Large area flat image sensor assembly

1. A low temperature method for producing a substantially flat large area image sensor assembly, the method comprising the steps of:

(a) providing a die attach substrate having a substantially planar surface;

(b) providing a lead frame having a bonding surface and a plurality of leads extending there from;

(c) adhering an imager die to the substantially planar surface of the die attach substrate with a low curing temperature first adhesive wherein step (c) further comprises the steps in any order:

(c1) dispensing said first adhesive onto the die attach substrate in a desired pattern;

(c2) placing said die attach substrate with first adhesive pattern into the substrate recess of a first plate of a die attach fixture;

(c3) placing the imager die into the imager die recess of a second plate of the die attach fixture while applying vacuum through a vacuum port in said second plate; and

wherein, after steps (c1) through (c3), step (c) further comprises in sequential order the steps of:

(c4) bringing the second plate towards the first plate of the die attach fixture to provide an even force distribution over the entire imager surface;

(c5) pressing the first and second plate at constant pressure for a period of time; and

(c6) removing the pressure, the vacuum and the die attach substrate with adhered imager die for curing; and

(d) adhering the die attach substrate with adhered imager die to a bonding surface of the lead frame with a low curing temperature second adhesive for producing an image sensor assembly.

2. The method as in claim 1 , wherein step (c) includes the step of curing the adhesive at room temperature.

3. The method as in claim 1 , wherein step (b) includes providing a substantially rectangular shaped lead frame.

4. The method as in claim 1 wherein said imager die has an active surface dimensions of substantially 20 by 20 mm or greater and a deviation from flatness of the active imager surface of less than substantially 15 microns.

5. The method as in claim 1 wherein said imager die has an active surface dimensions of substantially 35 by 35 mm or greater and a deviation from flatness of the active imager surface of less than substantially 10 microns.

6. The method as in claim 1 further comprising providing an alignment mechanism for precisely positioning the imager die with respect to the substrate.

7. The method as in claim 1 , wherein said die attach substrate is composed of aluminum nitride.

8. The method as in claim 1 , wherein said die attach substrate is double side lap polished to maintain a surface flatness of less than 2 microns total indicated run-out.

9. The method as in claim 1 wherein the adhesive contains beads to provide a uniform first adhesive layer thickness as the die is pressed against the die attach substrate.

10. The method as in claim 1 wherein a z height of the bonded imager die varies by less than 15 microns with respect to the second surface of the die attach substrate.

11. The method as in claim 1 , wherein step (c) includes the step of curing the first adhesive at room temperature.

12. The method as in claim 1 , wherein step (b) includes providing a substantially rectangular shaped lead frame.

13. The method as in claim 1 wherein said imager die has an active surface dimensions of substantially 20 by 20 mm or greater and a deviation from flatness of the active imager surface of less than substantially 15 microns.

14. The method as in claim 1 wherein said imager die has an active surface dimensions of substantially 35 by 35 mm or greater and a deviation from flatness of the active imager surface of less than substantially 10 microns.

15. The method as in claim 1 further comprising providing an alignment mechanism for precisely positioning the imager die with respect to the substrate.

16. The method as in claim 1 , wherein said die attach substrate is composed of aluminum nitride.

17. The method as in claim 1 wherein said die attach substrate is double side lap polished to maintain a surface flatness of less than 2 microns total indicated run-out.

18. The method as in claim 1 wherein the adhesive contains beads to provide a uniform first adhesive layer thickness as the die is pressed against the die attach substrate.

19. The method as in claim 1 wherein a z height of the bonded imager die varies by less than 15 microns with respect to the second surface of the die attach substrate.