Welding Structure for Optical Module Lens Assembly

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Solution Overview

Problem

Conventional optical modules face issues with deformation due to thermal expansion and contraction, leading to stability and imaging quality problems, especially with increased lens counts, and require precise alignment and smaller sizes for modern devices.

Innovation Solution

A welding structure is used to fix the multi-group lens assembly, allowing for thermal expansion compensation and alignment adjustments, reducing assembly errors and maintaining stable optical performance while minimizing module size.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If glue is used to fix the lens assembly and other components, then the components can be mounted and fixed, but thermal expansion and contraction cause deformation affecting optical performance

Engineering Contradiction:

Improvemounting and fixingVSAvoidoptical performance stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent changes the fixing method from adhesive bonding to welding, fundamentally altering the connection parameter from chemical bonding to metallurgical bonding. This eliminates the thermal expansion mismatch problem that causes deformation in glue-fixed structures, thereby maintaining stable optical performance across temperature variations.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical/adhesive fixing system with a welding system. Instead of using glue that is sensitive to thermal expansion differences, the invention uses welding to create a rigid, thermally stable connection between the lens assembly and the circuit board, eliminating deformation issues.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If glue is used for fixing structures, then components can be assembled, but a certain thickness of glue layer increases module size and design difficulty

Engineering Contradiction:

ImproveassemblyVSAvoidmodule size

Core Design Contradiction:

Ease of manufactureVSVolume of moving object

Solution Approach 1:

The patent replaces the adhesive bonding system with a welding system, eliminating the need for a glue layer of certain thickness. Welding creates a direct metal-to-metal connection without requiring the intermediate adhesive layer, thereby reducing the overall module size and simplifying design constraints related to gap tolerances.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Quantity of substance

If multiple lenses are assembled into a lens barrel, then high pixel imaging is achieved, but cumulative assembly errors reduce production yield

Engineering Contradiction:

Improvenumber of lensesVSAvoidoptical axis consistency

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The patent segments the lens assembly into multiple independent lens groups, each with its own optical axis. By welding each lens group separately to the circuit board with its optical axis aligned to the photosensitive chip, the cumulative assembly error problem is eliminated. Each lens group is independently positioned and fixed, preventing error accumulation that would occur with sequential assembly into a single lens barrel.

Inventive Principle:

Principle #1Segmentation

4Ease of manufacture

If lenses are assembled into a lens barrel, then the lens assembly can be formed, but the assembly process is time-consuming and reduces productivity

Engineering Contradiction:

Improvelens assembly formationVSAvoidassembly speed

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent divides the lens assembly into multiple lens groups that can be independently prepared and then welded to the circuit board in parallel. This segmentation enables concurrent processing of different lens groups, significantly reducing the overall assembly time compared to sequential assembly into a single lens barrel, thereby improving productivity.

Inventive Principle:

Principle #1Segmentation

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 welding structure ensures stable optical performance and improved production efficiency by reducing thermal deformation and assembly errors, enabling higher pixel imaging with smaller module sizes.

Implementation Method 1

since the thermal expansion or contraction coefficient of the medium is different from that of the material of a surface of a structure required to be fixed, the structure which is relatively fixed by glue is easily deformed when it is cooled after being heated

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentEP3637754B1Welding structure for optical module and application thereof

Publication Date: 2024.02.21 NINGBO SUNNY OPOTECH CO LTD

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Figure 3A~3C

AI summary

Disclosed is a welding structure (20) for an optical module (300) and an application thereof, wherein the optical module (300) comprises at least a first module assembly and at least a second module assembly, the welding structure (20) comprises at least a first welding part (21) and at least a second welding part (22), wherein the welding part (21) is provided on the first module assembly and the second welding part (22) is provided on the second module assembly, and after the first welding part (21) is welded to the second welding part (22), the first module assembly and the second module assembly are fixed relative to each other.