Camera Module Laser Welding Optical Axis Alignment
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Solution Overview
Problem
Super small camera modules used in vehicles face quality deterioration and reliability issues due to misalignment of optical axes during adhesive hardening, decreased adhesive strength from humidity exposure, and thermal expansion/ shrinkage effects.
Innovation Solution
A camera module design featuring a lens barrel, lens holder, image sensor, and printed circuit board with aligned optical axes, coupled using welding points formed by a laser beam, which enhances bonding strength and resistance to humidity and thermal changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If adhesive agent is used to bond lens barrel and lens holder, then alignment of optical axes can be achieved, but adhesive strength decreases due to humidity exposure and thermal expansion
Solution Approach 1:
The patent replaces the chemical bonding mechanism (adhesive agent) with a mechanical bonding mechanism (welding). The welding process joins the lens holder and lens barrel through direct metallurgical bonding, eliminating the reliance on adhesive agents that are susceptible to humidity and thermal degradation. This substitution maintains alignment precision while significantly improving bonding reliability under environmental stress.
2Ease of manufacture
If adhesive agent is used for bonding, then assembly can be performed, but adhesive characteristics decrease due to thermal expansion and thermal shrinkage
Solution Approach 1:
The patent replaces adhesive-based bonding with welding-based bonding. The welding process creates a metallurgical joint that is inherently resistant to thermal expansion and shrinkage effects, maintaining bonding strength across temperature variations. This approach preserves ease of manufacture through automated welding processes while eliminating the strength degradation issues associated with adhesive agents.
3Strength
If epoxy resin is used as adhesive, then bonding can be achieved, but adhesive power decreases due to hydrolysis reaction with humidity
Solution Approach 1:
The patent replaces chemical bonding using epoxy resin with mechanical bonding through welding. This substitution eliminates the hydrolysis reaction issue entirely, as welding creates a metallurgical bond that is immune to humidity-induced chemical degradation. The bonding strength is maintained or improved while removing the vulnerability to humidity exposure that plagues adhesive-based systems.
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 prevents quality deterioration and enhances reliability by maintaining aligned optical axes and robust bonding, even under varying temperature conditions and humidity exposure.
Implementation Method 1
at least one welding point for mutually coupling the lens barrel and the lens holder while an optical axis of the lens and an optical axis of the image sensor are aligned
Data Source
AI summary
A camera module comprising: a lens barrel comprising a lens; a lens holder for accommodating the lens barrel; an image sensor disposed below the lens barrel; a printed circuit board on which the image sensor is mounted and is coupled to the lens barrel; and at least one welding point for mutually coupling the lens barrel and the lens holder while an optical axis of the lens and an optical axis of the image sensor are aligned.