Array Camera Lens Stack Alignment
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Solution Overview
Problem
Existing array camera technologies face challenges in achieving precise alignment of lens stacks with focal planes due to manufacturing tolerances, leading to variations in focal lengths and suboptimal image capture.
Innovation Solution
The implementation of independently aligned lens stacks within array camera modules, utilizing active alignment processes and ceramic or glass carriers to ensure precise alignment and reduce thermal expansion mismatches, allowing each lens stack to be optimally aligned with its corresponding focal plane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If lens stacks are mounted using conventional manufacturing processes, then production efficiency is maintained, but alignment precision between lens stacks and focal planes deteriorates due to manufacturing tolerances
Solution Approach 1:
The patent applies preliminary action by pre-aligning lens stacks to carriers with precise positioning features before final assembly. The carriers are prepared in advance with precision-machined mounting locations that establish accurate optical alignment, allowing lens stacks to be mounted with correct positioning before the alignment tolerance window closes during assembly.
Solution Approach 2:
The patent replaces conventional mechanical alignment methods with a precision carrier-based positioning system. Instead of relying on manual or post-assembly mechanical adjustment of lens stacks, the system uses precisely manufactured carrier structures with integrated positioning features that mechanically constrain lens stacks to their correct optical positions during mounting.
2Adaptability or versatility
If monolithic sensors with multiple focal planes are used, then device integration is improved, but alignment flexibility and thermal expansion management deteriorate
Solution Approach 1:
The patent applies segmentation by separating the sensor array into multiple independent sensor modules, each with its own focal plane. This allows each sensor module to be independently aligned and mounted on the carrier, providing flexibility to adjust alignment for each focal plane separately while managing thermal expansion independently for each sensor module.
Solution Approach 2:
The patent introduces precision carriers as intermediary components between the sensor modules and the final assembly. These carriers serve as mediators that provide stable mounting surfaces with precise positioning features, enabling accurate alignment of multiple sensor modules while isolating them from thermal expansion issues in the final assembly structure.
3Manufacturing precision
If active alignment processes are implemented, then lens stack alignment precision is improved, but manufacturing complexity and time increase
Solution Approach 1:
The patent reduces active alignment complexity by performing preliminary alignment through precision manufacturing of carrier positioning features. This pre-establishes accurate optical positions for lens stacks, reducing or eliminating the need for complex active alignment processes during final assembly.
Solution Approach 2:
The patent applies self-service by designing self-aligning mounting structures where the precision carrier features automatically guide lens stacks into correct positions during mounting. This self-alignment mechanism eliminates or reduces the need for external active alignment equipment and complex alignment procedures.
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 approach enables high-quality image capture by ensuring each lens stack is accurately aligned with its focal plane, improving image resolution and robustness against thermal variations, and allowing for the synthesis of higher resolution images through super-resolution processes.
Implementation Method 1
a lens stack in each lens barrel directs light through the at least one hole in the at least one carrier and focuses the light onto one of the plurality of focal planes
Implementation Method 2
utilizing active alignment processes and ceramic or glass carriers to ensure precise alignment and reduce thermal expansion mismatches
Data Source
AI summary
Array cameras, and array camera modules incorporating independently aligned lens stacks are disclosed. Processes for manufacturing array camera modules including independently aligned lens stacks can include: forming at least one hole in at least one carrier; mounting the at least one carrier relative to at least one sensor so that light passing through the at least one hole in the at least one carrier is incident on a plurality of focal planes formed by arrays of pixels on the at least one sensor; and independently mounting a plurality of lens barrels to the at least one carrier, so that a lens stack in each lens barrel directs light through the at least one hole in the at least one carrier and focuses the light onto one of the plurality of focal planes.