Camera Module Molding Groove Layout for Complete Resin Filling

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Solution Overview

Problem

The existing molding process for camera modules faces issues with inconsistent flow of thermosetting packaging material due to uneven flow passage widths, leading to incomplete filling of the molding cavity, deformation of leads, and defective products.

Innovation Solution

A method for manufacturing a photosensitive assembly of a camera module using a molding die with a base jointed panel molding guide groove, where the molding material fills a guide groove to avoid defective products, and the dimensions of the flow passages are optimized to ensure consistent flow and complete filling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If the widths of the two flow passages are not the same, then the packaging material flows at different rates, but this causes inconsistent flow and incomplete filling of the molding cavity

Engineering Contradiction:
Improveflow rate of packaging materialVSAvoidfilling completeness of molding cavity
Core Design Contradiction:
SpeedVSManufacturing precision

Solution Approach 1:

The patent applies local quality by making the flow passages have different widths at different locations. Specifically, the first flow passage has a first width and the second flow passage has a second width, where the ratio between these widths is controlled within 0.5:1 to 1:2. This localized variation in geometry allows each flow passage to have optimized flow characteristics appropriate to its position, ensuring uniform filling across the entire molding cavity while avoiding turbulence that would cause lead deformation.

Inventive Principle:
Principle #3Local quality

2Productivity

If the packaging material flows forward quickly, then filling is complete, but friction with leads causes deformation and damage

Engineering Contradiction:
Improvefilling speedVSAvoidlead integrity
Core Design Contradiction:
ProductivityVSReliability

Solution Approach 1:

The patent applies parameter changes by controlling the width ratio of the flow passages to be within 0.5:1 to 1:2. This parameter optimization ensures that the packaging material flows at a controlled speed that is fast enough to complete filling within the curing time, yet slow enough to minimize friction with the leads. The optimized dimensions prevent both incomplete filling and lead deformation, resolving the contradiction between filling speed and lead integrity.

Inventive Principle:
Principle #35Parameter changes

3Ease of operation

If the packaging material viscosity is low, then flow is easy, but the material may not fill narrow passages completely before curing

Engineering Contradiction:
Improveflowability of packaging materialVSAvoidfilling completeness
Core Design Contradiction:
Ease of operationVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by designing the flow passage dimensions in advance to account for the viscosity changes of the thermosetting packaging material during the molding process. The flow passages are sized to ensure that even as the material viscosity increases during curing, the material can still complete filling of all passages including narrow ones before the curing process terminates the flow. This pre-calculated dimensional design ensures complete filling throughout the entire curing cycle.

Inventive Principle:
Principle #10Preliminary action

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 optimized molding process ensures that the molding material consistently fills the molding cavity, preventing defects such as incomplete packaging and lead deformation, and allowing for the formation of a closed light window, thus improving the quality of the camera module.

Implementation Method 1

thermosetting packaging material has a curing time T in the molding process, as time passes, its viscosity decreases to the lowest point, and then gradually rises to the highest point to be completely cured

Methodology Applied
Scientific EffectViscosity change:

Implementation Method 2

the packaging material is a thermosetting material, and after melting, enters the two flow passages, and is cured under the action of heating conditions

Methodology Applied
Scientific EffectThermal curing:

Implementation Method 3

The upper die and the lower die are clamped to form a molding cavity

Methodology Applied
Scientific EffectMechanical clamping:

Implementation Method 4

the friction of the lead between the circuit board and the photosensitive chip is relatively large, which may easily cause deformation and damage of the lead

Methodology Applied
Scientific EffectFriction: Friction

Data Source

PatentEP3684045B1Camera module, and photosensitive component, forming mold and manufacturing method thereof
Publication Date: 2025.04.30 NINGBO SUNNY OPOTECH CO LTD
  • EP3684045B1 patent drawingFigure 1A
  • EP3684045B1 patent drawingFigure 1B~1C
  • EP3684045B1 patent drawingFigure 1D~1E

AI summary

A camera module, and a photosensitive assembly and a manufacturing method thereof, the photosensitive assembly includes: a circuit board and a photosensitive chip, as well as a molded base, the molded base being integrally formed on the circuit board and the photosensitive chip, and forming a light window for providing a light path for the photosensitive chip; for a portion of the molded base corresponding to a first end side of the molded base adjacent to a flexible region, a distance between an outer edge and an inner edge thereof is a; for a portion of the molded base corresponding to an opposite second end side of the molded base away from the flexible region, a distance between an outer edge and an inner edge thereof is c, wherein 0.2 mm≤a≤1 mm, and 0.2 mm≤c≤1.5a. The dimensions a and c enable a corresponding forming groove in a molding process to be filled with molding material, preventing defective products from being formed because of a part not being able to be filled with the molding material.