Camera Module Assembly for Resolution and Image-Plane Tilt Correction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing camera modules face challenges in achieving high resolution and large aperture due to manufacturing deviations in lens assembly, leading to low yield and high failure rates, which are not adequately addressed by current active alignment processes.
Innovation Solution
A method for assembling a camera module by adjusting the relative position and inclination of sub-lens assemblies and the photosensitive assembly to optimize imaging resolution and compensate for image plane inclination, using multiple degrees of freedom and real-time adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If dimensional tolerances of elements are controlled and lens turning is performed to increase resolution, then imaging resolution is improved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The lens assembly is divided into multiple independent lens elements (first lens, second lens, third lens, etc.) with separate mounting structures. Each lens element can be independently adjusted via its mounting bracket, allowing resolution optimization without requiring complex overall lens turning operations. This segmentation enables localized adjustments to correct optical aberrations.
Solution Approach 2:
The patent introduces adjustable mounting brackets with movable components that allow dynamic adjustment of lens element positions and angles after assembly. The mounting brackets include adjustment mechanisms (such as screws, springs, or motors) that enable real-time optimization of lens alignment and tilt, replacing static precision manufacturing with dynamic adaptability.
2Manufacturing precision
If manufacturing precision of lens elements is improved to reduce deviations, then imaging resolution is improved, but production cost increases and yield decreases
Solution Approach 1:
The patent changes the approach from controlling manufacturing parameters (dimensional tolerances) to adjusting operational parameters (lens position, angle, and spacing) after assembly. The mounting brackets allow adjustment of lens element positions along optical and non-optical axes, enabling compensation for manufacturing deviations without requiring higher precision manufacturing.
Solution Approach 2:
The patent implements an active alignment process with feedback mechanisms where the imaging performance is measured and used to guide adjustments of lens element positions. The adjustment mechanisms allow iterative optimization based on measured optical performance, enabling compensation for manufacturing variations through closed-loop control.
3Measurement precision
If active alignment process is used to compensate for photosensitive chip inclination, then imaging quality is improved, but the process cannot compensate for optical system aberrations
Solution Approach 1:
The mounting bracket structure serves multiple functions: it not only positions the lens elements but also provides adjustment capabilities for both optical axis alignment and tilt compensation. The same mounting structure that positions lenses can adjust their angles to compensate for various types of optical aberrations, making the system universally adaptable to different error sources.
Solution Approach 2:
The patent extends the adjustment capability from one-dimensional position correction to multi-dimensional adjustment including lateral position, axial position, and angular tilt. The mounting brackets allow adjustment in multiple degrees of freedom, enabling compensation for both chip inclination and optical system aberrations by adjusting lens elements in different spatial dimensions.
Data Source
Figure 1~2
Figure 3~6
Figure 7~8
AI summary
The present invention provides a method for assembling a camera module, including: arranging a first sub-lens assembly and a photosensitive assembly on an optical axis of a second sub-lens assembly to form an optical system capable of imaging; increasing an actual measured resolution of imaging of the optical system to a first threshold by adjusting a relative position of the first sub-lens assembly with respect to the second sub-lens assembly; decreasing an actual measured image plane inclination of imaging of the optical system, obtained by using the photosensitive element, to a second threshold by adjusting an angle of an axis of the photosensitive assembly with respect to a central axis of the second sub-lens assembly; and connecting the first sub-lens assembly, the second sub-lens assembly, and the photosensitive assembly. The present invention further provides a corresponding camera module. The present invention can improve the resolution of the camera module; can improve the capability of process index of mass production of the camera module; can reduce the overall costs of the optical imaging lens assembly and module; and can reduce the failure rate and the production costs, and improve the imaging quality.