Optical Lens Assembly with Air Escape Channels for Precise Alignment

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Solution Overview

Problem

The manufacturing process of high-pixel, large-aperture optical lenses is hindered by cumulative manufacturing errors, assembly difficulties, and the expansion of air during adhesive curing, leading to reduced resolution and reliability in camera modules.

Innovation Solution

A method involving pre-positioning lens components with structural gaps for sequential adhesive curing and incorporating air escape channels to mitigate the effects of air expansion during the baking process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If lens components are assembled with tight tolerances to improve resolution, then image quality improves, but manufacturing difficulty and assembly complexity increase significantly

Engineering Contradiction:

Improvelens assembly precisionVSAvoidassembly difficulty

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The lens assembly is divided into multiple independent lens components, each with its own mounting structure and adjustment mechanism. This segmentation allows each component to be manufactured and adjusted independently, reducing the cumulative error propagation that would occur in a monolithic assembly while maintaining overall imaging precision.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each lens component is pre-adjusted and pre-positioned on its mounting structure before final assembly. The mounting structures include pre-designed adjustment mechanisms that allow for preliminary alignment and positioning, reducing the need for complex post-assembly adjustments and lowering overall assembly difficulty.

Inventive Principle:

Principle #10Preliminary action

2Strength

If adhesive is applied between lens components for bonding, then structural strength improves, but air expansion during curing causes positioning errors and reduces reliability

Engineering Contradiction:

Improvebonding strengthVSAvoidpositioning accuracy

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The air that causes harmful expansion during adhesive curing is extracted from the bonding interface by designing gap structures between lens components. These gaps allow air to escape during the curing process, preventing air expansion from pushing the lens components apart and causing positioning errors, while still allowing the adhesive to form strong bonds.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The mounting structures include pre-designed gap structures and positioning features that anticipate and compensate for air expansion during adhesive curing. By providing escape paths for air before curing begins, the design prevents positioning errors from occurring in the first place, ensuring reliable lens component positioning.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Manufacturing precision

If multiple lens components are assembled to achieve high pixel density, then resolution improves, but cumulative manufacturing errors increase and reduce image quality

Engineering Contradiction:

Improveimage resolutionVSAvoiderror accumulation

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The optical system is segmented into multiple independent lens components, each with its own mounting and adjustment structure. This segmentation breaks the cumulative error chain by allowing independent adjustment of each component, preventing errors from propagating through the entire assembly and degrading overall image quality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mounting structures incorporate dynamic adjustment mechanisms that allow lens components to be positioned and aligned after assembly. This dynamic capability enables compensation for manufacturing tolerances and cumulative errors, maintaining high image resolution despite the presence of multiple assembled components.

Inventive Principle:

Principle #15Dynamics

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

Enhances the resolution and reliability of optical devices by allowing precise adjustment of lens components and reducing the impact of air expansion, thereby improving image quality and module stability.

Implementation Method 1

the expansion of air during adhesive curing

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS12510721B2Imaging optical device and manufacturing method therefor

Publication Date: 2025.12.30 NINGBO SUNNY OPOTECH CO LTD

AI summary

A manufacturing method of an imageable optical device includes pre-positioning at least two lens components along the optical axis so that the at least two lens components are able to form an image. A first structural gap and a second structural gap are arranged at different positions between two adjacent lens components. The method also includes adjusting relative positions of the pre-positioned at least two lens components by active alignment, arranging a first adhesive in the first structural gap, arranging a second adhesive in the second structural gap, and sequentially curing the first and second adhesives. The influence of later steps of the manufacturing process on the imageable optical device may thus be reduced, and connection strength and reliability of the imageable optical device are improved by subsequently curing the second adhesive. Also provided are an optical lens having an air escape channel, and an assembly method thereof.