Patent Document

This application claims priority to European application No. 05014149.8 filed Jun. 30, 2005. 
     FIELD OF THE INVENTION 
     The present invention is in the field of digital color imaging and relates to a color image sensor, a method for its manufacture and a method for color image sensing, according to the preambles of the independent claims. 
     BACKGROUND OF THE INVENTION 
     A digital, solid-state camera comprises imaging optics for imaging a scene onto an image sensor. The image sensor comprises a one- or two-dimensional array of picture elements (pixels) that transduce the incident light into electric signals; it is typically a solid-state device using the charge-coupled device (CCD) or the complementary-metal-oxide-semiconductor (CMOS) technology. The electric signals are read out and processed. 
     For capturing color images, each pixel of the image sensor has to selectively be sensitive only to certain light wavelengths. The wavelength (or color) selectivity is usually achieved by a color filter on top of each pixel. Filters for different colors are distributed in certain patterns on the pixel array. The most common pattern of filters is the Bayer filter pattern which alternates a row of red and green filters with a row of blue and green filters. Seldom, other patterns and/or colors are used. 
     The filters themselves are usually executed as absorption filters. Such an absorption filter is a layer of organic material comprising an organic dye that essentially transmits one color—e.g., red—and absorbs all other colors—e.g., green and blue. The main drawback of absorption filters is their limited lifetime. The organic materials degrade and age. The aging process is speeded up by external influences such as ultraviolet (UV) radiation, high temperature, humidity, etc. Consequently, the quality of a conventional digital camera decreases with time. Further disadvantages of image sensors with absorption filters are the complexity and the expensiveness of their manufacture. In order to manufacture the filters for one color, a corresponding layer is deposited on the chip, a mask defining the pixels for detecting the corresponding color has to be provided, the layer is exposed through the mask, and the superfluous areas of the layer are removed. This procedure has to be performed for each of the at least three colors—e.g., the primary colors red, green and blue. Moreover, the spectral characteristics of the absorption filters are often not precisely defined and difficult to adapt to a desired behavior. 
     Diffractive zero-order filters are known in optics, e.g., from U.S. Pat. No. 4,484,797. They consist of non-absorbing diffractive structures, i.e., phase objects, made of different material layers with different refractive indices. Their typical dimensions (grating periods) are equal to or smaller than the light wavelength. These diffractive filters are mainly used as optically variable security devices in banknotes, credit cards, passports etc. To date, diffractive optics has hardly been used in microelectronics. The technologies are believed to be incompatible, and the dimensions of the diffractive structures are often in the same range or larger than those of the microelectronic device and thus not applicable to it. 
     SUMMARY OF THE INVENTION 
     It is therefore an object of this invention to provide a color image sensor, a method for its manufacturing and a method for color image sensing that avoid the drawbacks of the prior art. In particular, the color image sensor shall be less sensitive to environmental influences. It shall be manufacturable in a simple, cheap process that is preferably compatible with standard semiconductor processes. Moreover, the manufacturing method shall provide a high number of degrees of freedom so that the spectral characteristics of the color filters can be tailored and adapted to fit given demands. 
     These and other problems are solved by the color image sensor, its manufacturing method and the method for color image sensing as defined in the independent claims. Advantageous embodiments of the invention are given in the dependent claims. 
     The basic idea of the invention is to utilize diffractive color filters (DCFs) for the selective spectral filtering of incident electromagnetic radiation. Different zero-order diffractive color filters, e.g., three types of such DCFs, are allocated to the pixels of the color image sensor. 
     The use of DCFs for color imaging devices brings better defined band-pass or notch filters than the presently used lacquers. The DCFs do not include any dyes or color absorbers; therefore they are more stable with respect to time, temperature and any environmental aggression. The manufacture of the DCF pattern is simpler and cheaper than that of a conventional dye-filter pattern, since the different types of DCFs can be manufactured simultaneously. 
     Thus, the color image sensor according to the invention has a plurality of pixels, at least part of the pixels comprising color filters. The color filters comprise zero-order diffractive color filters. 
     In the method for manufacturing the color image sensor according to the invention, an image sensor with a plurality of pixels is manufactured, and at least part of the pixels are provided with color filters. The color filters are realized as zero-order diffractive color filters. 
     The invention also encompasses the use of zero-order diffractive color filters for color image sensing. 
     The inventive method for color image sensing comprising the steps of providing a color image sensor with a plurality of pixels, impinging incident electromagnetic radiation onto the image sensor, and selectively spectrally filtering at least part of the incident electromagnetic radiation. The spectral filtering makes use of zero-order diffraction. 
     Throughout this document, terms such as “light”, “optical” or “color” are not limited to visible light, but also refer to other parts of the electromagnetic spectrum close to the visible light, especially to near ultraviolet (NUV) or near infrared (NIR) radiation. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Embodiments of the invention are described in greater detail hereinafter relative to the attached schematic drawings. 
         FIG. 1  shows two possible patterns of color filters for color image cameras. 
         FIG. 2  shows a cross-section through an embodiment of a color filter according to the invention, and spectra corresponding to three light beams involved. 
         FIG. 3  shows cross-sections of three possible grating profiles of the color filter according to the invention. 
         FIG. 4  shows an example of reflection spectra of three color filters according to the invention. 
         FIG. 5  shows cross sections of photodetector according to the invention during various steps of the manufacturing method. 
     
