Guided Autofocus Assembly with Buckler Mechanism

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Solution Overview

Problem

Current shape memory alloy (SMA) systems for autofocus applications result in bulky designs with limited Z-stroke range and a large footprint, failing to achieve a compact, low-profile configuration with high actuation height.

Innovation Solution

A guided autofocus assembly incorporating a housing element with a hall housing wall, magnetic elements, and SMA wires, along with ball bearings and a flexible printed circuit board, which enables precise control and actuation of a lens carriage in the z-direction, utilizing SMA wires for actuation and ball bearings for reduced friction and increased Z-stroke range.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If traditional SMA systems are used for autofocus, then the system can achieve actuation function, but the system becomes bulky with large footprint and limited Z-stroke range

Engineering Contradiction:
Improvefoot printVSAvoidZ-stroke range
Core Design Contradiction:
Volume of moving objectVSLength of moving object

Solution Approach 1:

The patent transitions from traditional linear SMA wire actuation to a buckler mechanism with rotational motion. The buckler arms rotate about a pivot point, converting linear SMA contraction into amplified linear displacement of the lens carriage. This dimensional transformation enables larger Z-stroke range within a compact footprint by exploiting rotational degrees of freedom.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent employs a dynamic buckler mechanism where the buckler arms rotate dynamically during actuation. The pivot point allows the buckler to transition between extended and retracted positions, creating a dynamic structure that amplifies the actuation stroke. This dynamic configuration enables the system to achieve large Z-stroke range without increasing the static footprint.

Inventive Principle:
Principle #15Dynamics

2Ease of operation

If traditional flexure elements are used, then the moving assembly is supported for movement, but the system complexity increases resulting in bulky design

Engineering Contradiction:
Improvemovement supportVSAvoidsystem complexity
Core Design Contradiction:
Ease of operationVSDevice complexity

Solution Approach 1:

The patent extracts the support function from complex flexure elements and implements it through a simplified pivot-based buckler mechanism. The pivot point provides the necessary support and guidance for the buckler arms, eliminating the need for complex flexure assemblies while maintaining smooth movement support. This extraction reduces system complexity and achieves a more compact design.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical flexure element system with a pivot-based rotational mechanism. Instead of relying on elastic deformation of flexures, the system uses a pivot point to enable controlled rotation of the buckler arms. This substitution simplifies the mechanical system, reduces complexity, and achieves the same support function with fewer components.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

3Extent of automation

If SMA wires are used for actuation, then the system can be actuated electrically, but friction and force imbalance occur limiting Z-stroke range

Engineering Contradiction:
Improveelectrical actuationVSAvoidZ-stroke range
Core Design Contradiction:
Extent of automationVSLength of moving object

Solution Approach 1:

The patent introduces the buckler mechanism as an intermediary between the SMA wires and the lens carriage. The buckler arms transmit and amplify the force from the SMA wires to the lens carriage through rotational motion. This intermediary mechanism overcomes the limitations of direct SMA actuation by converting small SMA contractions into larger linear displacements, thereby extending the effective Z-stroke range while maintaining electrical actuation capability.

Inventive Principle:
Principle #24Intermediary (Mediator)

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 solution provides a compact footprint with enhanced Z-stroke range and improved actuation height, reducing dynamic tilt and enhancing picture quality by minimizing friction and force imbalance through the use of ball bearings and even heat distribution in SMA wires.

Implementation Method 1

a magnetic element disposed at the hall housing wall and configured to magnetically attract the hall magnet

Methodology Applied
Scientific EffectMagnetic attraction: Magnetism

Implementation Method 2

The moving assembly and support assembly are coupled by four shape memory alloy (SMA) wires extending between the assemblies. Each of the SMA wires has one end attached to the support assembly, and an opposite end attached to the moving assembly. The suspension is actuated by applying electrical drive signals to the SMA wires.

Methodology Applied
Scientific EffectShape memory alloy effect: Shape Memory Alloy

Data Source

PatentUS12007618B2Guided autofocus assembly
Publication Date: 2024.06.11 HUTCHINSON TECH INC
  • US12007618B2 patent drawing
  • US12007618B2 patent drawing
  • US12007618B2 patent drawing

AI summary

Autofocus assembly and related methods are described. One example of an autofocus assembly includes a housing element. The housing element including a hall housing wall configured to secure a hall sensor. The autofocus assembly includes a lens carriage configured to secure a hall magnet and configured to be received within the housing element and configured to define a receiving space between the lens carriage and the housing element to receive one or more bearing elements. The autofocus assembly includes a magnetic element disposed at the hall housing wall and configured to magnetically attract the hall magnet and to secure the hall housing wall to the housing element and secure the one or more bearing elements between the hall housing wall and the lens carriage.