Camera Image Sensor Holder Captive Alignment Mechanism
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Solution Overview
Problem
Conventional methods for aligning image sensors in cameras are limited by manufacturing tolerances, are mechanically complex, and often result in imprecise adjustments due to the use of screws and springs or require cumbersome shim systems, which can lead to misalignment over time and increased costs.
Innovation Solution
A camera design featuring a holder that captively moves and fixedly holds the image sensor relative to the lens mount, utilizing elastic supports for precise alignment and dust sealing, with the option of robotic movement for precise positioning and soldering or adhesion for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing tolerances are used for aligning the image sensor, then the assembly process is simple, but the alignment precision is limited due to compounding tolerances
Solution Approach 1:
The holder is pre-adjusted to provide captivation of the image sensor at the correct aligned position before final assembly. This preliminary positioning action ensures that when the image sensor is installed, it is automatically held in the correct position, eliminating the need for complex post-assembly alignment mechanisms and achieving high precision without increasing device complexity.
2Ease of operation
If threaded screws with coil springs are used for adjusting the image sensor position, then the image sensor can be positioned, but the mechanism becomes mechanically complicated and cumbersome to adjust
Solution Approach 1:
The complex threaded screw and coil spring adjustment mechanism is completely removed from the design. Instead, the holder is designed to directly captivate the image sensor at the correct position through its pre-adjusted structure, extracting the unnecessary mechanical complexity while maintaining the essential function of precise positioning.
3Manufacturing precision
If shims of varying thicknesses are used to adjust the image sensor position, then the position can be fixed, but selecting the appropriate shim is tedious and requires a large inventory
Solution Approach 1:
The design eliminates the need for multiple shim components of varying thicknesses. A single holder design with built-in captivation capability replaces the entire shim inventory system, making assembly simpler and more efficient while maintaining precise positioning capability.
4Temperature
If conventional heat sinks are used for thermal management, then the electronic components can be cooled, but the camera becomes bulky
Solution Approach 1:
The holder structure is designed to serve dual functions: mechanically captivating the image sensor and providing thermal management. By integrating heat dissipation capabilities into the holder itself, the design eliminates the need for separate conventional heat sinks, thereby reducing camera volume while maintaining effective cooling of electronic components.
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
This solution enables precise and durable alignment of the image sensor, reducing misalignment issues and costs associated with shim inventory, while maintaining dust protection and efficient thermal management.
Implementation Method 1
a support for resiliently supporting the image sensor when the image sensor is captively held by the holder. The support may be made of an elastic material.
Implementation Method 2
The support may be operable to seal the image sensor against dust ingress. The support may be made of a foam material.
Implementation Method 3
The image sensor may be removably attachable to the holder by soldering.
Data Source
AI summary
An image sensor attached to a printed circuit board is installed in a camera. A holder includes first and second rails comprising first and second printed circuit boards, respectively, and the holder is fastened to a lens mount of the camera. The holder may be fastened to captively hold the image sensor, and the image sensor may be resiliently supported when captively held. A gripper grasps the image sensor proximate to the holder and aligns the image sensor to an aligned position of the image sensor relative to the lens mount. The image sensor may be moved to the aligned position after directing an image toward the image sensor to produce a processed image for determining relative alignment. The printed circuit board is soldered to the first and/or second printed circuit board such that the holder fixedly holds the image sensor so it is unmovable in its aligned position.