Sensor device having an integral lens

• US 20040130789A1
• Filed: 12/18/2003
• Published: 07/08/2004
• Est. Priority Date: 01/25/1999
• Status: Abandoned Application

• Current Assignee: Harold C. Ockerse, John K. Roberts, Jon H. Bechtel, Joseph S. Stam
• Original Assignee: Harold C. Ockerse, John K. Roberts, Jon H. Bechtel, Joseph S. Stam
• Inventors: Roberts, John K., Stam, Joseph S., Bechtel, Jon H., Ockerse, Harold C.
• Application Number:
  US10/740,282
• Publication Number:
  US 20040130789A1
• Time in Patent Office: Days
• US Class Current: 359/604
• CPC Class Codes: B60R 1/088 using a cell of electrically changeable optical characteristic, e.g. liquid-crystal or electrochromic mirrors
• CPC Class Codes: G01J 1/0266 Field-of-view determination; Aiming or pointing of a photometer; Adjusting alignment; Encoding angular position; Size of the measurement area; Position tracking; Photodetection involving different fields of view for a single detector
• CPC Class Codes: G01J 1/0271 Housings; Attachments or accessories for photometers
• CPC Class Codes: G01J 1/04 Optical or mechanical part supplementary adjustable parts
• CPC Class Codes: G01J 1/0411 using focussing or collimating elements, i.e. lenses or mirrors; Aberration correction
• CPC Class Codes: G01J 1/42 using electric radiation detectors optical or mechanical part G01J1/04; by comparison with a reference light or electric value G01J1/10
• CPC Class Codes: G01J 1/46 using a capacitor
• CPC Class Codes: G02B 19/0028 refractive and reflective surfaces, e.g. non-imaging catadioptric systems
• CPC Class Codes: G02B 19/0076 for use with a detector G02B19/009, G02B19/0095 take precedence
• CPC Class Codes: G02B 5/021 the diffusion taking place at the element's surface, e.g. by means of surface roughening or microprismatic structures
• CPC Class Codes: G02B 5/0215 the surface having a regular structure
• CPC Class Codes: G02B 5/0221 the surface having an irregular structure G02B5/0226 takes precedence
• CPC Class Codes: G02B 5/0242 by means of dispersed particles
• CPC Class Codes: G02B 5/0278 used in transmission
• CPC Class Codes: H01L 2224/48091 Arched
• CPC Class Codes: H01L 2224/48247 connecting the wire to a bond pad of the item
• CPC Class Codes: H01L 2924/00014 the subject-matter covered by the group, the symbol of which is combined with the symbol of this group, being disclosed without further technical details

Abstract

The inventive sensor device includes a support structure, a sensing element mounted on the support substrate for sensing optical radiation and generating an electrical output signal in response thereto, and an encapsulant encapsulating the sensing element on the support structure. The encapsulant includes an integral lens. Alternatively or additionally, the encapsulant may have at least a first zone and a second zone, where the second zone exhibits at least one different characteristic from the first zone, such as a different optical, physical, thermal, or compositional characteristic. In addition, the encapsulant may include an integral diffuser. Further, the sensing element may have an active sensing area of less than 1 mm², and may be positioned closer to the surface of the integral lens than a distance corresponding to a focal length of the integral lens.

Claims

1. A sensor device comprising:

a support structure;

a sensing element mounted on said support structure for sensing optical radiation and generating an electrical output in response thereto; and

an encapsulant encapsulating said sensing element on said support structure, said encapsulant including an integral lens for directing incident optical radiation toward said sensing element,

wherein said sensing element has an active sensing area of less than 1 mm².

2. The sensor device of claim 1, wherein said lens has different focal lengths for transverse directions.

3. The sensor device of claim 1, wherein said lens is anamorphic.

4. The sensor device of claim 1, wherein said support structure is a lead frame having at least first and second electrical leads electrically coupled to said sensing element.

5. The sensor device of claim 4, wherein said sensing element is mounted on one of said first and second electrical leads.

