Lens Unit Tapered Projection for Precision Assembly
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Solution Overview
Problem
Current lens units face challenges in achieving high positional precision and joining strength between the lens frame and lens element, while also suppressing harmful light rays, and require improvements in manufacturability and optical performance.
Innovation Solution
A lens unit design featuring a lens element with convex surfaces and a lens frame with tapered surfaces that incline relative to the optical axis, providing enhanced support and light shielding, along with a press-molding method that ensures precise positioning and stability during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a projection structure is used to support the lens element, then joining strength is improved, but manufacturing precision deteriorates due to alignment difficulties
Solution Approach 1:
The projection is designed with asymmetric tapered surfaces (first surface inclined at angle α, second surface inclined at angle β) rather than symmetric cylindrical or conical shapes. This asymmetry creates a unique fit with the corresponding recess in the lens element, ensuring precise alignment and positioning while maintaining strong joining force through the tapered engagement surfaces.
Solution Approach 2:
The invention changes the geometric parameters of the projection from traditional cylindrical or conical shapes to tapered surfaces with specific inclination angles (α and β). These parameter changes optimize both the joining strength through increased contact area and friction, and the manufacturing precision through self-aligning geometric constraints during assembly.
2Strength
If the lens frame structure is increased to support the lens element firmly, then joining strength is improved, but device complexity increases
Solution Approach 1:
The projection structure serves multiple functions simultaneously: it provides mechanical support for the lens element, ensures precise positional alignment, creates airtight sealing through the tapered engagement, and shields harmful light rays. This multi-functionality eliminates the need for separate components, reducing overall device complexity while maintaining or improving joining strength.
Solution Approach 2:
The invention merges the support function, positioning function, sealing function, and light shielding function into a single integrated projection structure on the lens frame. Traditionally, these would require multiple separate components (support ring, positioning features, seals, and light shields), but the projection combines all these functions into one element, simplifying the overall device structure.
3Object-affected harmful factors
If light shielding structures are added to block harmful light rays, then optical performance is improved, but device complexity increases
Solution Approach 1:
The projection structure simultaneously provides mechanical support and light shielding functions. The tapered surfaces that engage with the lens element also extend radially to block harmful light rays, eliminating the need for separate light shielding components and maintaining structural simplicity while improving optical performance.
4Ease of manufacture
If traditional cylindrical or conical projections are used, then manufacturing is simple, but positional precision and joining strength are insufficient
Solution Approach 1:
The projection uses asymmetric tapered surfaces with different inclination angles (α for the first surface, β for the second surface) instead of symmetric cylindrical or conical shapes. This asymmetric geometry provides superior positional precision through self-aligning engagement with the corresponding recess, while remaining manufacturable using standard precision machining or molding techniques.
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
The design achieves superior positional precision, joining strength, and optical performance by effectively shielding harmful light rays and improving manufacturability through a simple and efficient structure.
Implementation Method 1
a lens element (10) provided with a convex surface on at least one of an incident surface (11) and an exit surface (12) of the lens element, the lens element having a positive refractive power that condenses light rays
Implementation Method 2
the first, second and third surfaces are tapered surfaces that are respectively inclined relative to the optical axis direction... shields light that passes outside the effective aperture diameter of the lens element
Data Source
AI summary
A lens unit includes a positive lens element provided with a convex surface on an incident surface and/or an exit surface; and a lens frame supporting the lens element and being provided with a projection that projects in an inner radial direction from inside the lens frame. The lens frame supports the lens element with the projection fixedly fitted into an outer peripheral portion of the lens element. The projection is provided, on an inner peripheral portion thereof, with a first surface positioned on an incident side in an optical axis direction, a second surface positioned on an exit side in the optical axis direction, and a third surface positioned between the first surface and the second surface. The first, second and third surfaces are tapered surfaces that are respectively inclined relative to the optical axis direction. A method of manufacturing the lens unit is also provided.