Camera Module Spacer Welding for Focus Stability

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Solution Overview

Problem

Existing camera module assembly methods face challenges in achieving a stable focus position due to the limitations of adhesive connections, which are affected by moisture and temperature changes, and the requirement for minimal clearances for welded connections.

Innovation Solution

The method involves using spacer elements that are initially movable, allowing for precise alignment of the objective with respect to the image sensor on multiple axes. Once aligned, these spacer elements are welded to both the objective and the joining partner, creating a robust and stable connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If adhesive connections are used to connect the objective to the support or housing, then the connection process is simple and flexible, but the focus position becomes unstable due to moisture-induced swelling and thermal expansion

Engineering Contradiction:

Improveconnection process simplicityVSAvoidfocus position stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent replaces the chemical adhesive connection system with a mechanical welding connection system. The spacer elements are welded to both the objective and the support/housing, creating a mechanical bond that is immune to moisture and temperature changes, thereby resolving the reliability issue while maintaining manufacturing feasibility through automated welding processes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the fundamental connection parameter from chemical bonding (adhesive) to metallurgical bonding (welding). This parameter change transforms the connection properties to be thermally and moisture-stable, eliminating the swelling and expansion issues inherent in adhesive materials.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If welded connections are used to connect the objective to the support or housing, then the focus position stability is improved due to immunity to temperature and moisture, but the alignment precision deteriorates because welded connections require minimal clearances that prevent multi-axis alignment

Engineering Contradiction:

Improvefocus position stabilityVSAvoidalignment precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent segments the connection function into two distinct phases: first, the spacer elements enable precise multi-axis alignment of the objective with the image sensor; second, the spacer elements are welded to both the objective and the support/housing to create a rigid, stable connection. This segmentation allows both alignment precision and connection stability to be achieved.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The spacer elements serve as an intermediary component between the objective and the support/housing. During alignment, they allow precise positioning; after alignment, they are welded to create a stable mechanical bond. The intermediary enables the transition from flexible alignment to rigid fixation.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Device complexity

If the objective is directly connected to the support or housing, then the structure is simple, but the alignment on multiple axes becomes difficult and the focus position cannot be precisely adjusted

Engineering Contradiction:

Improvestructural simplicityVSAvoidalignment precision

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The spacer elements are designed to be movable during the alignment process, allowing the objective to be positioned precisely on multiple axes. After alignment is achieved, the spacer elements are welded to fix the position. This dynamic approach transitions from flexible positioning to rigid fixation, achieving both alignment precision and structural stability.

Inventive Principle:

Principle #15Dynamics

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 approach enables a stable focus position to be maintained, even in varying environmental conditions, by creating a robust welded connection that is immune to thermal and moisture-induced changes, while allowing for precise alignment during assembly.

Implementation Method 1

the spacer elements are welded to the objective and the joining partner

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 2

The spot welds are executed by means of a laser

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Data Source

PatentUS12235507B2Method for producing a camera module, camera module

Publication Date: 2025.02.25 ROBERT BOSCH GMBH

AI summary

A method for producing a camera module. An objective is aligned with respect to an image sensor and is then fixed in position by being joined to a support that receives the image sensor, a housing that surrounds the image sensor, or an interposed connection structure as a joining partner. The objective is mounted on spacer elements, which are initially still movable, and is then aligned with respect to the image sensor by moving the spacer elements. After the objective is aligned, the spacer elements are welded to the objective and the joining partner. A camera module is also described.