Prism Block Mounting Surface Accuracy for Camera Modules
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Solution Overview
Problem
The positional accuracy of prisms in beam splitters is often low due to the lower formation accuracy of mounting surfaces at tilt angles, which affects the alignment of incident and reflected light axes.
Innovation Solution
A prism block design with a holder having a perpendicular mounting surface and a prism that is positioned and retained by the holder, enhancing positional accuracy through improved alignment mechanisms and surface contact configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mounting surface is formed at a tilt angle θ1 on the prism fixing stage, then the beam splitter can achieve the required optical function, but the formation accuracy of the mounting surface is lower than that of a level surface, resulting in low positional accuracy of the prisms
Solution Approach 1:
The patent introduces a mounting plate as an intermediary component between the prism fixing stage and the prisms. The mounting plate is formed at a tilt angle θ1 on the prism fixing stage, and the prisms are mounted on this plate. This intermediary structure allows the complex tilted mounting to be decoupled from the prism positioning, as the mounting plate's tilt is independent of the prism alignment references.
Solution Approach 2:
The patent segments the mounting structure into separate functional components: the prism fixing stage provides the base structure, the mounting plate provides the tilted mounting surface, and the prism support structure provides the optical axis alignment. This segmentation allows each component to be optimized independently - the mounting plate for tilt angle formation and the support structure for precise optical alignment.
2Manufacturing precision
If the bottom surface of the first prism and the bottom surface of the second prism are in surface-contact together forming a light-ray-bundle reflecting surface, then the optical function is achieved, but the positional accuracy depends on the accuracy of forming the tilted mounting surface
Solution Approach 1:
The mounting plate serves as an intermediary that carries the prisms while providing a tilted surface. The key innovation is that the mounting plate includes separate reference surfaces (first and second reference surfaces) that are used for positioning the prisms' optical axes, independent of the tilted mounting function. This separates the mounting function from the alignment function.
Solution Approach 2:
The mounting plate has different surface properties in different regions: the mounting surface is tilted at angle θ1 for optical function, while the reference surfaces are positioned to provide precise alignment references. This local differentiation allows the plate to simultaneously provide both tilted mounting and precise alignment capabilities.
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 enhances the positional accuracy of prisms, improving the alignment of light axes and reducing variations in optical axis positions, thereby enhancing the overall performance of the camera module.
Implementation Method 1
a prism configured to receive first light that travels in a first direction, and to cause second light that travels in a second direction perpendicular to the first direction to exit
Data Source
AI summary
A prism block includes the following: a holder having an opening surface and a mounting surface perpendicular to the opening surface; and a prism configured to receive first light that travels in a first direction, and to cause second light that travels in a second direction perpendicular to the first direction to exit. The prism is positioned and retained by the holder while being in abutment with the mounting surface.