Six-axis lens mount with elastic gasket for single-step alignment
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Solution Overview
Problem
Existing imaging systems face challenges in achieving precise optical alignment between the lens and optical imager due to tolerance stack-ups during fabrication and assembly, which are not sufficient for accurate optical metrology applications, requiring complex and multi-step active alignment processes.
Innovation Solution
A lens mount system with six-axis active alignment capability using an elastic gasket that allows for single-step joining, enabling the lens assembly to move in multiple directions and rotate, ensuring precise alignment of the optical axis with the imager while maintaining a seal and allowing for focusing without adjusting the lens position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional rigid mounting with tight tolerances is used, then manufacturing precision is maintained, but device complexity and assembly difficulty increase due to multiple alignment steps
Solution Approach 1:
The mounting structure transitions from a rigid fixed-position design to a dynamic adjustable design. The lens carrier includes adjustment mechanisms that allow the lens assembly to be positioned and aligned dynamically during assembly, then fixed once the optimal position is achieved. This resolves the contradiction by enabling high precision alignment without requiring extremely tight manufacturing tolerances on all components.
Solution Approach 2:
The invention changes the mounting parameters from fixed dimensional tolerances to adjustable positional parameters. Instead of relying on precisely manufactured fixed positions, the system allows for parameter adjustment (lens position, angle, etc.) to achieve the desired optical alignment. This reduces the stringency of manufacturing tolerances while maintaining alignment precision.
2Manufacturing precision
If active alignment process is used to achieve tighter tolerances, then manufacturing precision improves, but productivity decreases due to multiple alignment and securing steps
Solution Approach 1:
The lens carrier is pre-configured with adjustment mechanisms and mounting features that enable alignment to be performed in a preliminary stage before final assembly. This preliminary alignment action is facilitated by the built-in adjustment capabilities, allowing the lens to be positioned correctly before being permanently fixed, thereby streamlining the overall assembly process and improving productivity.
Solution Approach 2:
The invention merges multiple functions into the lens carrier structure: alignment adjustment, positioning, and mounting are combined into a single integrated component. This consolidation reduces the number of separate alignment and securing steps required, as the lens carrier performs multiple functions that would otherwise require separate operations, thereby improving assembly speed and productivity.
3Manufacturing precision
If multiple piece lens mount carrier is used, then alignment capability is improved, but device complexity increases due to multiple components and joining steps
Solution Approach 1:
The invention merges multiple separate components (lens mount, carrier, adjustment mechanisms) into a single integrated lens carrier assembly. This unified structure maintains all necessary alignment capabilities while eliminating the need for multiple separate parts and their associated joining steps, thereby reducing device complexity without sacrificing alignment precision.
Solution Approach 2:
The lens carrier is designed as a universal component that performs multiple functions: it provides mechanical support, enables alignment adjustment, and facilitates mounting to the base substrate. This multi-functionality reduces the need for separate specialized components, simplifying the overall structure while maintaining comprehensive alignment capability.
4Manufacturing precision
If tight dimensional tolerances are specified for all components, then manufacturing precision is maintained, but ease of manufacture decreases due to difficulty in maintaining tolerances
Solution Approach 1:
The invention changes the approach from controlling dimensional tolerances of all components to controlling the final positional and orientational parameters of the lens assembly. Instead of requiring tight tolerances on each component's dimensions, the system allows for parameter adjustment to achieve the desired optical alignment, significantly easing fabrication requirements while maintaining manufacturing precision.
Solution Approach 2:
The invention extracts the alignment function from the manufacturing process itself and places it in the assembly process. Rather than requiring tight tolerances to be built into each component during fabrication, the alignment is achieved by adjusting the lens position within the carrier during assembly. This separates dimensional manufacturing from optical alignment, making both easier to achieve.
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
This solution simplifies the attachment process, reduces tolerance stack-ups, and achieves precise optical alignment compatible with high-volume manufacturing and automation, ensuring accurate optical metrology measurements with improved alignment accuracy.
Implementation Method 1
an elastic gasket that allows for single-step joining, enabling the lens assembly to move in multiple directions and rotate
Implementation Method 2
an adhesive is then applied within the mounting apertures to secure the lens assembly to the base substrate
Implementation Method 3
a lens or other image-forming element capable of capturing light from a scene/object and focusing/projecting that light onto a surface that is capable of sensing the light
Data Source
AI summary
Provided herein is a lens mount system and related process that allow for performing six-axis active alignment with a single joining step. This system and/or process simplifies the lens attachment in a manner that makes such attachment compatible with high volume manufacturing and/or full automation.