Aligning Non-Rotational Aperture with Linear Sensor
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Solution Overview
Problem
Existing imaging lens assemblies lack design flexibility to align non-rotationally symmetrical apertures with linear imaging sensors, which limits the optical imaging performance, especially in applications requiring improved signal-to-noise ratio and extended working distances.
Innovation Solution
The implementation of alignment elements, including keying and turning elements, within a part-plastic, part-glass hybrid lens design allows for precise alignment of a non-rotationally symmetrical aperture with a linear imaging sensor, enhancing signal-to-noise ratio and extending the working distance range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a non-rotationally symmetrical aperture is used to improve signal-to-noise ratio and extend working distance, then optical imaging performance is improved, but alignment with the imaging sensor becomes critical and difficult to achieve
Solution Approach 1:
The patent introduces alignment features (protrusions and recesses) as intermediary elements between the aperture and imaging sensor. These features act as mediators that automatically guide and constrain the aperture to the correct position relative to the sensor, eliminating the need for complex manual alignment while maintaining the benefits of non-rotationally symmetrical aperture design.
Solution Approach 2:
The alignment features are pre-configured during manufacturing of the aperture and sensor assemblies. The protrusions and recesses are designed with specific geometries that predetermined the correct alignment orientation, so that when the components are assembled, the alignment is achieved automatically without requiring additional adjustment steps.
2Stability of the object's composition
If glass lenses are used to minimize focal shift over temperature range, then thermal stability is improved, but weight and manufacturing cost increase
Solution Approach 1:
The patent applies different materials to different parts of the lens assembly based on local requirements. Glass lenses are used specifically where thermal stability is critical (in the optical path), while plastic materials are used for the holder and other non-optical components where weight reduction is beneficial. This localized material selection optimizes the overall system by applying heavy, thermally stable materials only where necessary.
Solution Approach 2:
The lens assembly employs a composite construction combining glass optical elements with plastic mounting components. This composite design allows the system to leverage the thermal stability of glass for the critical optical function while using lighter plastic materials for structural support, achieving a balance between thermal performance and weight reduction.
3Ease of manufacture
If plastic lenses are used to reduce weight and simplify manufacture, then ease of manufacture and weight are improved, but thermal stability and focal shift control deteriorate
Solution Approach 1:
The patent applies different materials to different parts of the lens assembly based on local requirements. Glass lenses are used specifically where thermal stability is critical (in the optical path), while plastic materials are used for the holder and other non-optical components where weight reduction is beneficial. This localized material selection optimizes the overall system by applying heavy, thermally stable materials only where necessary.
4Manufacturing precision
If alignment elements are added to the lens assembly to enable precise aperture alignment, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent combines the alignment function with the existing structural components of the lens assembly. The alignment features (protrusions and recesses) are integrated into the aperture and sensor housings rather than being separate adjustment mechanisms. This merging of alignment functionality into existing structural elements achieves precise alignment without significantly increasing overall device complexity.
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 alignment method improves the reliability and responsiveness of the imaging reader by optimizing the optical imaging performance, achieving better thermal stability and ease of manufacture while minimizing weight and cost.
Implementation Method 1
capturing return light scattered and/or reflected from a target being imaged
Implementation Method 2
imaging lens assembly for capturing return light scattered and/or reflected from a target being imaged over a working range of distances, and for projecting the return light onto the imaging sensor
Implementation Method 3
alignment elements on the imaging lens assembly and are operative for aligning the non-rotationally symmetrical aperture with the imaging array
Implementation Method 4
Since glass, as compared to plastic, had a relatively lower coefficient of thermal expansion and a relatively lower refractive index variation over temperature
Data Source
AI summary
An apparatus and method for imaging a target, includes a housing having a presentation area, a solid-state imaging sensor having an imaging array of image sensors looking at a field of view that extends through the presentation area to the target, and an imaging lens assembly for capturing return light over the field of view from the target through the presentation area, and for projecting the captured return light onto the imaging array during imaging of the target. The assembly has a plurality of lenses, an aperture stop, and a holder for holding the lenses and the aperture stop in spaced relation along an optical axis. The aperture stop has a non-rotationally symmetrical aperture through which the optical axis extends. Alignment elements on the imaging lens assembly are used to align the non-rotationally symmetrical aperture with the imaging array.