6. The sensor device of claim 5 and further including a wire bond extending from one of said first and second electrical leads to said sensing element.

7. The sensor device of claim 1, wherein a sensing area of said sensing element is positioned closer to the surface of said integral lens than a distance corresponding to a focal length of said integral lens.

8. A discrete sensor device comprising:

a support structure;

a sensing element mounted on said support structure for sensing optical radiation and generating an electrical output in response thereto; and

an encapsulant encapsulating said sensing element on said support structure, said encapsulant including an integral lens for directing incident optical radiation toward said sensing element, said encapsulant further including an integral diffuser.

9. The discrete sensor device of claim 8, wherein said integral diffuser comprises a diffusant dispersed throughout at least a portion of said encapsulant.

10. The discrete sensor device of claim 8, wherein said diffuser comprises textured surface of at least a portion of said integral lens.

11. The discrete sensor device of claim 8, wherein said support structure is a lead frame having at least first and second electrical leads electrically coupled to said sensing element.

12. The discrete sensor device of claim 11, wherein said sensing element is mounted on one of said first and second electrical leads.

13. The discrete sensor device of claim 12 and further including a wire bond extending from one of said first and second electrical leads to said sensing element.

14. The discrete sensor device of claim 8, wherein said sensing element has an active sensing area less than 1 mm².

15. A vehicle accessory for mounting in a vehicle, said vehicle accessory comprising:

a discrete sensor device comprising;

a support structure;

a sensing element mounted on said support structure for sensing optical radiation and generating an electrical output in response thereto; and

an encapsulant encapsulating said sensing element on said support structure, said encapsulant including an integral lens for directing incident optical radiation toward said sensing element, said encapsulant further including an integral diffuser.

16. The vehicle accessory of claim 15, wherein the vehicle accessory is a rearview mirror assembly, and wherein said discrete sensor device is included in said rearview mirror assembly.

17. The vehicle accessory of claim 16, wherein the rearview mirror assembly comprises an electrochromic mirror element.

18. The vehicle accessory of claim 17 and further comprising a processing circuit coupled to said discrete sensor device for controlling said electrochromic mirror element in response to light levels sensed by said sensing element.

19. The vehicle accessory of claim 18, wherein said discrete sensor device is aimed forward of the vehicle for sensing ambient light levels.

20. The vehicle accessory of claim 18, wherein said discrete sensor device is aimed rearward of the vehicle for sensing glare.

21. The vehicle accessory of claim 18 and further comprising a second discrete sensor device for sensing light levels from sources in a different field of view from the first discrete sensor device.

22. The vehicle accessory of claim 21, wherein said second discrete sensor device comprises:

a support structure;

a sensing element mounted on the support structure for sensing optical radiation and generating an electrical output in response thereto; and

an encapsulant encapsulating said sensing element on said support structure, said encapsulant including an integral lens, said encapsulant further including an integral diffuser.

23. The vehicle accessory of claim 18, wherein said processing circuit is further configured to generate light control signals to control at least one vehicle light in response to light levels sensed by said sensing element.

24. The vehicle accessory of claim 16 and further comprising a processing circuit coupled to said discrete sensor device for generating light control signals to control at least one vehicle light in response to light levels sensed by said sensing element.

25. The vehicle accessory of claim 15 and further comprising a processing circuit coupled to said discrete sensor device for generating light control signals to control at least one vehicle light in response to light levels sensed by said sensing element.

26. The vehicle accessory of claim 25, wherein said at least one vehicle light includes vehicle headlamps and said processing circuit controls the on/off state of the vehicle headlamps.

27. The vehicle accessory of claim 25, wherein said at least one vehicle light includes interior vehicle lights.

28. The vehicle accessory of claim 15 and further comprising a processing circuit coupled to said discrete sensor device for generating windshield wiper control signals to control windshield wipers of the vehicle in response to light levels sensed by said sensing element.

29. The vehicle accessory of claim 15 and further comprising a processing circuit coupled to said discrete sensor device for generating climate control signals to control a climate control system of the vehicle in response to light levels sensed by said sensing element.

