Apparatus and method for manufacturing positive or negative microlenses

Abstract

A variety of structures and methods used to adjust the shape, radius and/or height of a microlens for a pixel array. The structures affect volume and surface force parameters during microlens formation. Exemplary microlens structures include a microlens frame, base, material, protrusions or a combination thereof to affect the shape, height and/or radius of the microlens. The frame, base and/or protrusions alter the microlens flow resulting from the heating of the microlens during fabrication such that a height or radius of the microlens can be controlled. The radius can be adjusted by the height differences between the microlens and frame. The bigger the difference, the smaller the radius will be.

1 - 64 . (canceled)  
   
   
       65 . A lens frame structure comprising: 
 a plurality of frames configured to receive and interact with a liquid-phase lens material by tension and adhesion force to form a lens shape, each frame comprising: 
 a substantially vertical surface, the substantially vertical surface comprising a substantially flat portion.  
   
   
   
       66 . The lens frame structure of  claim 65 , wherein the substantially vertical surface slopes inwardly from a bottom of the substantially flat portion.  
   
   
       67 . The lens frame structure of  claim 65 , wherein the substantially vertical surface comprises laterally sloping side end portions below the substantially flat portion.  
   
   
       68 . The lens frame structure of  claim 65 , wherein the substantially vertical surface comprises a greater inward protrusion into the space defined by each of the plurality of frames at a first point than another point below the substantially flat portion.  
   
   
       69 . The lens frame structure of  claim 65 , wherein each of the plurality of frames is separated from each other.  
   
   
       70 . The lens frame structure of  claim 65 , further comprising a plurality of protrusions formed within the plurality of frames.  
   
   
       71 . The lens frame structure of  claim 65 , wherein at least one of the plurality of frames comprises a rectangular cavity.  
   
   
       72 . The lens frame structure of  claim 65 , wherein the plurality of frames cause a liquid-phase lens material to transition to a convex shaped solid-phase lens structure after heat processing.  
   
   
       73 . The lens frame structure of  claim 65 , wherein the plurality of frames are configured to cause the liquid-phase lens material to transition to a concave shaped solid-phase lens structure after heat processing.  
   
   
       74 . An image processing system, comprising: 
 a semiconductor substrate;    a plurality of image pixels formed on the semiconductor substrate;    a plurality of lens structures respectively over each of the plurality of image pixels, each of the plurality of lens structures comprising a plurality of lens frames, each of the plurality of lens frames comprising a substantially vertical surface, the substantially vertical surface comprising a substantially flat portion; and    a lens formed within each of the lens frames having a shape at least partially defined by surface adhesion force interaction of a liquid-phase lens material with the frames which solidifies as the lens.    
   
   
       75 . The image processing system of  claim 74 , wherein the plurality of surface interactions further include a plurality of forces exerted against the liquid-phase lens material by a plurality of the substantially vertical surfaces.  
   
   
       76 . The image processing system of  claim 74 , wherein the substantially vertical surface slopes inwardly from a bottom of the substantially flat portion.  
   
   
       77 . The image processing system of  claim 74 , wherein the substantially vertical surface comprises laterally sloping side end portions below the substantially flat portion.  
   
   
       78 . The image processing system of  claim 74 , wherein the substantially vertical surface comprises a greater inward protrusion into the space defined by each of the plurality of lens frames at a first point than another point below the substantially flat portion.  
   
   
       79 . The image processing system of  claim 74 , wherein each of the plurality of lens frames is separated from each other.  
   
   
       80 . The image processing system of  claim 74 , further comprising a plurality of protrusions formed within the plurality of lens frames.  
   
   
       81 . An intermediate lens structure comprising: 
 a planar layer comprising a plurality of protrusions;    a plurality of liquid-phase lens material deposits disposed around the protrusions, whereby the liquid-phase lens material has a shape related to a plurality of surface interactions, a surface tension force and a geometric shape of the plurality of protrusions.    
   
   
       82 . An imager lens structure comprising: 
 a containing structure formed over a pixel, the containing structure including a plurality of sidewalls; and    a lens the comprising a shape defined by an interaction of the containing structure and surface tension force of a liquid phase form of the lens material, the lens having a height dependent on at least one dimension of the sidewalls.    
   
   
       83 . An intermediate lens structure comprising: 
 a plurality of lens frames, each of the plurality of lens frames comprising a substantially vertical surface, the substantially vertical surface comprising a substantially flat portion; and    a plurality of liquid-phase lens material deposits disposed in respective ones of the plurality of lens frames, whereby the liquid-phase lens material has a shape related to a plurality of surface interactions, a surface tension force and a geometric shape of the respective ones of the plurality of lens frames.