Integrated Sensor Lens Assembly for Post-Tuning Focus Alignment
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Solution Overview
Problem
Manufacturing high-resolution camera lenses faces challenges in achieving precise alignment and focus due to dimensional shifts and tilts of the lens barrel relative to the image sensor, which are introduced during assembly and temperature cycling.
Innovation Solution
An integrated sensor and lens assembly design using a collet and lens mount with tunable fastening structures allows for post-tuning adjustments of the lens barrel's position to maintain alignment with the image plane, compensating for shifts caused by assembly and temperature effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the lens barrel position is adjusted for optical focal length and axial tilt during assembly, then the focus alignment is improved, but dimensional shifts are introduced during post-curing and cycling tests
Solution Approach 1:
The lens barrel is designed with movable components that allow dynamic adjustment of its position relative to the image sensor. The barrel can be shifted along the optical axis and tilted to compensate for dimensional changes during post-curing and temperature cycling, maintaining focus alignment while accommodating dimensional instability.
Solution Approach 2:
The patent employs adjustable parameters including the axial position of the lens barrel and the tilt angle of the optical axis. These parameters can be modified during assembly and testing to compensate for dimensional shifts, allowing the system to adapt to changing dimensional conditions while maintaining proper focus.
2Reliability
If the lens barrel is made adjustable to compensate for dimensional shifts, then the focus stability is improved, but the assembly complexity increases
Solution Approach 1:
The lens barrel incorporates movable components such as adjustable mounts and positioning mechanisms that enable dynamic compensation for dimensional shifts. These dynamic elements allow the barrel to be repositioned along the optical axis and tilted to maintain focus stability throughout the product lifecycle.
Solution Approach 2:
The patent implements preliminary adjustment mechanisms during assembly that allow the lens barrel to be pre-positioned and tuned before final installation. This preliminary action enables compensation for anticipated dimensional shifts during post-curing and cycling tests without requiring complex real-time adjustment systems.
3Manufacturing precision
If manual tuning of the lens barrel position is performed, then the alignment precision is improved, but the manufacturing time and productivity are reduced
Solution Approach 1:
The lens barrel positioning system incorporates self-aligning features such as automated adjustment mechanisms and built-in tuning capabilities that allow the system to compensate for dimensional shifts without requiring extensive manual intervention. This self-service approach maintains high alignment precision while reducing assembly time.
Solution Approach 2:
The patent implements feedback mechanisms that enable monitoring and adjustment of the lens barrel position based on actual performance data. This feedback loop allows for rapid iteration and adjustment, maintaining high alignment precision while improving manufacturing efficiency through automated or semi-automated tuning processes.
Data Source
AI summary
An integrated image sensor and lens assembly may include a lens barrel, a collet, and a lens mount. The lens barrel may be coupled to the collet which is coupled to the lens mount. The lens barrel and the collet may each include a fastening structure reciprocal to each other. Alternatively, the collet and the lens mount may each include a fastening structure reciprocal to each other. The optical distance between the set of lenses and the image sensor may be tuned such that the focal plane of the lenses coincides with the image plane. The fastening structures allow the lens barrel to be adjusted relative to the lens mount in order to shift the focal plane in a direction along the optical axis to compensate for focal shifts occurring during assembly/cure and/or temperature cycling.