  42  of  FIG. 3 . 
     The foregoing is merely illustrative of the principles of this invention and various modifications can be made by those skilled in the art without departing from the scope and spirit of the invention.

Metadata:
Filing Date: 20101230
Publication Date: 20180213
Grant Date: 20180213
Priority Date: 20101230
Inventors: SHEDLETSKY ANNA-KATRINA
Assignee: APPLE INC
CPC Classifications: [{"code": "G09G2360/144", "inventive": false, "first": false, "tree": "[]"}, {"code": "G02F1/13318", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01J1/0474", "inventive": true, "first": false, "tree": "[]"}, {"code": "G09G3/3406", "inventive": false, "first": false, "tree": "[]"}, {"code": "G09G2320/0626", "inventive": false, "first": false, "tree": "[]"}, {"code": "G01J1/0407", "inventive": true, "first": true, "tree": "[]"}, {"code": "G09G3/3406", "inventive": false, "first": false, "tree": "[]"}, {"code": "G01J1/0407", "inventive": true, "first": true, "tree": "[]"}, {"code": "G09G2320/0626", "inventive": false, "first": false, "tree": "[]"}, {"code": "G02F1/13318", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01J1/0474", "inventive": true, "first": false, "tree": "[]"}, {"code": "G09G2360/144", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 46380623