Plastic Lens Barrel Segmentation for Optical Precision
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Solution Overview
Problem
Conventional injection molded plastic lens barrels for optical systems often suffer from issues such as insufficient roundness, flatness, coaxiality, and structural strength due to poor melt flow rate and holding pressure during manufacturing.
Innovation Solution
The proposed imaging lens system incorporates a plastic lens barrel with a specific design featuring an object-side surface, an image-side surface, inner and outer annular portions, and an imaging lens assembly. The lens barrel includes inner parallel annular surfaces, gate traces, and a tapered first outer annular surface to enhance structural integrity and optical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional injection molded plastic lens barrel is used, then manufacturing cost is reduced and shape design flexibility is increased, but roundness, flatness, coaxiality, and structural strength are insufficient
Solution Approach 1:
The lens barrel is divided into multiple segments including a first lens barrel, a second lens barrel, and a third lens barrel, each with specific functions. The first lens barrel has a first inner wall surface and first outer wall surface, the second lens barrel has a second inner wall surface and second outer wall surface, and the third lens barrel has a third inner wall surface and third outer wall surface. This segmentation allows each segment to be optimized for specific manufacturing requirements while maintaining overall precision.
Solution Approach 2:
Different regions of the lens barrel are given different structural characteristics. The first lens barrel portion has a first thickness, the second lens barrel portion has a second thickness greater than the first thickness, and the third lens barrel portion has a third thickness greater than the second thickness. This local quality variation strengthens critical areas while maintaining manufacturing feasibility.
2Ease of manufacture
If conventional injection molded plastic lens barrel is used, then manufacturing cost is reduced, but structural strength is insufficient due to poor melt flow rate and holding pressure
Solution Approach 1:
The thickness parameters of the lens barrel are strategically varied along its length. The second lens barrel portion has a second thickness greater than the first thickness, and the third lens barrel portion has a third thickness greater than the second thickness. This parameter change strengthens the structure where needed while maintaining cost-effective manufacturing in less critical areas.
Solution Approach 2:
The lens barrel incorporates multiple material regions with different properties. The varying thickness regions create composite structural characteristics that enhance overall strength and rigidity while maintaining the cost benefits of plastic injection molding. The different thickness zones act as reinforced sections without requiring entirely different materials.
3Manufacturing precision
If lens elements with larger outer diameter are used, then optical resolution is improved, but the lens barrel structure becomes more complex
Solution Approach 1:
The lens barrel is segmented into three distinct portions, each optimized for supporting specific lens elements. This segmentation allows each segment to be precisely engineered for its specific function while maintaining overall structural coherence, avoiding the need for a completely complex redesign.
Solution Approach 2:
Each lens barrel portion has locally optimized characteristics: the first portion has a first thickness suitable for smaller lens elements, while the second and third portions have progressively greater thicknesses to support larger diameter lens elements requiring higher optical resolution. This local optimization avoids unnecessary complexity throughout the entire structure.
Data Source
AI summary
An imaging lens system has an optical axis and includes a plastic lens barrel and an imaging lens assembly disposed in the plastic lens barrel. The plastic lens barrel surrounds the optical axis and includes an object-side surface, an image-side surface, an inner annular portion and an outer annular portion. The object-side and image-side surfaces are oppositely disposed and substantially perpendicular to the optical axis. The inner and outer annular portions are connected to the object-side and image-side surfaces. The inner annular portion has an inner parallel annular surface, and the outer annular portion has a first outer annular surface and a gate trace. The imaging lens assembly includes a plurality of imaging lens elements. One of the imaging lens elements has an outer diameter larger than π2 millimeters. The one of the imaging lens elements has an outer edge in physical contact with the inner parallel annular surface.