Smartphone Camera Advances Made Possible by Mems Cam Technologies February 20131

Smartphone Camera Advances Made Possible by mems|cam Technologies
February 2013
www.doc.com
Abstract
Traditional autofocus camera modules employ voice coil motors to move the lens module along the optical axis of the camera. This technology originally patented in 1874 has reached a point of diminishing returns, where further reduction in size or cost creates unacceptable performance compromises. Mechanical actuators based on silicon MEMS have fundamentally different mechanical and electrical characteristics, as well as the advantage of modern manufacturing processes. This makes them highly suitable for next-generation miniature autofocus cameras, providing greater autofocus speed, dramatically reduced power consumption, and higher precision. The mems|cam module from DigitalOptics now brings these benefits to smartphone cameras.
mems|cam autofocus module
2013 DigitalOptics Corporation Inc. All rights reserved.
Table of Contents
Introduction .................................................................................................................4
The Voice Coil Motor...................................................................................................5
MEMS Actuators ..........................................................................................................7
Characteristics of MEMS AF Cameras ......................................................................8 Faster and More Accurate Focus .......................................................................8 Lower Power Consumption and Cooler Operation .............................................9 Better Precision ................................................................................................10 Smaller Z-Height and XY-Footprint...................................................................11 Better Reliability and Longer Lifetime ...............................................................11 Particle-Free Assembly ....................................................................................11 Simple, Scalable, Solid-State Construction ......................................................12
The MEMS Revolution in Smartphones...................................................................13
MEMS vs. VCM Summary Table ...............................................................................14
Introduction
More than two billion miniature cameras are manufactured annually for the cell phone and tablet markets. Of these, about 40% use autofocus (AF). An AF camera uses an actuator to move one or more lenses along the optical axis, while an algorithm calculates a figure of merit for the image sharpness for that lens location. The focus is then changed accordingly by moving the lens, and a new figure of merit is obtained. By repeating this procedure, the best focus for the scene can be obtained. As the mobile phone has evolved, a very thin form factor has become a paramount design consideration. Compressing an 8-13 MPixel AF camera into a package 5 mm high while still producing high fidelity images is extremely challenging, but it is now a necessity in the modern smartphone. This white paper highlights the speed, power, and performance advantages of replacing the voice coil motor (VCM) with a MEMS actuator. DOCs mems|cam delivers these benefits with MEMS autofocus in smartphone cameras.
The Voice Coil Motor

The incumbent actuator technology for miniature AF cameras is the voice coil motor. VCMs are named as such because they are based on the principles of attraction and repulsion between magnets to generate sound from electricity (see Fig. 1). The technology was first patented in 1874.
Fig. 1: A VCM is the incumbent technology used in a miniature camera to move a lens module and alter focus. The technology, shown in an 1888 patent by Alexander Graham Bell (left), is not fundamentally different from the VCM in a HTC OneX+ smartphone (right).
Operation of a VCM involves passing current through the electromagnet (coil). This creates a magnetic field that is repulsive with respect to the permanent magnets, causing the lens holder to move vertically away from the image sensor. The restoring force is provided by springs. The rest position is infinity focus. It is increasingly apparent that VCMs are compromising the performance of small AF cameras. These effects include: VCMs suffer from hysteresis of stroke, typically around 8%. The resulting variability of position complicates and slows the autofocusing process sufficiently to prevent rapid photography and tracking of focus distance changes during video capture. VCMs consume excessive power, typically more than 100 mW peak. This demand for current drains the battery quickly and generates heat that degrades optical performance and image quality. VCMs suffer from lens tilt and de-centering, typically 0.25 and 50 m, respectively. The requirement for clearance between the lens module holder and the yoke permits this uncontrolled movement, and both tilt and de-centering vary with the orientation of the camera and the focus position. These effects decrease the image fidelity.
The problem becomes more acute as image sensor resolution increases, pixel dimensions decrease, and f-number decreases. VCMs are challenged to serve the demand for thinner handsets with better image quality. Making a VCM smaller requires smaller coils, magnets and springs. Because magnetic force is proportional to volume, smaller coils and magnets require more current to create enough force for actuation, making the power consumption and heat problems worse. Furthermore, smaller springs are weaker, exacerbating hysteresis of stroke, lens tilt, reliability, and de-centering issues. VCM technology is over 100 years old. This means that there are limited opportunities for further cost reduction, thus providing a commercial opportunity for a competing technology that can deliver better performance at a suitable cost.
MEMS Actuators
Silicon MEMS technology is able to integrate all three parts of a linear actuator into a single component. As shown in Fig. 2, these are a stage, to provide vertical movement, a spring to provide the restoring force, and an electrostatic comb drive to displace the stage.
Fig. 2: Silicon stage (left), spring (middle), and electrostatic comb drive (right).
A comb drive is a pair of electrically conductive structures arranged so the interdigitated fingers never touch. When a DC voltage is applied, the resulting electrostatic charge develops an attractive force that causes the combs to be drawn together. By attaching a lens in the center, a silicon MEMS autofocus actuator (Fig. 3) can be created. Using MEMS, the movement of the stage can be precisely controlled. This makes it possible to employ a novel optical configuration where only the first lens is moved, while the remainder of the lens module is locked in an optimal position. Using this approach, excellent image quality is obtained over the entire focus range from 10 cm to infinity, and a number of other important benefits also result.
Fig. 3: A MEMS autofocus actuator holds the lens in the center and moves it along the optical axis when electrostatic charge produces vertical motion in a comb drive.
Characteristics of MEMS AF Cameras

