Lens Modules Using Patterned Substrate Recesses for Alignment
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Solution Overview
Problem
Conventional lens module packaging techniques face challenges such as high spacer production costs, substrate limitations, and misalignment due to inaccurate spacer thickness and optical center alignment, which complicate the manufacturing of high-volume, portable electronic devices with changing performance and functionality requirements.
Innovation Solution
A lens module design featuring patterned substrates with recesses and lens elements aligned along an optical axis, where the substrates are stacked and diced into individual modules, utilizing UV-embossing of polymer-on-glass lenses and optional coating layers, to improve alignment and reduce production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional packaging techniques with spacers are used to stack and align lens modules, then the lens module can be assembled, but the production cost increases and alignment precision deteriorates due to inaccurate spacer thickness and optical center alignment
Solution Approach 1:
The patent merges the spacer function directly into the substrate by forming recesses in the substrate itself, eliminating the need for separate spacer components. This integration reduces the number of parts, simplifies the assembly process, and improves alignment precision by removing the alignment errors inherent in separate spacer components.
Solution Approach 2:
The patent extracts the alignment function from separate spacer components and embeds it directly into the substrate structure through precisely formed recesses. This extraction of the alignment function into the substrate itself eliminates the need for additional alignment mechanisms and reduces production costs.
2Manufacturing precision
If conventional spacer processes are used to separate substrates, then the lens module structure can be formed, but the optical center alignment becomes inaccurate due to spacer thickness variations
Solution Approach 1:
The patent combines the substrate and spacer functions into a single integrated structure. The recesses formed in the substrate serve as both structural features and alignment references, eliminating the need for separate spacer components and their associated alignment problems.
Solution Approach 2:
The patent performs preliminary action by forming the recesses in the substrate before assembling the lens elements. This preliminary formation of the recesses establishes precise alignment references in advance, ensuring accurate optical center alignment without requiring complex spacer processes.
3Productivity
If high-volume production is pursued for portable electronic devices, then market competitiveness improves, but production costs increase due to conventional packaging techniques
Solution Approach 1:
The patent merges multiple functions (substrate support, spacing, alignment) into a single integrated structure, reducing the number of components and assembly steps. This integration is particularly beneficial for high-volume production as it simplifies the manufacturing process and reduces costs associated with producing and managing multiple separate components.
Solution Approach 2:
The patent extracts the alignment and spacing functions from separate components and embeds them in the substrate structure. This extraction eliminates the need for additional alignment mechanisms and reduces the overall component count, leading to lower production costs that scale effectively with high-volume manufacturing.
Data Source
AI summary
According to an embodiment of the present invention, a lens module is provided, which includes a first lens assembly including a first patterned substrate, a first recess formed from a first surface of the first patterned substrate, a first lens element disposed in the first recess, and a second lens element disposed on the first patterned substrate, wherein the second lens element aligns along an optical axis through the first lens element.