Packaged Lens Modules Mold Plate Filling Process
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Solution Overview
Problem
Conventional methods for forming packaged lens modules are complex and risk physical damage to lenses and imaging performance degradation due to adhesive residue and the need for coating and removing adhesive layers.
Innovation Solution
A method involving securing lens modules between mold plates, filling black material between them, and removing the plates after curing, which eliminates the need for adhesive layers and allows for height adjustability and back focal length compensation through mold plate design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional coating process with adhesive layer is used to form black material, then lens module can be temporarily blocked during coating, but process complexity increases and lens may be damaged or imaging performance may degrade
Solution Approach 1:
The invention extracts and eliminates the adhesive layer from the coating process. Instead of using adhesive to temporarily block the lens opening, the method directly coats the black material on the lens module without any intermediate adhesive layer, thereby simplifying the process and eliminating sources of lens damage and imaging degradation.
Solution Approach 2:
The invention applies preliminary protective measures by designing a specialized fixture that holds the lens module in a specific orientation during coating. This preliminary positioning ensures that the lens opening is naturally protected from black material contamination without requiring additional adhesive blocking steps.
2Productivity
If adhesive layer is used to block lens opening during coating, then coating can be performed, but time consumption increases due to coating and removing adhesive layers
Solution Approach 1:
The invention removes the adhesive layer step entirely from the manufacturing process. By eliminating the need to coat and subsequently remove adhesive, the overall manufacturing time is significantly reduced while maintaining effective protection of the lens opening through alternative means.
Solution Approach 2:
The fixture is designed in advance with specific structural features that automatically protect the lens opening during coating. This preliminary design eliminates the need for time-consuming adhesive application and removal steps, as the protective function is built into the fixture itself.
3Reliability
If adhesive layer is removed after coating, then lens opening is exposed, but adhesive residues may remain causing imaging performance degradation
Solution Approach 1:
The invention extracts and eliminates the adhesive layer that causes residue problems. By coating the black material directly without using adhesive as an intermediate blocking layer, there is no adhesive to remove and no risk of adhesive residues contaminating the lens opening or affecting imaging performance.
Solution Approach 2:
The fixture is designed with features that prevent black material from entering the lens opening in the first place. This preliminary protective design eliminates the need for subsequent cleaning or removal steps, ensuring the lens opening remains free of contaminants without additional manufacturing complexity.
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 method simplifies the process, reduces the risk of lens contamination, and enhances the reliability and performance of packaged lens modules by ensuring efficient filling and attachment without adhesive-related issues, while enabling height adjustability and back focal length compensation.
Implementation Method 1
after the black material is cured
Data Source
AI summary
A method of forming packaged lens modules is disclosed which includes: securing first ends of a plurality of lens modules equidistantly on a first mold plate; providing a second mold plate matching with second ends of the lens modules and securing the second mold plate on the second ends of the lens modules; filling a black material in gaps between the lens modules; and removing the first and second mold plates after the black material is cured and performing a dicing process. The method can effectively block lens openings to protect lenses from being contaminated and can eliminate the need for adhesive application and removal generally performed on second ends of the lens modules, thereby resulting in time savings and an efficiency improvement. Additionally, a height of the resulting packaged lens modules can be modified for back focal length compensation thereof by changing the size of the second mold plate.