DOCs mems|cam integrates a MEMS actuator and novel optics (Fig. 4) to deliver the benefits discussed below.
Fig. 4: An exploded view of a mems|cam module.
Faster and More Accurate Focus: Consumers complain that miniature AF cameras with the incumbent VCM technology are slow to achieve focus. This prevents capturethe-moment photography. mems|cam modules are two to four times faster than VCM, thus enabling instant autofocus and support for 60 fps continuous focus video. There are several reasons for the dramatic speed advantage offered by mems|cam: 1) Fast settling time: The mems|cam moves a single lens weighing a mere 3.5 mg, but a VCM must move the entire lens module holder, weighing about 45 mg. VCMs must also travel farther, approximately 250 m from infinity to macro, compared to just 80 m for MEMS. The silicon MEMS comb drive system has inherently less oscillation, typically <10 ms, compared to the metal springs and magnets of VCM. 2) Less hysteresis: mems|cam modules can also execute autofocus algorithms faster than VCM-based cameras due to improved positional accuracy and lack of hysteresis. The MEMS AF actuator is extremely accurate, with <1 m of directional hysteresis. A VCM is far less predictable in its location due to directional hysteresis (typically about 10-20 m), temperature dependencies, and coil resistance variation. This necessitates open-loop control with multiple adjustments before the focus is
correct. MEMS by contrast can operate closed-loop and more rapidly execute efficient AF algorithms. 3) Faster Algorithms: DOCs patented FastFaceFocus technology accelerates autofocus when people are in the image by detecting a face and immediately focusing at that distance. This combination of benefits leads to significantly faster autofocus speed. Figure 5 compares measurements of the VCM autofocus of leading smartphones with MEMS autofocus.
1800
Focus Time 10 cm to 1.2 m (ms)
1600 1400 1200 1000 800 600 400 200 0
mems|cam
Fig. 5: Measurements of autofocus speed show mems|cam to be significantly faster than VCM autofocus in four leading smartphones.
Lower Power Consumption and Cooler Operation: One of the main sources of power drain during image capture is operation of the VCM. Peak consumption can be as high as 200 mW, while a MEMS AF actuator, being electrostatically driven, requires only 1 mW. The power is needed only to partially charge or discharge a 200 pF capacitor. The capacitor is an air-gap device and therefore high quality with negligible loss. The camera is the single most power consuming function in current smartphones, so the shift from VCM to MEMS AF directly addresses one of the largest factors in battery life and thermal effects on the image sensor. The excess power consumed by a VCM generates more heat, as shown in the thermal testing results in Fig. 6. Two problems are caused by this elevated temperature:
Image Sensor:
CMOS image sensors suffer from thermally induced problems including reduction in sensitivity, which is often wavelength dependent, an increase in background noise or dark current (doubling with every 6 of temperature increase), and degradation of micro lenses and color filters. Optics: Thermal expansion causes shift in the focal length of the lens module. This means that mechanical stops that set the infinity focus rest position might not always
result in a focused image. Secondary effects include changes in the shape of the lens surfaces and shifts in the refractive indices of lens materials, both of which reduce image fidelity. The net effect is a 5-10% decrease in image quality for every 10 of temperature increase.
Fig. 6: Thermal testing of MEMS vs. VCM autofocus shows a significant temperature difference due to the higher power of VCMs. The measurements were with focus at 35 cm in a 25C ambient environment.
Better Precision: In addition to the image quality benefits of a lower operating temperature, MEMS actuators also help lens tilt, one of the most challenging image quality issues for VCM cameras. VCMs have a typical dynamic tilt of >0.25, causing defocus and a fall-off in image quality. In comparison, the dynamic tilt of MEMS is less than 0.1. The 5X improvement in tilt translates to a 2X better corner image quality and a 3X larger in-focus window. Fig. 7 shows interferometer data of MEMS vs. VCM tilt.
Fig. 7: Interferometer data shows MEMS AF to have 80% less tilt than VCM.
Similarly, de-centering of a VCM, due to the floating action between the two planar springs, can be as much as +/-50 m. This can give rise to vignetting and other optical defects. A MEMS actuator will be centered within +/-0.1 m through its stroke, thus ensuring good optical fidelity throughout the focus range.
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Smaller Z-Height and XY-Footprint: The small size of a MEMS AF actuator allows it to fit inside the lens module. This contrasts with a VCM where the magnets, springs, coils, and housings must be mounted outside the lens module, adding to the XY footprint. Similarly, the reduced lens travel in a MEMS design (moving only the top lens 80 m), allows the Z-height of a MEMS camera to be up to 170 m shorter than comparable VCM designs, since VCMs move the entire lens barrel with 250 m of travel. DOCs proprietary flip chip packaging technology affords further reduction in Z height (Fig. 8). The benefit can vary for specific designs, but a MEMS AF camera will always be smaller than an equivalent VCM AF camera.
Fig. 8: Flip chip packaging enables low z-height camera modules.
Better Reliability and Longer Lifetime: VCM springs are made of metal, which is a malleable material. As a result, the position and stiffness of the spring vary over time and use, and they are subject to fatigue. Even small mechanical or thermal shock loads can permanently change the rest position and the spring rate calibration of the VCM. This in turn leads to changes in lens barrel tilt, centering, and actuator threshold current. All of these variations affect the image quality and the time required to focus. In marked contrast, the actuator at the heart of a mems|cam module uses silicon springs, which are ten times stronger than steel and are not malleable or subject to fatigue. As a result, the mechanical movement of the actuator will be the same after five years of use as it is the day it was made. This leads to stable image quality and consistently high-speed focus. While VCMs are typically rated only for 300,000 cycles, MEMS actuators are rated for up to 10,000,000 cycles. With the shift to video for both making calls and image capture, the increased cycle life reliability is even more important. Particle-Free Assembly: Particles, if present and of sufficient size, can block light from reaching the imager, giving the appearance of defective pixels in the image. By design, a VCM AF camera has to be unsealed since there must be a clearance space between the lens holder and the yoke to allow for movement. This passageway permits particles
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in the air to reach the sensor. In a mems|cam module, only the first lens moves. This permits the static portion of the lens module to be sealed over the imager, preventing particles from reaching the imager. Simple, Scalable, Solid-State Construction: Fig. 9 shows the components of a disassembled VCM. As can be seen, it consists of many mechanical components, including springs, coils, magnets, housings, and guides. Assembling these parts requires many operations, all of which take time, cost money, and contribute to a lack of precision in the final assembly.
Fig. 9: A typical voice coil motor, such as this one from the HTC One X+, requires the assembly many components, including springs, coils, magnets, and carriers.
In comparison, a silicon MEMS actuator suitable for an AF camera requires only two components, the silicon actuator, which includes the integrated stage, springs and comb drive, and a housing (Fig. 10). This considerable reduction in piece parts simplifies assembly and improves reliability. Furthermore, the mechanical elements in a MEMS actuator are defined lithographically using semiconductor wafer processing techniques. This provides an aggressive path to support future cost reduction through wafer diameter increases and continual yield improvement, the cornerstones of progress in semiconductor manufacturing for decades.
Fig. 10: A MEMS autofocus component consists of just two components, a silicon actuator integrating a stage, spring, and comb drives, plus a low-cost housing.
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The MEMS Revolution in Smartphones

