Lens Unit with Lateral Support for Thin Camera Modules
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Solution Overview
Problem
Current camera modules have complex manufacturing processes and high costs due to the need for multiple components and assembly steps, such as COB or COF schemes, which complicate the integration of image sensors and lenses, and require additional components like ACF and adhesives for bonding.
Innovation Solution
A lens unit with a curved lens part and a support part with a hole, where the lens part is installed laterally, allowing for separate formation processes to inhibit resin shrinkage and achieve a thin, high-heat-resistant structure, and a manufacturing method involving a preliminary lens array substrate and molds to fill resin and cure it, preventing layered structures and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If COB or COF scheme is used to attach image sensor to substrate, then electrical connection and mounting are achieved, but manufacturing process complexity and cost increase
Solution Approach 1:
The patent merges the lens barrel and image sensor into a single integrated module, eliminating the need for separate COB/COF assembly processes. The lens barrel directly houses the image sensor without requiring additional substrates, ACF, or adhesives, thereby simplifying the manufacturing process while maintaining electrical connection functionality.
Solution Approach 2:
The lens barrel is designed to serve multiple functions: it acts as both the optical lens housing and the image sensor substrate. This multi-functional design eliminates the need for separate mounting substrates and complex electrical connection processes, directly addressing the contradiction between ease of manufacture and device complexity.
2Reliability
If multiple bonding components (ACF, adhesives) are used to assemble camera module, then reliable electrical and mechanical connection is achieved, but manufacturing cost and process complexity increase
Solution Approach 1:
The patent combines the electrical connection and mechanical support functions into the integrated lens barrel structure, eliminating the need for separate ACF and adhesive layers. The lens barrel itself provides both structural support and electrical pathways, reducing the number of bonding components while maintaining assembly reliability.
3Length of stationary object
If lens part is formed by filling hole in support part, then resin shrinkage is inhibited and thin structure is achieved, but manufacturing precision requirements increase
Solution Approach 1:
The support part with pre-formed holes is prepared before lens resin injection. This preliminary preparation ensures proper positioning and alignment, allowing the lens resin to be accurately injected into the holes without requiring extremely high manufacturing precision during the filling process itself.
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 solution enables the production of camera modules with superior optical and mechanical performance, reduced manufacturing complexity, and lower costs by simplifying the assembly process and eliminating the need for additional bonding components, while maintaining high heat resistance.
Implementation Method 1
forming the lens part in the opening by injecting a resin material into the inside of the mold such that the opening is filled with the resin material and curing the resin material
Data Source
AI summary
Disclosed are a lens unit and a method of manufacturing the same. The lens unit includes a lens part including a curved region having a predetermined curvature; and a support part including a hole, in which the lens part is installed, and attached to the lens part at a lateral side of the hole. The lens part having the curvature and the support part of the lens unit are formed in separate processes such that the hole is formed in the support part having the strength, and the lens part is formed by filling the hole with the lens part, so that the movement of resin caused by shrinkage of the lens part when the lens part is cured is inhibited, and the support part and the lens part does not form the layered structure, thereby allowing the lens unit to be formed with a thin thickness.