    
    
     DESCRIPTION OF PREFERRED EMBODIMENTS 
     To date, almost all color imaging cameras use different lacquers as color filters on their pixels. Three filters for different colors are commonly used in various patterns. Two examples of patterns for color image sensors are shown in  FIG. 1 .  FIG. 1(   a ) shows an RGB Bayer pattern with the primary colors red R, green G and blue B. This pattern alternates a row of red and green filters with a row of blue and green filters. The distribution with more green filters than red and blue filters better imitates the sensitivity of the human eye. Instead of adding the different values of red, green and blue, it is possible to subtract values of the typesetting colors cyan C, magenta M and yellow Y. An example of a CMY filter is shown in  FIG. 1(   b ). 
     According to the invention, the color selectivity of the pixels is achieved by means of diffractive color filters (DCF) on top of the pixels. A DCF comprises diffractive gratings and/or structures with different material layers of different refractive indices. These structures act like color filters with respect to reflection and/or transmission. A schematic example of a DCF  1  is shown in the cross section of  FIG. 2(   a ). The DCF  1  is a two- or three-dimensional structure made of at least two essentially transparent materials  11 ,  12  with different refractive indices. The refractive index n low  of a first one  11  of the at least two materials is lower than the refractive index n high  of a second one  12  of the at least two materials. The layers of the DCF  1  may comprise a material or a combination of materials such as epoxy, acrylate, polycarbonate, UV-curable sol-gel material, silicon oxide, carbide, diamond, carbon, carbon derivative, ZnO, ZnS, and/or titanium oxide. The layers of the DCF  1  may also comprise inorganic materials filled with inorganic nanoparticles. 
     Low-index materials  11  may be, e.g., a polymer (n low =1.34−1.65), SiO 2  (n low ≈1.46) or MgF 2  (n low ≈1.39); the indices of refraction are data for a wavelength of 550 nm. The low-index material  11  may also be a porous aerogel (n low  close to 1.0). The index of refraction of sol-gel processed silica aerogel as described by Tsutsui et. al. (“Doubling Coupling-Out Efficiency in Organic Light-Emitting Devices Using a Thin Silica Aerogel Layer”, Adv. Mater. 13, 2001, p. 1149-1152) is between 1.01 and 1.10. The low-index material  11  forms a layer on top of a pixel of the solid-state image sensor. 
     In the low-index layer  11 , a structure of high-index material  12  is embedded, that acts as subwavelength waveguide. The high-index material  12  may be, e.g., ZnS (n high ≈2.38), TiO 2  (n high ≈2.1−2.5), Ta 2 O 5  (n high ≈2.1−2.3) or Si 3 N 4  (n high ≈2.03). The high-index structure is inhomogeneous in at least one direction of a plane defined by the pixel surface. In the example of  FIG. 2 , the high-index structure comprises a ruled grating. The ruled grating is essentially a two-dimensional structure. A plurality of such gratings can be arranged one above the other within the low-index layer  11 , thus making a three-dimensional DCF. If the low-index material  11  has an index of refraction well below 1.5, the high-index material  12  can even be a layer with index of refraction of about 1.5, e.g. a polymer layer. The important parameter is the refractive-index difference between the high index n high  and the low index n low . A wet-process-able class of high-index materials  12  are nano-sized particles of a high-index material embedded in a polymeric matrix. An example are mixtures of PbS nano-particle and gelatine that have indices of refraction of up to 2.5 (Zimmermann et. al. J. Mater. Res., Vol. 8, No. 7, 1993, 1742-1748). Mixtures containing Al 2 O 3 , ZrO 2  or TiO 2  particles are also possible. 