MEMS devices have revolutionized smartphones by creating the functionality of formerly stand-alone devices in a miniaturized, low-cost, high-reliability format suitable for mobile handsets. Functions now supported by MEMS include microphones, gyroscopes, accelerometers, pressure sensors, and clocks (Fig. 11). DigitalOptics is now providing mems|cam modules for smartphones, ushering in the next phase of MEMS fast, low-power MEMS AF that lets users catch the moment with their smartphone cameras while easing worries of battery life and image sensor degradation. Table 1 summarizes the many advantages of mems|cam vs. VCM autofocus cameras.
Fig. 11: MEMS components have already enabled many electro-mechanical functions for smartphones. MEMS autofocus is next.
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MEMS
SPEED
VCM
11-50 ms 8% of travel (<20 m) 400 2000 ms 250 m travel
Significance
MEMS is intrinsically faster. Focusing is faster with fewer steps and more precision. Consumers value fast focus so they capture the moment Less distance to travel and less lens mass with L1 motion only allows faster focus. Every milliwatt matters to smartphone designers. A smaller camera allows a smaller phone and/or more functionality. Thin design is an appealing feature for consumers. Higher precision means better image quality, especially with lower F#s. Greater tilt decreases corner image quality. De-centering creates vignetting and optical defects that hurt image quality. Higher reliability means fewer warranty returns, happier users. Higher reliability means consistent lifetime performance.
Settling time Hysteresis Focus time (including settling and hysteresis) Optical travel (macro to infinity)
POWER
<10 ms 3% of travel (<3 m) <300 ms typical 80 m travel
Power
SIZE
1 mW 6.5 x 6.5 mm limited only by sensor 5.35 mm (COB) 5.1 mm (flip chip) 1% of travel (1 m) 0.05 0.1 m
50 200+ mW
XY-footprint (1/3 format) Z-height at macro (DOC8324)

PRECISION
8 x 8 mm iPhone 5 Module: 5.5 mm 4% of travel (10 m) 0.26 50 m
Repeatability Dynamic tilt De-centering

RELIABILITY
Reliability cycles Reliability environmental
Up to 10,000,000 No degradation
300,000 Spring constant (k) degradation
Table 1: MEMS AF provides many advantages over VCMs in terms of speed, power, size, precision, and reliability. The comparison data here is for a 1/3 format camera.
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Smartphone Camera Advances Made Possible by mems|cam Technologies