30. The vehicle accessory of claim 29, wherein said discrete sensor device is positioned to sense sun loading on the vehicle.

31. The vehicle accessory of claim 15, wherein said sensing element has an active sensing area of less than 1 mm².

32. A discrete sensor device comprising:

a support structure;

a sensing element mounted on said support structure for sensing optical radiation and generating an electrical output in response thereto; and

an encapsulant encapsulating said sensing element on said support structure, said encapsulant including an integral lens for directing incident optical radiation toward said sensing element,

wherein a sensing area of said sensing element is positioned closer to the surface of said integral lens than a distance corresponding to a focal length of said integral lens.

33. The discrete sensor device of claim 32, wherein said sensing element has an active sensing area less than 1 mm².

34. The discrete sensor device of claim 32, wherein said encapsulant includes an integral diffuser.

35. The discrete sensor device of claim 34, wherein said integral diffuser comprises a diffusant dispersed throughout at least a portion of said encapsulant.

36. The discrete sensor device of claim 34, wherein said diffuser comprises textured surface of at least a portion of said integral lens.

37. The discrete sensor device of claim 32, wherein said support structure is a lead frame having at least first and second electrical leads electrically coupled to said sensing element.

38. The discrete sensor device of claim 37, wherein said sensing element is mounted on one of said first and second electrical leads.

39. The discrete sensor device of claim 38 and further including a wire bond extending from one of said first and second electrical leads to said sensing element.

40. A sensor device comprising:

a support structure;

a sensing element mounted on said support structure for sensing optical radiation and generating an electrical output in response thereto; and

an integral encapsulant configured to encapsulate said sensing element on said support structure, said encapsulant having at least a first zone and a second zone, the second zone exhibiting at least one different characteristic from the first zone.

41. The sensor device of claim 40, wherein said at least one different characteristic is a physical characteristic.

42. The sensor device of claim 40, wherein said at least one different characteristic is an optical characteristic.

43. The sensor device of claim 42, wherein said at least one different optical characteristic is transparency.

44. The sensor device of claim 42, wherein said at least one different optical characteristic is diffusivity.

45. The sensor device of claim 40, wherein said at least one different characteristic is a thermal characteristic.

46. The sensor device of claim 40, wherein said at least one different characteristic is a structural characteristic.

47. The sensor device of claim 46, wherein said at least one different characteristic includes at least one of tensile strength and compression strength.

48. The sensor device of claim 40, wherein said at least one different characteristic is a compositional characteristic.

49. The sensor device of claim 40, wherein the at least one different characteristic includes at least one of the following:

mechanical strength, thermal conductivity, thermal capacity, specific heat, coefficient of thermal expansion, adhesion, oxygen impermeability, moisture impermeability, and transmittance for radiation emitted from said radiation emitter.

50. The sensor device of claim 40, wherein a region of said first zone of said encapsulant is configured to function as a lens.

51. The sensor device of claim 40, wherein said second zone of said encapsulant is configured to retain electrical leads of said support structure.

52. The sensor device of claim 40, wherein said first zone of said encapsulant is optically transparent and extends from said sensing element to a light input surface of said encapsulant.

53. The sensor device of claim 40, wherein said second zone has a lower thermal resistance than said first zone.

54. The sensor device of claim 40, wherein said second zone has a higher thermal capacity than said first zone.

55. The sensor device of claim 40, wherein said second zone has a greater mechanical strength than said first zone.

56. The sensor device of claim 40, wherein said second zone has a lower coefficient of thermal expansion than said first zone.

57. The sensor device of claim 40, wherein said second zone has a greater adhesion strength than said first zone.

58. The sensor device of claim 40, wherein said second zone has lower oxygen permeability than said first zone.

59. The sensor device of claim 40, wherein said second zone has lower moisture permeability than said first zone.

60. The sensor device of claim 40, wherein said encapsulant includes an integral anamorphic lens for directing incident optical radiation toward said sensing element.

61. The sensor device of claim 40, wherein said sensing element has an active sensing area of less than 1 mm².