Wafer-Level Lens Module Alignment via Segmented Plate Assembly
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Solution Overview
Problem
Conventional wafer level lens manufacturing methods using two or three lens plates struggle to achieve high optical quality due to alignment challenges, which are exacerbated by consumer demands for improved image quality.
Innovation Solution
A manufacturing method for a lens module that involves aligning and connecting multiple lens units from separate lens plates, with a focus on adjusting the relative position of first lens units with respect to corresponding second and third lens sections to form a lens module, where the most sensitive lens units are precisely aligned to enhance optical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If three lens plates are aligned and connected to improve optical quality, then imaging quality is improved, but alignment difficulty and manufacturing complexity increase
Solution Approach 1:
The patent applies preliminary action by pre-connecting the second and third lens plates before aligning them with the first lens plate. This sequence reduces the overall alignment complexity by breaking down the three-plate alignment problem into manageable steps, where the second and third plates are already positioned relative to each other before being integrated with the first plate.
Solution Approach 2:
The patent segments the lens module assembly into distinct stages: first connecting the second and third lens plates, then aligning the first lens plate with the already-connected second and third plates. This segmentation of the assembly process simplifies the alignment task by treating it as a series of smaller alignment problems rather than a single complex three-plate alignment.
2Manufacturing precision
If conventional two-lens-plate manufacturing is used, then manufacturing process is simpler, but optical quality cannot satisfy consumer demands
Solution Approach 1:
The patent uses preliminary action by pre-assembling the second and third lens plates into a connected unit before integrating with the first lens plate. This approach maintains relative manufacturing simplicity by reusing the conventional two-plate connection process twice (first between plates 2 and 3, then between plate 1 and the 2-3 unit), rather than attempting to align all three plates simultaneously.
Data Source
AI summary
A method of manufacturing a lens module including following is provided. A first lens plate having a plurality of first lens sections, a second lens plate having a plurality of second lens sections and a third lens plate having a plurality of third lens sections are provided. The first lens sections of the first lens plate are separated to form a plurality of first lens units. The second and third lens plates are connected. A relative position between each of the first lens units and one of the second lens sections corresponding to the first lens unit is adjusted. Each of the first lens units and the second lens section corresponding to the first lens unit are connected. The second and third lens sections are separated to form a plurality of second lens units and a plurality of third lens units connected to the second lens units.