Optical Lens Glue Spreading Surface Design for Camera Module Yield
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Solution Overview
Problem
The challenge lies in manufacturing camera modules with high pixels, small size, and large aperture, where the complex optical system is sensitive and prone to manufacturing errors, affecting image quality and yield, and existing solutions struggle to balance accuracy, cost, and reliability.
Innovation Solution
An optical lens design featuring a first lens component and a second lens component with a specific glue arrangement and Active Alignment process to adjust and bond the relative position of sub-lenses, improving the process capability index and reducing production costs while enhancing image quality and structural reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the optical system is designed with large aperture and large wide angle to improve photographing quality, then the imaging performance is improved, but the manufacturing sensitivity increases and yield decreases
Solution Approach 1:
The optical lens is divided into multiple lens sheets (first lens sheet, second lens sheet, third lens sheet, etc.) with different optical functions. Each lens sheet can be manufactured and optimized independently, then assembled together. This segmentation allows complex optical requirements (large aperture, wide angle) to be achieved while maintaining manufacturing feasibility and quality control for each individual component.
Solution Approach 2:
Different lens sheets are designed with locally optimized properties - some lens sheets focus on specific wavelength ranges, others on particular optical corrections. The glue layers are strategically placed at specific positions between lens sheets to provide localized support and positioning. This local quality approach allows the overall system to achieve high imaging performance while each component remains manufacturable with standard tolerances.
2Measurement precision
If the number of lens sheets is increased to solve aberrations, then the optical performance is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The optical system is segmented into multiple lens sheets, each responsible for correcting specific types of aberrations. This functional segmentation allows complex aberration correction to be achieved through simpler individual lens elements rather than requiring each lens to be overly complex.
Solution Approach 2:
The patent uses composite construction with lens sheets made of different materials (positive refractive index materials and negative refractive index materials) combined with glue layers. This composite approach enables aberration correction through material properties rather than complex geometric shapes, simplifying the overall optical design.
3Measurement precision
If the accuracy of each lens sheet and assembly is improved to reduce manufacturing errors, then the image quality is improved, but the manufacturing cost increases
Solution Approach 1:
The patent incorporates preliminary positioning features directly into the lens sheet designs - such as protrusions fitting into grooves, or predefined alignment marks. These preliminary actions ensure correct assembly positioning without requiring ultra-precise manufacturing tolerances, thereby reducing manufacturing costs while maintaining image quality.
Solution Approach 2:
The glue layers serve as intermediaries between lens sheets, providing both optical function and mechanical positioning. The glue layers compensate for minor manufacturing variations and ensure proper alignment, reducing the need for high-precision manufacturing while maintaining assembly accuracy and image quality.
4Volume of moving object
If the camera module size is reduced to meet compact device requirements, then the portability is improved, but the aperture and imaging quality become harder to achieve
Solution Approach 1:
The patent employs a nested arrangement where lens sheets are stacked concentrically around a central optical axis, with each lens sheet positioned within the structure of the previous ones. This nesting allows multiple optical elements to be packed into a compact volume while maintaining the necessary aperture size and optical paths for high-quality imaging.
Solution Approach 2:
Instead of expanding the camera module in traditional lateral dimensions, the patent utilizes the axial dimension by stacking thin lens sheets in sequence. This dimensional transition allows the optical system to achieve complex imaging functions within a compact footprint by exploiting the third dimension (depth/axis direction) rather than increasing overall module width or height.
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 enhances the mechanical strength and reliability of the optical lens, improves yield, miniaturizes the camera module, and reduces production defects and costs, while maintaining high image quality and resisting environmental variations.
Implementation Method 1
a first glue material arranged between the outer top surface and a bottom surface of the first lens component, the first glue material being suitable for supporting and fixing the first lens component and the second lens component after curing
Data Source
AI summary
The present application provides an optical lens, comprising: a first lens component, a second lens component and a first glue material. A first lens sheet group of the first lens component and a second lens sheet group of the second lens component together constitutes an imageable optical system, wherein a second lens barrel of the second lens component has an outer top surface and an inner top surface, and the second lens sheet group bears against the inner top surface. The outer top surface comprises a glue spreading surface suitable for arranging the first glue material and an extension surface formed by extending from the glue spreading surface to a central axis of the second lens barrel, there is a first thickness from the glue spreading surface to the inner top surface, there is a second thickness from the extension surface to the inner top surface, and the first thickness is greater than the second thickness. The present application further provides a corresponding camera module and an assembling method. The present application can improve the mechanical strength and reliability of the black object of the second lens component, can improve the yield of the optical lens or the camera module, and contributes to the miniaturization of the camera module.