Camera Module Lens Unit with Stack Protrusion Recess Alignment
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Solution Overview
Problem
The challenge is to develop a camera module with improved optical performance and miniaturization, as existing camera modules face difficulties in integrating a larger optical system within the constraints of mobile device design, requiring smaller and lighter lenses while maintaining high resolution and functionality.
Innovation Solution
A lens unit with a curved surface and a supporting portion featuring protrusions or recesses is used, allowing for easy assembly and alignment, coupled using stack protrusions and recesses, and fabricated using photo-curable resin for enhanced thermal resistance and strength, enabling mass production and integration with image sensors or LEDs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the camera module increases in size to ensure performance, then optical performance and functionality are improved, but it becomes difficult to mount the camera module on the mobile device
Solution Approach 1:
The camera module is divided into multiple lens units (first lens unit, second lens unit, third lens unit) that can be independently designed and optimized. Each lens unit contains specific lenses (e.g., positive meniscus lens, negative meniscus lens) that perform specific optical functions, allowing the overall system to achieve high optical performance while maintaining a compact form factor through modular architecture.
Solution Approach 2:
The patent implements a nested arrangement where lens units are stacked along the optical axis with support portions and coupling portions interlocking with each other. The first lens unit couples to the second lens unit, which in turn couples to the third lens unit, creating a compact nested structure that minimizes the overall volume while maintaining optical performance through precise alignment of multiple lens elements.
2Volume of moving object
If lenses are miniaturized and lightened to decrease optical system size, then camera module compactness is improved, but manufacturing precision and optical quality become more difficult to maintain
Solution Approach 1:
Each lens unit is designed with specific local optical characteristics - for example, the first lens unit contains a positive meniscus lens with specific curvature radii (R1, R2) and the second lens unit contains a negative meniscus lens with specific curvature radii (R3, R4). These localized optical properties are optimized for their specific positions in the optical path, allowing miniaturization while maintaining overall optical quality through distributed functional optimization.
Solution Approach 2:
The support portions and coupling portions are pre-formed with precise geometric features (protrusions and recesses) that automatically guide alignment during assembly. The coupling portion of one lens unit includes a protrusion that fits into a recess of the next lens unit, pre-establishing the correct spatial relationship and optical axis alignment before final assembly, thereby maintaining manufacturing precision despite miniaturization.
3Manufacturing precision
If lens units are assembled with additional alignment apparatus, then optical axis alignment precision is improved, but device complexity and assembly difficulty increase
Solution Approach 1:
The lens units are designed with self-aligning coupling mechanisms where the coupling portion of one lens unit includes a protrusion that automatically fits into a corresponding recess of the next lens unit. This self-service alignment feature eliminates the need for external alignment apparatus or complex adjustment mechanisms, achieving precise optical axis alignment through the inherent geometric design of the coupling interfaces.
Solution Approach 2:
The support portions and coupling portions are designed with asymmetric geometric features - specifically, protrusions on one side and recesses on the corresponding side - that provide directional guidance for alignment. This asymmetric design ensures that lens units can only be assembled in the correct orientation, automatically establishing proper optical axis alignment without requiring symmetric adjustment mechanisms or additional alignment equipment.
4Illumination intensity
If traditional lens materials (plastic or glass) are used, then optical clarity is maintained, but microminiature optical system realization is limited
Solution Approach 1:
The patent changes the material parameter from traditional plastic or glass to a resin material that can be molded into microminiature forms. The resin material allows for precise molding of small lens elements with controlled curvature radii and thicknesses, enabling the realization of microminiature optical systems while maintaining optical clarity through proper material selection and molding process optimization.
Solution Approach 2:
The lens units are constructed using resin material that combines optical transparency with moldability for miniaturization. The resin can be integrated with the support portions and coupling portions in a single molded structure, creating a composite component that achieves both optical functionality and mechanical integration in a miniaturized form factor that traditional separate glass or plastic lens elements cannot achieve.
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
The solution allows for a compact, high-performance camera module with improved thermal resistance, reduced manufacturing complexity, and enhanced strength, enabling efficient alignment and coupling of lens units without additional alignment apparatus, facilitating mass production and integration with image sensors or LEDs.
Implementation Method 1
irradiating light onto the resin composition
Data Source
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AI summary
Provided are a lens unit, a lens assembly, a camera module, a method of fabricating the camera module and the lens assembly, a method of fabricating an optic member, and an apparatus of fabricating the optic member. The lens unit comprises a lens portion and a supporting portion. The lens portion has a curved surface. The supporting portion extends from the lens portion. The supporting portion comprises a protrusion or a recess. The method of fabricating the optic member comprises injecting a resin composition inside a mold die, pressing the resin composition; and irradiating light onto the resin composition. Due to the pressure, shrinkage of a photo-curable resin composition can be reduced, and thus, the lens unit comprising the protrusion or recess can be easily fabricated.