Optically Tuneable Lens Assemblies for Small-Form-Factor Cameras
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Solution Overview
Problem
Conventional lens tuning mechanisms are difficult and expensive to fabricate for small form factor lenses, such as those used in smartphones, and often fail to meet physical space requirements while providing desired imaging capabilities.
Innovation Solution
A method of manufacturing an optically tuneable lens assembly involves extruding a support structure with a monolithic body section defined by walls and supporting ribs, and integrating flexible membranes and optical cover plates, enabling faster and more cost-effective production of versatile lens architectures suitable for mobile devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional lens tuning structures are used to achieve focus, then imaging capability is provided, but manufacturing difficulty and cost increase significantly for small form factor lenses
Solution Approach 1:
The patent replaces conventional mechanical lens tuning structures with a liquid lens system that uses optical pressure to deform a membrane, changing the lens shape and focal length without mechanical moving parts. This substitution eliminates the complexity of fabricating precision mechanical tuning structures while maintaining focus adjustment capability.
Solution Approach 2:
The patent changes the physical state and shape parameters of the lens by using liquid pressure to deform a flexible membrane, thereby adjusting focal length and aperture. This parameter-based tuning approach avoids the need for complex mechanical structures, simplifying manufacturing for small form factor applications.
2Volume of moving object
If conventional lens structures are used to meet physical space requirements, then compact size is achieved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent merges multiple functions (focus adjustment, aperture control, and structural support) into a single integrated liquid lens assembly. The membrane deformation mechanism simultaneously controls both focal length and aperture opening, reducing the number of separate components and simplifying manufacturing while achieving compact dimensions.
Solution Approach 2:
The patent uses a flexible membrane as the lens element that can be deformed by liquid pressure. This thin-film approach enables compact lens design with adjustable parameters, avoiding the need for thick mechanical adjustment mechanisms and reducing overall assembly size while maintaining manufacturability.
3Speed
If tuneable optical lenses with high refraction changes are used to achieve compact size, then low response time is obtained, but manufacturing and assembly challenges increase
Solution Approach 1:
The patent uses hydraulic pressure from an optical liquid to deform the membrane and adjust lens parameters. This fluid-based actuation mechanism enables rapid response times by quickly transmitting pressure changes to the membrane, while the integrated design minimizes assembly complexity compared to traditional electromechanical 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
This approach overcomes manufacturing limitations, allowing for more practical camera integration solutions in smartphones by providing high accuracy and thin-walled metallic container units, enhancing productivity and architectural flexibility.
Implementation Method 1
Deflection of the membrane, such as by exerting a pressure on the membrane enables the shape of the membrane to be varied
Implementation Method 2
extruding a support structure comprising a monolithic body section defined by a first wall and a second wall separated from the first wall by multiple supporting ribs
Data Source
Figure 1
Figure 2a
Figure 2b~3b
AI summary
In some examples, a method of manufacturing an optically tuneable lens assembly comprises extruding a support structure comprising a monolithic body section defined by a first wall and a second wall separated from the first wall by multiple supporting ribs, the body section comprising a pair of opposing outer side wall sections disposed between the first wall and the second wall at respective outer edges thereof, forming a first opening in the body section, the first opening extending through the body section, forming a second opening in the body section, the second opening extending through the first wall or the second wall and respective portions of a first set of supporting ribs disposed between the first wall and a second wall at a position of the second opening, disposing a flexible optical membrane over, on or within the first opening at the first wall, disposing an optical cover plate over, on or within the first opening at the second wall, disposing a flexible actuator membrane over, on or within the second opening, and sealing the body section at a first edge and a second edge thereof, the first edge and the second edge extending laterally across the body section between the first and second walls and the opposing outer wall sections.