     When light  90  impinges onto the DCF  1  with a certain angle of incidence θ in , a first portion  91  of the light  90  is reflected and a second portion  92  is transmitted through the DCF  1 . Since the DCF  1  is a zero-order filter, the direction of propagation of the second, transmitted portion  92  is the same as that of the incident light  90 .  FIGS. 2(   b )-( d ) schematically show intensity spectra, i.e., intensity versus wavelength, of the incident light  90  and the two portions  91 ,  92 , respectively. It is assumed that the incident light  90  is white, i.e., all visible wavelengths are present with equal intensities ( FIG. 2(   b )). The DCF  1  of this example reflects blue light, i.e., the spectrum of the first light portion  91  ( FIG. 2(   c )) has a peak around the wavelength λ≈460 nm. The spectrum of the second light portion  92  ( FIG. 2(   d )) is complementary to that of the first light portion  91  and shows a notch around the wavelength λ≈460 nm. The transmitted light  92  is thus yellow, the complementary color of blue. In other words: the DCF  1  of  FIG. 2  is a blue band-pass filter in reflection and a yellow notch filter in transmission. 
     The diffractive structure profile can by made of gratings with various types of profiles.  FIG. 3  shows some examples of many possible grating profiles. The profile of  FIG. 3(   a ) is a simple square profile. The multiple square profile of  FIG. 3(   b ) is formed by arranging a plurality of profiles such as shown in  FIG. 3(   a ) one above the other.  FIG. 3(   c ) shows a multiple sinus profile, and  FIG. 3(   d ) a multiple triangular or sawtooth profile. The profile shapes have no restrictions about the symmetry, i.e., the profile shape need not be symmetric: the triangular profile can be blazed, or one side can be longer Further optical elements can be arranged beneath and/or above the DCF structure according to the invention. Such further optical elements may comprise as a thin layer or a stack of thin dielectric layers acting as a dielectric filter, metal layers, absorbing layers, diffractive elements, etc. They further may comprise a high-index layer acting as a waveguide, with a thickness between 10 nm and 1000 nm, and preferably between 50 nm and 500 nm, and with a refractive index that is at least by 0.2 higher than the refractive index of the surrounding material. Other appropriate means such as specialized camera optics, microlenses or additional grating structures may also be arranged on top of the DCF. 
     An appropriate choice of the DCF parameters will define the filter properties of the corresponding color band pass filter or notch filter. An important variable parameter, which essentially influences the spectral characteristics of the DCF, is the grating period. Other variable parameters are the grating depth, the grating profile, the height of the high-index layer, the refractive indices, the number of high-index/low-index transitions and/or the spacing between the high-index layers. 
     The DCFs according to the invention have periods that are approximately equal to or smaller than the wavelength of the light to be detected by the pixel. Typical grating periods are between 50 nm and 1000 nm, and preferably between 100 nm and 800 nm. The grating depth (of one layer) is between a few nanometers to a few micrometers, e.g., between 10 nm and 1000 nm, and preferably between 50 nm and 300 nm. The difference n 2 −n 1  of the refractive indices of the high-index material (waveguide material)  12  and the low-index material  11  should, but must not necessarily, be high, e.g., higher than 0.2 and preferably higher than 0.4. The number of layers has no upper limit. Distances between two high-index layers of less than a few (approximately 2 or 3) micrometers will produce a coupling effect between the different DCF layers; more than a few micrometers will decouple them. Both effects can be used for the DCFs. 
     Examples of calculated transmission spectra for three different DCFs are shown in  FIG. 4 . The three filters were designed to transmit the typesetting colors cyan, magenta and yellow. The calculations were performed for one square-shaped grating structure with one layer of high-index material (waveguide material)  12 . The parameters used in the calculation and some resulting characteristics are listed in Table I. Already with this simple model, very effective DCFs with the desired transmission characteristics were obtained. By entering further DCF parameters into the calculation, e.g., multiple high-index layers, the design can even more specifically fit a given need. 
     
