Barrel-Free Lens Structure for Precise Optical Axis Alignment
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Solution Overview
Problem
Existing lens structures with lens barrels face challenges in precision, yield, and size/weight due to manufacturing tolerances, thermal expansion, and the need for plastic injection molding, which increases costs and limits thinness and accuracy.
Innovation Solution
A lens structure without a lens barrel, where lenses and spacers are directly assembled, eliminating the need for a barrel and allowing for precise alignment and reduced weight and size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a lens barrel is used to install and align lenses, then the optical axes of the lenses can be arranged in alignment, but the manufacturing tolerances and assembly tolerances of the lens barrel and lenses lead to a reduction in the yield of high-precision lens structures
Solution Approach 1:
The patent removes the lens barrel from the optical system, extracting the harmful element that causes tolerance accumulation. The lenses are directly mounted on the circuit board without an intermediate barrel structure, eliminating the multiple interfaces (lens-to-barrel, barrel-to-board) that generate assembly tolerances and reduce yield.
Solution Approach 2:
The patent merges the lens mounting function directly with the circuit board structure. The circuit board serves both as the electrical connection substrate and as the mechanical support for lens alignment, eliminating the separate lens barrel component and reducing the number of assembly steps and tolerance sources.
2Ease of manufacture
If a lens barrel is manufactured by plastic injection molding, then the lens structure can be assembled, but the cost of lens production increases due to the requirement of molds
Solution Approach 1:
The patent extracts and removes the lens barrel component entirely from the assembly. By eliminating this dedicated molding component, the need for separate molds for the barrel is removed, reducing tooling costs and simplifying the manufacturing process while maintaining lens assembly capability through direct mounting.
Solution Approach 2:
The circuit board is given a dual function: it serves as both the electrical connection substrate and the mechanical support structure for lens mounting. This multi-functionality eliminates the need for a separate lens barrel component, reducing the number of parts and molds required, thereby lowering production costs.
3Volume of moving object
If the thickness of the lens barrel is reduced to save internal space, then the size of the lens structure is reduced, but the accuracy of lens assembly is affected
Solution Approach 1:
By removing the lens barrel entirely, the patent eliminates the thickness constraint that limited the optical system's internal space. The lenses are mounted directly on the circuit board, allowing for more flexible spatial arrangement and thinner overall profile while maintaining assembly accuracy through direct bonding and precise positioning features on the board.
4Ease of operation
If a lens barrel is provided to support lenses, then the lenses can be installed and aligned, but the weight and size of the overall lens structure increase
Solution Approach 1:
The patent extracts and removes the lens barrel, the heavy metal or plastic support structure, from the optical system. The lenses are directly mounted on the lightweight circuit board, significantly reducing the overall weight while maintaining installation and alignment capabilities through integrated mounting features and adhesive bonding.
Data Source
AI summary
A lens structure includes a first lens, a second lens and a first spacer. The first lens includes a first surface, a second surface opposite to the first surface and a first outer circumferential surface connecting the first surface and the second surface. The second lens includes a third surface, a fourth surface opposite to the third surface and a second outer circumferential surface connecting the third surface and the fourth surface. The first spacer is annular and includes a first end surface and a second end surface. The first end surface is connected to the first surface, and the second end surface is connected to the second surface, whereby the first lens is connected to the second lens through the first spacer.