D-Cut Lens Assembly for Compact Camera Module Moldability
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Solution Overview
Problem
Camera modules in portable electronic devices face challenges in miniaturization and performance improvement due to the mismatch in shape between the circular lens and rectangular image sensor, leading to inefficient light focusing and potential deformation during manufacturing.
Innovation Solution
A D-cut lens design with a pair of straight portions facing each other perpendicular to the optical axis, an arc portion connecting them, and a flange portion extending from the straight portion, optimized for size reduction and injection moldability, featuring specific ratios and angles for maintaining optical performance and assembly stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a circular lens is used, then optical performance is maintained, but the lens size cannot be reduced and causes mismatch with rectangular image sensor
Solution Approach 1:
The lens is divided into an optical portion and a non-optical portion (flange portion). The optical portion maintains the circular shape for optimal light refraction, while the flange portion is added only where needed for mounting and spacing functions, eliminating unnecessary material removal from the optical path.
Solution Approach 2:
The flange portion extends in the radial direction from the optical portion, adding a dimensional element that provides mounting functionality without reducing the optical portion's effective area. This allows the lens to maintain its circular optical shape while incorporating rectangular-compatible mounting features.
2Volume of moving object
If both sides of circular lens are removed (D-cut lens), then lens size is reduced, but manufacturing deformation occurs and moldability deteriorates
Solution Approach 1:
The flange portion is designed with protrusions and grooves that engage with the mold during injection molding. This preliminary structural design ensures that the lens is properly supported and constrained during the molding process, preventing deformation before the manufacturing is even completed.
Solution Approach 2:
The flange portion is provided only in specific regions (not uniformly around the entire perimeter) where mounting and spacing are needed. This localized approach maintains good moldability in the optical portion while providing necessary functionality in the flange region, avoiding the deformation issues associated with complete D-cut designs.
3Ease of operation
If flange portion is provided around entire perimeter, then assembly function is improved, but lens size increases and optical performance deteriorates
Solution Approach 1:
The flange portion is segmented and provided only in specific regions around the optical portion rather than forming a complete circular ring. This segmentation allows the lens to maintain a smaller overall size while still providing adequate assembly functionality at the necessary locations.
Solution Approach 2:
The unnecessary portions of the flange are removed, keeping only the minimal required flange structure that provides mounting and spacing functions. This extraction of essential functions from non-essential material reduces the overall lens size while maintaining assembly capability.
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 design achieves reduced lens and camera module size while preserving optical performance and moldability, preventing deformation and flare phenomena, and facilitating efficient assembly within a limited space.
Implementation Method 1
the optical portion refracts light
Data Source
AI summary
A lens includes an optical portion including a pair of straight portions facing each other in a direction perpendicular to an optical axis, and an arc portion connecting the pair of straight portions; and a flange portion extending along a portion of a perimeter of the optical portion, wherein the flange portion extends from a straight portion of the straight portions and is spaced apart from the arc portion, and the optical portion refracts light.