       
         
               
               
               
               
             
           
               
                 TABLE I 
               
               
                   
               
               
                   
                 FIG. 4(a) 
                 FIG. 4(b) 
                 FIG. 4(c) 
               
               
                   
               
             
             
               
                 Grating period 
                 360 nm 
                 300 nm 
                 250 nm 
               
               
                 Grating depth 
                 100 nm 
                  70 nm 
                  70 nm 
               
               
                 Grating profile 
                 square 
                 square 
                 square 
               
               
                 Height of the high-index 
                  70 nm 
                  70 nm 
                  70 nm 
               
               
                 layer 
               
               
                 Refractive-index difference 
                 0.8 
                 0.8 
                 0.8 
               
               
                 Number of high-index layers 
                 1 
                 1 
                 1 
               
               
                 Transmitted center wavelength 
                 628 nm 
                 545 nm 
                 470 nm 
               
               
                 Transmitted color 
                 cyan 
                 magenta 
                 yellow 
               
               
                   
               
             
          
         
       
     
     The lateral dimensions of a pixel and thus of the DCF may be a further parameter that influences the reflectivity and/or transmissivity characteristics of the DCF, especially when these dimensions are in the range of approximately twenty times the grating period or smaller. Of course, the pixels and DCFs need not have a square shape, as those of  FIG. 1 . Alternatively, they may be of rectangular, hexagonal or any other appropriate shape. 
     It is true that DCFs  1  as shown in  FIGS. 2 and 3  have a spectral characteristic that depends on the azimuthal angle of the incident light  90 . This undesired effect can be eliminated or reduced by choosing other diffractive structures than ruled gratings, e.g., circular gratings or two perpendicular ruled gratings, or by other measures. 
     It is also true that the transmissivity of the DCFs  1  as shown in  FIGS. 2 and 3  depends on the angle of incidence θ in  of the incident light  90 . This undesired dependence can be reduced, e.g., by depositing a high-index layer on top of the DCF. 
     The large number of degrees of freedom of the DCFs according to the invention opens a wide range of possibilities to design the properties of the DCFs. Consequently, many problems can be avoided, minimized or reduced by choosing an appropriate DCF design. 
     For the fabrication of the DCF according to the invention, only two essential steps are necessary: a replication step and a deposition step. Standard replication and evaporation processes can be used. For the replication, a specific master is needed. The master has the desired DCF pattern with the three grating periods and the profiles and depths which are necessary to obtain the specific color of the DCF. Any nano imprint process can be used for the replication process, such as nanolithography, UV casting or UV embossing. It is also possible to directly etch the grating into the semiconductor detector material by means of standard photolithography. For the deposition step, thermal evaporation and/or spin coating from the liquid phase can be used. The high-index material (waveguide material) can be deposited by an evaporation process in one step, provided that all the three DCFs need the same high-index-layer thickness. Multi-step evaporations with shadow mask are also possible, but more complicated. Depending on the materials used and the thickness required, spin coating of the materials on the wafer is also possible for the deposition of the dielectric layers. 
     The basic production steps are described in  FIG. 5 . An image sensor  2  with a plurality of pixels  21 , typically arranged in a one- or two-dimensional array, is provided. The low-index material  11 , e.g., in the form of a sol-gel, is spread over the image sensor  2  ( FIG. 5(   a )). A complex grating master  3  is used to replicate the grating structure on the image sensor  2 . The grating master  3  is aligned with the image sensor  2  with the aid of a microscope  5  ( FIG. 5(   b )); the alignment is indicated by two arrows  51 ,  52 . By using UV embossing, only selected regions of the image sensor  2  can be covered with the grating structures. For this purpose, the master  3  additionally comprises a mask  4  with transparent areas  41  and opaque areas  42 . The low-index material  11  is exposed to UV radiation  6  through the mask  4  ( FIG. 5(   c )). After an appropriate exposure time, the mask  4  is lifted up, and the superfluous low-index material (in this example, the shaded areas) is removed ( FIG. 5(   d )). Consequently, replicated grating structures  13 , which may differ from each other, remain on the light-sensitive areas of the pixels  21 . Once the grating is replicated, techniques such as thermal evaporation or spin coating are used to deposit the high-index material  12  on top of the grating structures  13  ( FIG. 5(   e )). On top of the high-index layer, low-index material and further layers can be deposited in order to obtain three-dimensional structures such as shown in  FIG. 3 , and/or to form multi-layered dielectric filters or waveguides. The alternate deposition of high-index material  12  and low-index material  11  can be repeated once or several times in order to obtain three-dimensional DCFs  1  as shown in  FIGS. 3(   b )-( d ). 
     This invention is not limited to the preferred embodiments described above, to which variations and improvements may be made, without departing from the scope of protection of the present patent. 
     
       
         
               
             
               
               
               
             
           
               
                   
               
               
                 LIST OF REFERENCE SIGNS 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                   
                  1 
                 Diffractive color filter 
               
               
                   
                 11 
                 Low-index material 
               
               
                   
                 12 
                 High-index material 
               
               
                   
                 13 
                 Replicated grating structure 
               
               
                   
                  2 
                 Image sensor 
               
               
                   
                 21 
                 Pixels 
               
               
                   
                  3 
                 Grating master 
               
               
                   
                  4 
                 Mask 
               
               
                   
                 41 
                 Transparent mask areas 
               
               
                   
                 42 
                 Opaque mask areas 
               
               
                   
                  5 
                 Microscope 
               
               
                   
                 51, 52 
                 Alignment directions 
               
               
                   
                  6 
                 UV radiation 
               
               
                   
                 90 
                 Incident radiation 
               
               
                   
                 91 
                 Reflected radiation 
               
               
                   
                 92 
                 Transmitted radiation

Technology Category: h