Optical Lens Assembly via Active Alignment and Adhesive Bonding
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Solution Overview
Problem
Existing camera modules face challenges in achieving high imaging quality due to manufacturing errors in lens elements and assembly processes, which are exacerbated by the need for high pixels and large apertures, leading to increased manufacturing complexity and defects.
Innovation Solution
An optical lens assembly method that adjusts the relative position of upper and lower sub-lenses using active alignment and bonds them directly, reducing assembly tolerances and adhesive variations to enhance connection strength and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high pixels and large aperture are implemented to meet market demands, then imaging quality is improved, but manufacturing precision requirements increase and defect rates rise
Solution Approach 1:
The optical lens is divided into multiple lens sheets (first lens sheet, second lens sheet, etc.) with distinct functions. Each lens sheet has specific structural features (aspherical surfaces, meniscus shapes) that address specific optical requirements. This segmentation allows independent optimization of each component while maintaining overall imaging quality, reducing the complexity of manufacturing the entire system as a single unit.
Solution Approach 2:
The patent implements preliminary positioning structures including protrusions on lens sheets that fit into corresponding recesses in the lens barrel, and pre-positioning of lens sheets before final adhesive bonding. The adhesive is applied in advance to specific regions (ineffective regions) of the lens sheets. These preliminary actions establish precise positions before final assembly, reducing assembly errors and defects.
2Measurement precision
If strict tolerances are imposed on lens elements to improve resolution, then imaging quality is enhanced, but manufacturing complexity and difficulty increase
Solution Approach 1:
The patent applies different quality requirements to different regions of the lens sheets. The effective regions (optical zones) require high precision for imaging quality, while the ineffective regions (margins) can tolerate larger variations. The adhesive is specifically applied to ineffective regions, and structural features like protrusions and recesses are positioned in these areas. This local differentiation reduces overall manufacturing complexity while maintaining resolution in critical optical areas.
Solution Approach 2:
The adhesive acts as an intermediary element between the lens sheets and lens barrel, and between adjacent lens sheets. Rather than requiring direct mechanical interference fits that would demand extremely tight tolerances, the adhesive provides a compliant bonding medium that can accommodate small variations in lens sheet dimensions and positions, thereby reducing manufacturing complexity while maintaining assembly precision.
3Ease of manufacture
If adhesive is used to bond lens components, then assembly is simplified, but adhesive deformation affects lens position and reduces reliability
Solution Approach 1:
The adhesive is applied selectively to specific regions of the lens sheets, particularly the ineffective regions or margins, rather than covering the entire surface. This localized application reduces the amount of adhesive used and minimizes its deforming influence on the lens sheets. The effective optical regions remain free of adhesive, preserving their positional accuracy and optical performance while still achieving reliable bonding through the adhesive in the non-critical areas.
Solution Approach 2:
Protrusions are provided on the lens sheets that fit into corresponding recesses in the lens barrel or adjacent lens sheets before adhesive bonding. These protrusions and recesses establish preliminary mechanical positioning and pre-load the lens sheets into their correct positions. When adhesive is subsequently applied to the ineffective regions, the lens sheets are already positioned accurately, and the adhesive primarily serves to lock this position rather than to create the position itself, thereby reducing adhesive-induced deformation.
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 method improves the process capability index, reduces defects, and enhances imaging quality by minimizing adhesive deformation effects on lens positions, thereby improving the yield and reliability of optical lenses and camera modules.
Implementation Method 1
an adhesive for bonding the first lens component and the second lens component together
Data Source
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AI summary
An optical lens, comprising: a first lens component (100) comprising a first lens barrel (101) and at least one first lens sheet (102) mounted in the first lens barrel; a second lens component (200) comprising a second lens barrel (201) and at least one second lens sheet (202) mounted in the second lens barrel, the at least one second lens sheet and the at least one first lens sheet together constituting an imageable optical system; and an adhesive bonding the first lens component and the second lens component together, at least a part of the adhesive being interposed between a lens barrel and a lens sheet, wherein the statement of between the lens barrel and the lens sheet specifically means between the second lens barrel and the first lens sheet or between the first lens barrel and the second lens sheet. A corresponding assembly method for optical lens, a camera module, an optical lens and assembly method for camera module are further provided. The position shift of the lens sheet caused by the deformation of the lens barrel can be reduced, and the imaging quality of the optical lens or the camera module can be improved.