Lens Module Protrusions Block Light Reflection
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Solution Overview
Problem
The existing lens modules in portable electronic devices face issues with adhesive layer distortion and cracking under lateral pressure, leading to lens separation and light reflection from metallic components, which results in image quality degradation due to flares or stains.
Innovation Solution
The lens module design incorporates protrusions on the surface of the lens unit that contact and abut the edges of the adhesive layer, increasing the bonding strength and blocking light that would otherwise pass through, thereby preventing rocking and separation, and using optically clear adhesives throughout to minimize light reflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive layer is used to bond lens unit to mounting bracket, then assembly is simplified and manufacturing is easier, but bonding strength decreases and adhesive layer distorts/cracks under lateral pressure
Solution Approach 1:
The mounting bracket is segmented to include multiple protrusions that extend into the lens unit, creating multiple discrete bonding interfaces. This segmentation distributes mechanical stress across multiple contact points rather than relying on a single continuous adhesive layer, thereby improving bonding strength while maintaining manufacturing simplicity.
Solution Approach 2:
The bonding interface combines mechanical interlocking (protrusions) with chemical bonding (adhesive layer) to create a composite bonding system. The protrusions provide structural support and stress distribution, while the adhesive layer provides additional bonding and sealing, together achieving both ease of manufacture and high bonding strength.
2Ease of manufacture
If adhesive layer is used to bond lens unit to mounting bracket, then assembly is simplified, but reliability decreases due to distortion and cracking under lateral pressure
Solution Approach 1:
The mounting bracket is segmented to include multiple protrusions that extend into the lens unit, creating multiple discrete bonding interfaces. This segmentation distributes mechanical stress across multiple contact points rather than relying on a single continuous adhesive layer, thereby improving bonding strength while maintaining manufacturing simplicity.
Solution Approach 2:
The protrusions are designed beforehand to absorb and distribute lateral pressure before it can cause distortion or cracking of the adhesive layer. This preemptive structural design cushions the adhesive layer against mechanical stress, improving reliability while keeping the assembly process simple.
3Ease of manufacture
If conventional adhesive is used, then manufacturing is easier and cost is lower, but light reflection occurs causing flares and stains in images
Solution Approach 1:
The adhesive material parameters are changed by selecting optically clear adhesives with specific optical properties (high transparency, low refractive index difference) that minimize light reflection. This parameter change allows the adhesive to maintain its bonding function while eliminating the harmful optical effect of reflection, thus improving image quality without significantly complicating manufacturing.
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 design enhances the bonding strength between the lens unit and the mounting bracket, reducing the likelihood of separation and light reflection, resulting in improved imaging quality by preventing flares and stains in images.
Implementation Method 1
using optically clear adhesives throughout to minimize light reflection
Data Source
AI summary
A lens module with physically stronger foundations and enhanced stability includes a circuit board, an image sensor thereon, a mounting bracket, an optical filter, and a lens unit. The mounting bracket is connected to the surface of the circuit board which has the image sensor. The optical filter is connected to mounting bracket and positioned above the image sensor. The lens unit is connected to the mounting bracket facing away from the circuit board through a frame of adhesive. The surface of the lens unit connected to the mounting bracket has protrusions which are positioned at inner edges of the adhesive layer. The protrusions are taller than the depth of the adhesive layer.