Foil Carrier Lens Mounting Alignment
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Solution Overview
Problem
Existing methods for mounting functional elements like LEDs, cameras, and passive optical components in lenses lack precise positioning and alignment, leading to inefficiencies in miniaturized optical systems such as eyewear and virtual reality headsets.
Innovation Solution
A method involving mounting functional elements on a foil, applying underpressure, cutting a flap, and aligning it using actuators, then embedding the foil in a casting mould for precise positioning and curing, which allows for accurate placement of active and passive elements without the need for a specific FPCB on the mould, enabling direct contact for passive elements and contact through the foil for active ones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If functional elements are mounted directly in the lens without a specific FPCB structure, then device complexity is reduced, but positioning and alignment precision deteriorates
Solution Approach 1:
A foil serves as an intermediary carrier between the functional elements and the lens structure. The foil can be easily positioned and aligned using actuators, and it provides a stable base for mounting various functional elements (LEDs, cameras, passive optical components) without requiring a complex FPCB structure. This intermediary approach simplifies the overall device structure while maintaining precise positioning capabilities through the foil's controllable placement.
2Ease of manufacture
If functional elements are positioned using traditional methods, then ease of manufacture is improved, but alignment precision deteriorates
Solution Approach 1:
The functional elements are pre-mounted on the foil before the foil is positioned in the final lens assembly. This preliminary mounting allows for standardized fabrication processes where elements can be attached to the foil using conventional techniques. Subsequently, the entire foil assembly is precisely positioned using actuators that apply underpressure through a central opening, combining easy manufacturing with high alignment precision.
Solution Approach 2:
The positioning system uses actuators that can dynamically adjust the position and orientation of the foil carrying the functional elements. The actuators apply controlled underpressure through a central opening in the alignment tool, allowing for real-time adjustment and precise alignment during the manufacturing process, thereby achieving high alignment precision while maintaining manufacturing flexibility.
3Manufacturing precision
If a specific FPCB structure is provided on the mould, then positioning control is improved, but device complexity increases
Solution Approach 1:
The positioning and alignment functionality is extracted from the mould structure itself and transferred to a separate alignment tool with actuators. Instead of incorporating complex FPCB structures directly into the mould, the invention uses a standalone alignment tool that applies underpressure through a central opening to precisely position the foil. This extraction simplifies the mould design while maintaining precise positioning control through the external actuation system.
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 method ensures precise, predefined alignment and positioning of functional elements within lenses, enhancing the functionality of miniaturized optical systems like eyewear and virtual reality headsets by ensuring accurate placement and orientation of active and passive components.
Implementation Method 1
applying underpressure on the central opening to maintain the foil portion with the mounted functional elements on the alignment tool
Implementation Method 2
casting and curing the lens with the embedded foil
Data Source
AI summary
A method for mounting functional elements in a lens includes mounting the functional elements on a foil, applying a closed contour alignment surface of an alignment tool having a central opening surrounded by the closed contour on the foil portion opposite to the mounted function elements, applying underpressure on the central opening to maintain the foil portion with the mounted functional elements on the alignment tool, cutting a flap including the foil portion and supporting the functional elements out of the foil, positioning and aligning the flap through actuator, fixing the position of the flap against the adjacent foil surface, embedding the foil with the mounted functional elements in a predetermined distance to the front surface of a mould, and casting and curing the lens with the embedded foil.