Camera Assembly Using Laser Welding and Retainer Alignment
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Solution Overview
Problem
Existing camera assembly methods, such as gluing and screwing, face issues with alignment maintenance, viscosity variations, gas emission, and screw loosening, which affect the precision and durability of the camera's optical alignment.
Innovation Solution
Laser welding is used to fix the camera's lens and sensor in place, with retainers providing resilient forces to maintain alignment during the welding process, allowing for quick and durable assembly without material addition or contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If gluing is used to fix the lens and sensor, then the alignment is preserved without destruction, but the glue viscosity varies between batches and the glue may creep
Solution Approach 1:
The patent replaces the chemical bonding mechanism of gluing with a mechanical fixing mechanism using a retainer component. The retainer uses elastic deformation and mechanical interference to secure the lens and sensor in position, eliminating the reliability issues associated with glue viscosity variation and creep while maintaining precise alignment through mechanical constraints.
Solution Approach 2:
The patent changes the fixing mechanism from chemical (glue) to mechanical (retainer with elastic properties). The retainer's elastic modulus and geometric parameters are optimized to provide sufficient holding force while maintaining alignment precision, transforming the fixation approach from material-dependent to structure-dependent.
2Strength
If screwing is used to fix the components, then the parts are securely connected, but the components may move during screwing and screws may loosen with time
Solution Approach 1:
The patent replaces the threaded mechanical connection with a snap-fit retainer mechanism that uses elastic deformation and interference fit. This eliminates the need for screws that can loosen over time while maintaining strong connection through continuous elastic force, and prevents component movement during assembly since the retainer engages in a single deterministic motion.
Solution Approach 2:
The retainer is designed with elastic properties that allow it to dynamically adapt to the lens and sensor positions. The elastic deformation absorbs assembly tolerances and maintains constant contact force, ensuring both strong connection and precise alignment without the loosening issues of rigid screw connections.
3Object-affected harmful factors
If UV hardening glue is used, then no gas is emitted, but long hardening times are required
Solution Approach 1:
The patent replaces the chemical curing process of UV glue with an immediate mechanical locking mechanism. The retainer provides instant fixation upon engagement, eliminating the time-consuming UV hardening process entirely while also eliminating gas emissions associated with traditional glues. The mechanical engagement is instantaneous and requires no waiting period.
4Productivity
If laser welding is used to fix the parts, then quick and durable fixing is achieved, but the positions of the lens and sensor must not be influenced during welding
Solution Approach 1:
The patent performs preliminary alignment of the lens and sensor using the retainer's mechanical guidance features before laser welding. The retainer's geometric constraints pre-establish the correct positions, and the laser welding then merely secures this pre-aligned configuration. This preliminary mechanical alignment ensures that even during the thermal process of welding, the positions remain stable and precise.
Solution Approach 2:
The retainer acts as an intermediary component between the lens/sensor and the housing during laser welding. It provides mechanical support and position maintenance during the welding process, shielding the optical components from thermal distortion while allowing the welding to proceed quickly. The retainer's high thermal conductivity or thermal mass may also help dissipate heat away from sensitive components.
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
Laser welding ensures precise and long-lasting alignment of the camera's optical components, eliminating issues related to traditional fixing methods like gluing and screwing, while maintaining the alignment without the need for additional materials or contact.
Implementation Method 1
The at least one retainer may have at least one pressing portion arranged to apply a resilient force on the at least one connection part in a direction towards the carrier
Implementation Method 2
Laser welding enables fixing the parts without influencing the positions of the lens and the sensor
Data Source
Figure 1a~1b
Figure 1c
Figure 2
AI summary
The present invention relates to a camera and a method for assembling a camera. The camera comprises a sensor 3000, a lens 2000, and a housing 1100. The method comprises: adjusting a position of at least one of the sensor 3000 and the lens 2000 such that the sensor 3000 is positioned at a predetermined angle in relation to an optical axis 500 of the lens 2000, and laser welding the at least one of the sensor 3000 and the lens 2000 in relation to the housing 1100 such that the sensor 3000 and the lens 2000 are fixed in relation to each other.