Self-Aligning Lens Array Module for High-Resolution Optical Systems
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Solution Overview
Problem
Existing multiple-layered lens array assemblies face challenges in achieving precise alignment of optical axes, leading to low yield and high manufacturing costs due to the lack of effective alignment mechanisms, which affects the resolution and efficiency of miniature optical lens modules in devices like mobile phones and tablets.
Innovation Solution
A multiple-layered lens array assembly with engaging surfaces co-axial with the optical axis on both the object-side and image-side surfaces, allowing for self-alignment of independent lens units without the need for additional jigs or retaining means, ensuring precise alignment of optical axes during stacking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple optical lenses are combined with precise alignment, then resolution is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent implements self-alignment mechanisms where the lens arrays automatically align their optical axes through built-in structural features such as positioning protrusions and recesses, eliminating the need for complex external alignment procedures and achieving high precision without increasing manufacturing complexity
Solution Approach 2:
The patent incorporates pre-designed alignment structures including positioning notches and guiding features on the lens arrays before assembly, enabling automatic optical axis alignment during the stacking process without requiring complex real-time adjustment procedures
2Power
If multiple lens arrays are stacked sequentially, then optical power is increased, but alignment accuracy deteriorates due to accumulation of errors
Solution Approach 1:
Each lens array in the stacked configuration incorporates self-alignment features that automatically correct positioning errors relative to adjacent arrays, preventing error accumulation and maintaining high optical axis alignment accuracy even as the number of stacked arrays increases
Solution Approach 2:
The patent designs pre-aligned reference features on each lens array that establish precise optical axis relationships before stacking, enabling multiple arrays to be assembled with consistent alignment accuracy throughout the stack
3Measurement precision
If space interval is provided between lenses, then optical performance is improved, but module size increases
Solution Approach 1:
The patent transitions from lateral spacing between lenses to vertical stacking configuration, maintaining necessary optical spacing while utilizing the third dimension to minimize the overall footprint and volume of the lens module
Data Source
AI summary
The present invention provides a multiple-layered lens array assembly comprising: at least a lens array set comprising a plurality of lens units, each of the lens units having an engaging surface surrounding an optical axis thereof and formed on an object-side surface or an image-side surface thereof; and at least an independent lens unit having an engaging surface surrounding an optical axis thereof and formed on an object-side surface or an image-side surface thereof; wherein the engaging surface of each of the lens units of the at least an lens array set connects with the engaging surface of a corresponding independent lens unit.