Camera Module Composite Base Strength-Size Trade-off
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Solution Overview
Problem
Conventional camera module bases face a trade-off between structural strength and size, as increasing dimensions to enhance strength results in a larger module, which is not suitable for lightweight designs.
Innovation Solution
A composite base is created by combining a metal frame with a plastic frame, where the metal and plastic strips form a structure that enhances strength while reducing overall size, incorporating a filter mounting system with an adhesive layer and protrusions for enhanced connection and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the length, width, or thickness of the base is increased to improve structural strength, then the base can better support and protect the optical lens and filters, but the size of the camera module increases, which contradicts lightweight design requirements
Solution Approach 1:
The base is constructed using a composite structure combining a metal frame and a plastic frame. The metal frame provides high structural strength and rigidity, while the plastic frame fills gaps and reduces overall material usage. This composite approach achieves the required structural strength without increasing the base dimensions, thereby resolving the contradiction between strength and size.
Solution Approach 2:
The base is divided into two distinct components: a metal frame structure and a plastic frame structure. The metal frame forms the primary load-bearing skeleton, while the plastic frame supplements the structure and occupies gap regions. This segmentation allows each material to be used where it provides the most benefit, optimizing strength-to-size ratio.
2Strength
If a metal frame is used to enhance structural strength, then the base can better resist external forces, but the manufacturing complexity and cost increase
Solution Approach 1:
The base is segmented into a metal frame and a plastic frame that can be manufactured separately using different processes optimized for each material. The metal frame can be produced via metal forming or extrusion, while the plastic frame can be injection molded. After independent manufacturing, the two components are assembled together, combining the manufacturing advantages of both materials while achieving superior structural strength.
Solution Approach 2:
The metal frame and plastic frame are combined through assembly to form the complete base structure. The plastic frame is positioned to fill gaps between metal strips and connect to the metal frame at specific locations. This merging of two separately manufactured components creates a unified structure that leverages the strengths of both materials without requiring complex integrated manufacturing processes.
Data Source
AI summary
A camera module includes a composite base, an optical lens arranged at a first side of the composite base; and a circuit board arranged at a second side of the composite base. The composite base includes a metal frame and a plastic frame. The metal frame includes a plurality of first metal strips connected end to end and at least one second metal strip corresponding extending from part of the plurality of first metal strips. The plastic frame includes a plurality of first plastic strips connected end to end and at least one second plastic strip extending from part of the plurality of first plastic strip. The first plastic strips are fixed to the first metal strips to form a top wall of the composite base, and the second plastic strips are connected to the second metal strips to form a side wall of the composite base.