Lens Module Prism Alignment via Mechanical Engaging Structures
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Solution Overview
Problem
In existing lens modules, the prism is often decentered with respect to the optical axis of the lens set, leading to a decentered imaging path and compromised image quality for the image sensor.
Innovation Solution
A lens module design where the lens set and prism are assembled using engaging structures on their respective surfaces, ensuring the prism is centered with respect to the optical axis of the lens set, thereby aligning the imaging path with the image sensor's center, using processes like compression and injection molding to form these structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the prism is attached onto the lens set by glue, then the assembly process is simple, but the prism becomes decentered with respect to the optical axis
Solution Approach 1:
The patent replaces the chemical bonding method (glue) with a mechanical interlocking system. The first engaging structure on the lens set and the second engaging structure on the prism work together to mechanically constrain the prism's position, eliminating the decentering problem caused by glue while maintaining assembly simplicity through the complementary fit of the engaging structures.
2Ease of manufacture
If the prism is made of glass and attached by glue, then the manufacturing process is conventional, but the imaging path becomes decentered with respect to the image sensor center
Solution Approach 1:
The engaging structures are pre-formed as integral parts of the lens set and prism during their respective manufacturing processes (compression molding for the lens set, injection molding for the prism). This preliminary formation of the engaging structures ensures that when the components are assembled, the prism is automatically positioned correctly relative to the optical axis, guaranteeing proper imaging path alignment without requiring post-assembly adjustment.
3Manufacturing precision
If the lens set and prism are assembled by engaging structures, then the prism positioning is improved, but the structural complexity increases
Solution Approach 1:
The engaging structures are designed as integrated features of the lens set and prism components themselves rather than separate elements. The first engaging structure on the lens set and the second engaging structure on the prism combine to form a unified positioning system that achieves precise prism positioning while minimizing additional structural complexity, as the engaging structures are formed during the normal molding processes of the respective components.
Data Source
AI summary
A lens module includes a lens set and a prism. The lens set has a first light emitting surface and a first engaging structure, wherein the first engaging structure is formed on the first light emitting surface. The prism is disposed adjacent to the lens set. The prism has a light incident surface and a second engaging structure, wherein the second engaging structure is formed on the light incident surface. The lens set and the prism are assembled with each other by engaging the first engaging structure with the second engaging structure.