Discrete Camera Module Arrays for High-Yield Multi-Camera Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manufacturing multi-camera arrays is challenging due to the need for precise alignment and testing of multiple lenses, leading to low yield, high cost, and reduced assembly line throughput, as well as limited re-workability of sub-array defects.
Innovation Solution
Assemble multi-camera systems using discrete off-the-shelf camera modules with geometric synchronization and synchronization using pins or software commands, attached to a substrate with a low coefficient of expansion material, allowing for standard assembly processes and reflowable materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a monolithic array sensor with lens-array is used, then multiple views can be captured simultaneously, but manufacturing complexity and alignment precision requirements increase significantly
Solution Approach 1:
The patent divides the monolithic array sensor into multiple discrete camera modules, each with its own sensor and lens assembly. These modular units can be manufactured separately with standard precision requirements, then assembled into the final array configuration, eliminating the need for high-precision monolithic fabrication and lens-array alignment.
Solution Approach 2:
The patent introduces a substrate as an intermediary platform to mount the discrete camera modules. This substrate provides a common reference frame for positioning multiple modules, allowing standard manufacturing tolerances to accumulate in a controlled manner rather than requiring all components to align to a single high-precision reference.
2Manufacturing precision
If active alignment process is used for lens positioning, then focus quality can be optimized, but assembly time and production cost increase
Solution Approach 1:
The patent performs lens positioning and focus optimization during the discrete camera module manufacturing process, before the modules are assembled into the final array. This preliminary action ensures that each module arrives at the assembly stage with pre-optimized focus, eliminating the need for time-consuming active alignment during array assembly.
Solution Approach 2:
Each discrete camera module is designed to be self-contained with its own optimized optical path and focus mechanism. The modules are manufactured as complete, functional units that require minimal adjustment during array assembly, allowing standard assembly processes to maintain high throughput while preserving focus quality.
3Reliability
If discrete camera modules are used instead of monolithic sensor, then manufacturing yield and re-workability improve, but device complexity increases
Solution Approach 1:
By segmenting the array into discrete, identical camera modules, the patent enables independent manufacturing and testing of each unit. This segmentation allows defective modules to be identified and replaced individually, improving overall yield and re-workability despite the increased number of components.
Solution Approach 2:
The patent uses identical or substantially similar discrete camera modules throughout the array, creating homogeneity in the system architecture. This uniformity simplifies the assembly process, as the same standardized modules can be manufactured, tested, and replaced using identical procedures, offsetting the complexity of managing multiple components.
Data Source
AI summary
An array imaging apparatus having discrete camera modules is disclosed. In one embodiment, the apparatus comprises a substrate; and heterogeneous camera modules attached to the substrate and in a geometric relationship with each other, the heterogeneous camera modules having a substantially similar photometric response.