Methods of adjustment free manufacture of focus free camera modules

摘要

Methods are provided for wafer scale manufacturing camera modules without adjustment components to compensate for assembly errors and optical errors incurred within manufacturing tolerances. Camera modules are assembled in wafer arrays from arrays of image sensors, arrays of lens structures and arrays of optical trim elements. At least one of the arrays is a wafer. Lens structures are configured to provide less optical power than necessary to focus an image at infinity on image sensors without trim elements. A test performed during the wafer scale assembly of camera modules, after at least the sensor array and the lens structure array assembled, determines optical errors by identifying optical distortions and aberrations quantified in terms of optical power, astigmatism, coma, optical axis shift and optical axis reorientation deficiencies. Corresponding trim elements are configured to counteract distortions and aberrations prior to singulating useful camera modules from the array.

主权项

1. A method of wafer scale manufacturing a camera module, said method comprising:
providing an array of image sensors; providing a corresponding array of lens structures; assembling said array of lens structures and said array of image sensors, each lens structure being mounted on a corresponding image sensor; providing an array of configurable optical trim elements, each configurable optical trim element being configured to correct a preset optical power of a corresponding lens structure when said configurable optical trim element is combined with a corresponding lens structure and image sensor assembly, said preset optical power being insufficient to focus an image at infinity on said image sensor assuming minimum manufacturing tolerances; determining optical errors of said assembled lens structure and image sensor array; configuring each said configurable optical trim element corresponding to each said image sensor and lens structure assembly to compensate for said optical errors, said configurable optical trim element correcting said preset optical power of said lens structure to cause said image at infinity to focus on said image sensor when said configurable optical trim element is combined with said corresponding lens structure and image sensor assembly; assembling said array of configurable optical trim elements and said array of lens structure and image sensor assemblies forming an array of camera modules; and singulating said camera module from said camera module array.