Plano-convex Lens Module for Reflow Temperature Resistance
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Solution Overview
Problem
Current optical modules for mobile phones face challenges in manufacturing due to the limitations of thermoplastic materials used in lenses, which do not withstand high temperatures during the reflow process, leading to increased costs and reduced reliability, and require multiple manufacturing steps.
Innovation Solution
A lens module comprising two positive glass lenses, one being a plano-convex lens, designed to withstand reflow conditions with a specific distribution of power between aspherical surfaces to minimize manufacturing costs and improve optical performance, including the use of a plan surface on the second lens for reduced manufacturing complexity and the incorporation of an infrared light cut filter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermoplastic materials are used for lenses, then manufacturing cost is reduced, but the lenses cannot withstand high temperatures during reflow process
Solution Approach 1:
The patent changes the material parameter from thermoplastic to glass, which fundamentally alters the temperature resistance properties. Glass lenses can withstand reflow temperatures (typically 260°C) without deformation or degradation, while maintaining manufacturability through precision molding techniques.
Solution Approach 2:
The patent employs composite lens designs where glass lenses are combined with plastic lens holders or mounting structures. This allows the optical elements to be made of temperature-resistant glass while the structural components can be thermoplastic, achieving both high-temperature resistance and cost-effective manufacturing.
2Manufacturing precision
If multiple manufacturing steps are used for lens assembly, then manufacturing precision is improved, but productivity is reduced
Solution Approach 1:
The patent combines multiple manufacturing operations into a single integrated process. Lens molding, coating application, and assembly are performed in one continuous operation, eliminating intermediate handling steps and enabling high-volume production while maintaining precision through automated in-line processes.
Solution Approach 2:
The patent incorporates preliminary actions during the lens molding process itself, such as applying anti-reflective coatings or infrared filters directly to the lens surfaces while the material is still in a receptive state. This eliminates separate post-processing steps and accelerates production.
3Reliability
If aspherical surfaces are used on all lenses, then optical performance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies aspherical surfaces only where optically necessary, rather than uniformly to all lens surfaces. By analyzing the optical path and aberration patterns, aspherical correction is concentrated on specific surfaces that contribute most to image quality, while other surfaces maintain simpler spherical or planar geometries for easier manufacturing.
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 reduces manufacturing costs, enhances optical performance by minimizing geometric aberrations, and allows the module to withstand high temperatures, enabling single-step manufacturing and improved reliability.
Implementation Method 1
a lens module including a plano-convex lens, preferably giving an image onto a sensor with a sensor resolution smaller or equal to 2.2 megapixels, with an EFL shorter than 3 mm
Implementation Method 2
The Effective Focal Length determines the overall dimension of the module. The Effective Focal Length will hereafter be referred to as EFL.
Implementation Method 3
the incorporation of an infrared light cut filter
Data Source
AI summary
An optical module (10) comprises a positive meniscus lens (16) having a focal length F1 and comprising a first convex optical surface (12) and a second concave optical surface (20), and a plano-convex lens (22) having a focal length F1 and comprising a third flat optical surface (24) and a fourth convex optical surface (26) from an object side (12) to an image side (14). The curvatures of the four optical surfaces (12, 20, 24, 26) are defined by the equation: Zi=CURViYi2/(1+(1+Ki)CURVi2Yi2)½)+(Ai)Yi2+(Bi)Yi4+(Ci)Yi6+(Di)Yi8, and the two lenses are defined by 0.35<F1/F2<0.90, 0.30<Conv2/Conv<0.70, and 0.50<M1/M2<1.20; where: i is the surface number (i=1 to 4); for the i-th surface, Zi is the distance between a point on the aspheric surface at the height of Yi above the optical axis and a plane tangent to the aspheric surface at the intersection of the surface with the optical axis; Ki is the conic constant; CURVi is the curvature at the intersection of the surface with the optical axis with CURV3=0; Ai, Bi, Ci, Di are the aspheric coefficients of the 2nd, 4nd, 6nd and 8nd order with A3=0, B3=0, C3=0, D3=0; Ri is the effective radius of aperture; Mi=(1−(1+Ki)(CURVi)2(Ri)2)½; and Conv2 and Conv are the convergence of the second lens (22) and the complete lens module (10), respectively.