Lens Doublet Self-Alignment Using Passive Centering Bells
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Solution Overview
Problem
Current methods for aligning lens doublets in camera systems are slow, costly, and not suitable for volume production, especially for small lenses like those in handheld or cell phone cameras, due to limitations in centration accuracy and efficiency.
Innovation Solution
A method and apparatus for aligning lens doublets using a system with a lockable lower chuck and upper bell chuck, where the upper lens self-aligns with respect to the lower lens's top surface or edge datums, utilizing precision balls and flexural bearings for precise alignment, and a passive alignment process that reduces capital and labor costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If active alignment methods are used to achieve micron level centration of lens doublets, then manufacturing precision is improved, but productivity decreases and cost increases
Solution Approach 1:
The patent implements self-aligning features where the lens pieces automatically center themselves on the centering bells during assembly. The upper lens piece is lowered onto the lower lens piece, and the self-aligning mechanism ensures automatic centration without requiring active alignment equipment or feedback control systems. This eliminates the need for slow, expensive active alignment while maintaining micron-level precision.
Solution Approach 2:
The patent replaces complex active alignment mechanical systems (including laser beams, CCD cameras, rotating air bearing stages, and feedback control mechanisms) with a simpler passive mechanical self-aligning system. The self-aligning centering bells and lens mounting structures provide automatic centration through pure mechanical means, achieving the same precision without the complexity and cost of active alignment equipment.
2Manufacturing precision
If active alignment equipment and methods are used for lens centration, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The alignment system uses self-aligning features built into the centering bells and lens mounting structures. When the upper lens piece is lowered onto the lower lens piece, the self-aligning mechanism automatically ensures that both pieces are concentric with their respective centering bells, eliminating the need for complex active alignment equipment with multiple adjustment mechanisms and feedback systems.
Solution Approach 2:
The patent extracts and eliminates the complex active alignment equipment (laser beams, CCD cameras, rotating stages, feedback control systems) from the manufacturing process, retaining only the essential passive mechanical centering structures. This simplification maintains centration accuracy while dramatically reducing device complexity.
3Manufacturing precision
If traditional centering methods are used for small lens pieces, then manufacturing precision can be maintained, but productivity decreases
Solution Approach 1:
The patent implements self-aligning features specifically designed for small lens pieces used in handheld and cell phone cameras. The self-aligning centering bells and lens mounting structures automatically ensure micron-level centration during high-speed assembly, enabling volume production without sacrificing precision. This is particularly valuable for small lenses where traditional active alignment would be prohibitively slow and expensive.
Data Source
AI summary
A method for aligning and assembling two lens pieces, and a machine to accomplish this task are provided. In one example of the method, the method includes holding an upper lens above a lower lens, holding the lower lens in a horizontal position, lowering the upper lens into a contact position with the lower lens, and allowing the upper lens to self-align to a top surface of the lower lens.