Fused Lens Stack With Metallic Disks For Compact Camera
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Solution Overview
Problem
Conventional small form factor cameras face challenges in achieving high-resolution, high-quality images due to limitations in compact optical lens systems, which require improved imaging quality and brightness within physical constraints.
Innovation Solution
A fused lens stack is created by interleaving optical lenses with metallic disks, where the lenses are subjected to an electromagnetic field for eddy current heating, causing the thermoplastic lens material to melt and adhere to the disks, forming a compact and immobilized lens system without external barrels or interlocking structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional lens systems are used in small form factor cameras, then the camera can be compact, but the imaging quality and resolution are limited
Solution Approach 1:
Multiple lenses are merged into a single integrated lens stack assembly, where individual lenses are stacked and fused together. This combining approach allows the compact camera to achieve high imaging quality through the cumulative optical power of multiple lenses while maintaining a small overall form factor.
Solution Approach 2:
The lens system employs a nested structure where multiple lens elements are stacked one on top of another in a compact arrangement. Each lens is positioned within the vertical space of the camera module, creating a nested configuration that maximizes optical performance within minimal volume.
2Measurement precision
If multiple lenses are stacked to improve imaging quality, then resolution increases, but the physical size and complexity of the lens system increases
Solution Approach 1:
Multiple lenses are merged into a single integrated lens stack assembly, where individual lenses are stacked and fused together. This combining approach allows the compact camera to achieve high imaging quality through the cumulative optical power of multiple lenses while maintaining a small overall form factor.
Solution Approach 2:
The invention changes the structural parameter of the lens system by transitioning from individual separate lenses to a fused stacked configuration. This parameter change enables multiple lenses to occupy reduced space while maintaining their individual optical functions, thereby improving resolution without proportionally increasing size.
3Stability of the object's composition
If lenses are immobilized using external barrels or interlocking structures, then lens position stability is achieved, but device complexity and size increase
Solution Approach 1:
The individual lenses and their mounting structures are merged into a single fused lens stack assembly. The lenses are bonded together and to support structures through fusion, eliminating the need for separate barrels, interlocking mechanisms, or external mounting components, thereby reducing complexity while maintaining stability.
Solution Approach 2:
The invention extracts and eliminates unnecessary external components such as separate lens barrels and interlocking structures. By fusing the lenses directly to support structures within a simplified assembly process, the design removes redundant elements that would otherwise increase device complexity and size.
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 solution enables a compact, high-resolution camera system with improved reliability and image quality, reducing the physical size and increasing the surface area available for other device features, while maintaining the optical properties of the lenses and enhancing image formation and contrast.
Implementation Method 1
A plurality of lenses, interleaved with metallic disks, is subjected to a varying electromagnetic field that results in eddy current heating of the metallic disks
Implementation Method 2
eddy current heating of the metallic disks, and subsequent heating and melting of adjacent thermoplastic lenses
Implementation Method 3
The melted thermoplastic lens material adheres to the respective adjacent interleaved metallic disk(s), resulting in a fused lens stack
Implementation Method 4
The melted thermoplastic lens material adheres to the respective adjacent interleaved metallic disk(s)
Implementation Method 5
A corresponding central portion of each lens is configured to refract light entering the lens
Data Source
AI summary
A lens assembly includes a stack of thermoplastic lenses that are aligned along a common optical axis and that are interleaved with metallic disks having an open central portion. Peripheral portions of each of the thermoplastic lenses adhere to the interleaved metallic disks to form a fused stack of lenses. A method of making the fused stack of lenses is disclosed and includes subjecting a set of interleaved lenses and metallic disks to an alternating current electromagnetic field that induces eddy currents in the metallic disks, causing heating that melts the adjacent lenses. The melted thermoplastic lens material adheres to adjacent metallic disks. The metallic disks reduce stray light from entering the lens stack, while permitting light to enter central portions of the lenses.