Adaptive Lens Module With Corrugated Spring Pressure Element
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Solution Overview
Problem
Existing methods for integrating adaptive lenses into optical sensors face challenges such as inconsistent force distribution, temperature sensitivity, and complex assembly processes, particularly with traditional O-rings and spring-based solutions, which can lead to contact problems and misalignment with the optical axis.
Innovation Solution
A lens module design utilizing a corrugated spring to maintain a consistent force on the adaptive lens within a cylindrical or annular module housing, combined with a multiturn spring for adjustable lens positioning and a flexible connection line for temperature compensation, ensuring secure and precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rubber O-ring is used to hold the adaptive lens, then the lens can be secured in position, but the contact pressure becomes inconsistent due to material tolerances and aging
Solution Approach 1:
The patent replaces the rubber O-ring elastic mechanism with a metallic corrugated spring mechanism. The corrugated spring provides predictable mechanical force through its geometric structure rather than relying on material elasticity, eliminating the need to control rubber cord strength and Shore hardness across tolerances and aging conditions.
Solution Approach 2:
The patent changes the material parameter from elastomeric (O-ring) to metallic (corrugated spring), fundamentally altering the force-generation mechanism. The metallic spring's force characteristics are determined by its geometry and elastic modulus, which are more controllable and stable than rubber material properties across temperature and aging ranges.
2Reliability
If the O-ring is screwed on with a threaded ring to control force, then contact pressure can be adjusted, but the force remains difficult to keep constant over the temperature range
Solution Approach 1:
The patent replaces the threaded ring adjustment mechanism with a pre-loaded corrugated spring system. The spring is pre-compressed during assembly to provide the required contact force, eliminating the need for temperature-compensated adjustment mechanisms and threaded connections that are sensitive to thermal expansion.
Solution Approach 2:
The corrugated spring is pre-compressed during assembly to establish the correct contact force before the device operates. This pre-loading compensates for temperature variations and dimensional changes that would otherwise occur during operation, maintaining stable contact pressure across the temperature range.
3Reliability
If the adaptive lens is mounted with a locking ring to keep the O-ring in position, then the O-ring remains secured, but the force distribution is not even and is still subject to tolerances
Solution Approach 1:
The patent uses the flexible corrugated spring structure to conform to the lens and module housing surfaces, distributing force evenly across the contact interface. The spring's flexible geometry allows it to accommodate minor surface irregularities and maintain uniform pressure distribution without requiring high manufacturing precision.
4Manufacturing precision
If plastic injection molding is used for centering the adaptive lens, then the lens can be aligned with the optical axis, but the lens must be shaped specifically for this attachment method and the size increases in diameter
Solution Approach 1:
The corrugated spring serves multiple functions: it provides the holding force, centers the lens on the optical axis, and compensates for dimensional variations. This eliminates the need for separate centering features like plastic injection molding, allowing the lens housing to maintain a simpler, more universal geometry.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables modular integration of adaptive lenses with standard lenses, reducing assembly complexity and maintaining consistent contact pressure across temperature ranges, while allowing for precise alignment and robustness against shock and vibration.
Implementation Method 1
A pressure element, in particular a corrugated spring, holds the adaptive lens in the module housing by exerting a force on the adaptive lens from above with which the adaptive lens is pressed against the floor
Implementation Method 2
a flexible connection line for temperature compensation
Data Source
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AI summary
A lens module (38) is described, comprising a module housing (42) with a base (44) and a side wall (46), an adaptive lens (40) with variable focal length within the module housing (42), and a pressure element (48) for holding the adaptive lens (40) in the module housing (42). The pressure element includes a wave spring (48).