Image Pickup Lens Unit Resin Welding Assembly
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Solution Overview
Problem
Existing manufacturing methods for image pickup lens units in mobile phones are costly, require large spaces, and result in increased component complexity, size, and optical defects such as ghosts and flares due to complex molding processes and positioning issues.
Innovation Solution
A method involving two molding steps to integrate a lens and holder members using resin, where the first holder member is molded with a positioning portion, and the second holder member is welded to it, eliminating the need for additional components and reducing size by avoiding resin flow paths and positioning shape-related issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the optical lens is mounted into the holder by an automatic assembly system with image recognition technique, then the positioning accuracy is very high, but the system is very costly and requires a very large space
Solution Approach 1:
The mold includes a positioning member that preliminarily positions the optical lens during the molding process itself, before the holder is formed. This preliminary positioning action eliminates the need for complex post-assembly positioning systems, as the lens is already correctly positioned when the holder is molded around it.
Solution Approach 2:
The invention merges the positioning function and the holding function into a single integrated process. The positioning member is built into the mold, and the holder is molded around the positioned lens in one continuous operation, combining what were previously separate positioning and assembly steps into a unified manufacturing process.
2Adaptability or versatility
If facility replacement is carried out for each change of lens type, then the production can be adjusted, but very extensive work and many worker-hours are required
Solution Approach 1:
The invention segments the manufacturing process into modular components: the positioning member is a separate, replaceable element within the mold, while the holder is molded around it. This segmentation allows the positioning member to be quickly changed for different lens types without replacing the entire mold or facility, reducing adjustment time.
3Ease of manufacture
If a resin flow path is created for joining the cover to the holder body, then the components can be connected, but it is very difficult to ensure filling properties and joint strength of a thin-wall holder
Solution Approach 1:
The invention extracts the covering function from a separate cover component and integrates it directly into the holder body through the molding process. The holder body is molded with an integrated cover portion that forms a seamless enclosure for the lens, eliminating the need for separate joining operations and associated resin flow paths.
4Productivity
If the optical lens and the stop are directly held between molds, then the assembly can be formed, but the allowable range of holding force is narrow and the optical lens or the stop may be deformed or damaged
Solution Approach 1:
The invention introduces the positioning member as an intermediary element between the mold and the optical lens. Instead of the mold directly holding the lens, the positioning member gently guides and positions it, distributing forces evenly and preventing direct contact that could cause deformation or damage to the delicate optical surfaces.
5Manufacturing precision
If a positioning shape for positioning the lens is formed in the molds, then the lens can be positioned, but the positioning shape may remain as a visible depression causing optical defects such as ghosts and flares
Solution Approach 1:
The invention extracts the positioning function from a permanent positioning shape in the mold and transfers it to a removable positioning member. This allows the positioning element to be removed after serving its purpose, leaving no permanent depression or visible mark on the holder that could cause optical defects like ghosts and flares.
Solution Approach 2:
The positioning member performs the positioning action preliminarily during molding, and then its role is complete. Unlike a permanent positioning shape that remains as a depression, the positioning member can be removed or is designed not to leave permanent marks, thus preventing optical defects while still achieving accurate lens positioning.
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 approach simplifies the assembly process, reduces the number of components, prevents optical defects, and maintains stable lens holding while minimizing the size of the image pickup lens unit, ensuring precise positioning and improved dimensional accuracy.
Implementation Method 1
molding the second holder member such that the second holder member is welded to the first holder member
Data Source
AI summary
An image pickup lens unit, in which a holder body and a cover can be easily connected together, without additional components and a resin flow path for the connection. A lens 10 is positioned in a first holder member 20 which remains in a mold. A second holder member 30 for preventing the lens 10 from falling off is molded such that it is welded to the first holder member having the lens 10 positioned therein. This facilitates molding of the second holder member 30 and joining of the second holder member 30 to the first holder member 20 at the same time. Since there is no need to provide a resin flow path for joining the first holder member 20 and the second holder member 30 together, the image pickup lens unit can be made small in size.