Edge-Cut Lens Sheet for Ultra-Narrow Camera Module
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Solution Overview
Problem
Conventional camera modules are bulky due to unnecessary volume in their design, leading to reduced imaging quality and increased size, especially in high-pixel applications where multiple lens sheets are used, making them unsuitable for compact smart devices.
Innovation Solution
The introduction of an edge-cut lens sheet with chord and circular edges that reduce the non-imaging region, allowing for a more compact camera module design while maintaining imaging quality by minimizing stray light and simplifying assembly, achieved through injection molding and matching the lens barrel and base with the edge-cut lens sheet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a conventional round lens sheet is used, then the lens barrel and other components must be designed with larger dimensions to accommodate the complete circular shape, but this increases the overall volume of the camera module
Solution Approach 1:
The patent extracts only the necessary imaging portion of the lens sheet by cutting away the non-imaging circular edges. The lens sheet is transformed from a complete circle to a shape that matches the photosensitive chip's active area, removing redundant material that would otherwise require additional space in the lens barrel and increase overall module volume.
Solution Approach 2:
The patent introduces asymmetric cutting patterns (such as rectangular, square, or irregular shapes) to the traditionally symmetric circular lens sheet. This asymmetric design allows the lens sheet to precisely match the photosensitive chip's active area while reducing the overall footprint and allowing for more compact lens barrel and housing designs.
2Volume of moving object
If the lens sheet size is reduced to match the photosensitive chip, then the camera module volume decreases, but stray light may affect imaging quality
Solution Approach 1:
The patent converts the potentially harmful effect of exposed edges into a beneficial feature by designing the cut edges to act as light-blocking boundaries. The exposed edges of the cut lens sheet are positioned to naturally block stray light paths without requiring additional light-blocking components, thus maintaining imaging quality while reducing module volume.
Solution Approach 2:
The patent applies different properties to different regions of the lens sheet. The central imaging region maintains full transparency for light transmission, while the cut edges and non-imaging portions are designed with light-blocking characteristics to prevent stray light. This local differentiation allows the lens sheet to simultaneously achieve compact size and effective stray light rejection.
3Reliability
If the lens barrel is designed to match a complete circular lens sheet, then the lens sheet is properly supported, but unnecessary portions increase the overall device size
Solution Approach 1:
The patent segments the lens barrel structure to match the segmented lens sheet shape. Instead of a complete circular lens barrel, the lens barrel is designed with corresponding cutouts or reduced dimensions in areas where the lens sheet has been trimmed. This segmentation allows the lens barrel to provide adequate support for the imaging portion while eliminating unnecessary material and reducing overall volume.
Solution Approach 2:
The patent designs the lens barrel to serve multiple functions: it provides structural support for the lens sheet, defines the optical path, blocks stray light, and reduces overall module volume. By integrating these functions into a single component designed to match the cut lens sheet shape, the lens barrel achieves compact dimensions without compromising support reliability.
4Ease of manufacture
If a complete circular lens sheet is used, then the manufacturing process is simple, but the non-imaging region creates redundant volume in the camera module
Solution Approach 1:
The patent performs the lens sheet cutting operation as a preliminary step in the manufacturing process, before final assembly. By pre-cutting the lens sheet to the desired shape (rectangular, square, or irregular) to match the photosensitive chip's active area, the design eliminates redundant material from the outset, allowing for compact camera module assembly without requiring post-assembly trimming or modification of other components.
Data Source
AI summary
A lens (10) and a camera module (100) and a manufacturing method thereof, wherein the lens (10) comprises an edge-cut lens sheet (114), wherein the edge-cut lens sheet (14) includes at least one chord edge (1141) and at least one circular edge (1142), wherein the chord edge (1141) and the circular edge (1142) are adjacently connected to each other, and wherein the chord edge (1141) and the circular edge (1142) have different curvatures, so that the lens sheet (114) becomes narrow and the width of the lens (10) become narrow, to form an ultra-narrow camera module (100).