Split-Camera Autoalignment for Ultra-Thin Handheld Devices
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Solution Overview
Problem
Engineering thin handheld devices with integrated cameras is challenging due to the focal length of the objective lens system, which imposes a lower limit on thickness, and the decrease in overall rigidity affects precise alignment of internal componentry, particularly in optical systems like cameras.
Innovation Solution
A handheld electronic device with a camera component divided into two separable portions, each portion having equal or comparable thickness, is equipped with an alignment-sensing system and linear actuators to ensure precise alignment and realignment of the objective and sensor portions, using piezoelectric actuators for dynamic adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the device is made thinner to improve portability and aesthetics, then the overall thickness is reduced, but the focal length requirement and rigidity are compromised, affecting alignment precision
Solution Approach 1:
The camera component is divided into two separable portions: an objective portion containing the lens system and a sensor portion containing the image sensor. Each portion can be independently manufactured with precise alignment features, and they are designed to mate together with complementary alignment mechanisms. This segmentation allows each portion to be optimized for thinness while maintaining alignment precision through the interface between portions.
Solution Approach 2:
Alignment features and mechanisms are pre-integrated into both the objective portion and sensor portion during manufacturing. The portions include pre-configured alignment pins, slots, or other registration features that automatically guide precise alignment when the portions are assembled, eliminating the need for post-assembly alignment adjustments.
2Length of stationary object
If the device is made thinner, then portability is improved, but the rigidity decreases, causing misalignment of internal components
Solution Approach 1:
By separating the camera into two portions that attach to different sides of the device, the structural load is distributed. Each portion can be independently supported by the device structure, reducing the rigidity requirements for any single thin section while maintaining overall camera alignment.
Solution Approach 2:
Rigidity-compensating features such as reinforcement ribs, stiffening structures, or pre-stressed connection elements are built into the portions during manufacturing. These features provide localized structural support at the camera interface without increasing the overall device thickness.
3Ease of manufacture
If the objective and sensor portions are separated for modularity, then ease of manufacture and repair are improved, but alignment precision becomes more difficult to maintain
Solution Approach 1:
Alignment features are pre-configured into both portions during manufacturing, including precision-machined alignment pins, slots, or magnetic registration elements. These features are designed to automatically guide the portions into precise alignment when assembled, eliminating the need for complex alignment procedures during manufacturing or repair.
Solution Approach 2:
The alignment system is designed to be self-aligning, where the portions automatically find their correct relative position through mechanical interference features, magnetic attraction, or compliant elements that guide alignment. This self-service alignment mechanism maintains precision without requiring skilled operators or specialized equipment during assembly or repair.
4Manufacturing precision
If alignment-sensing systems and actuators are added to maintain precision, then alignment accuracy is improved, but device complexity increases
Solution Approach 1:
The alignment system uses self-aligning mechanical features that automatically maintain precision without requiring active sensing or actuation. Compliant elements, elastic deformable features, or spring-loaded alignment mechanisms automatically compensate for manufacturing tolerances and environmental changes, maintaining alignment precision while avoiding complex electronic control systems.
Solution Approach 2:
Complex electronic alignment-sensing and actuation systems are replaced with purely mechanical alignment solutions. This includes using precision-machined mechanical interfaces, elastic compliant elements, or shape memory alloy components that automatically maintain alignment through physical principles rather than electronic control, thereby reducing system complexity.
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
Enables the construction of ultra-thin handheld devices with high-quality imaging capabilities by maintaining precise alignment and realigning the camera components, ensuring optimal image capture even in varying states of separation and folding.
Implementation Method 1
using piezoelectric actuators for dynamic adjustment
Data Source
Figure 1A
Figure 1B~1D
Figure 2
AI summary
An electronic device comprises a camera and a retaining member. The camera includes an objective portion configured to collect light from a subject, a sensor portion reversibly separable from the objective portion, an alignment-sensing system configured to sense a state of alignment between the objective portion and the sensor portion, an actuator configured to move the objective or sensor portion, and a computer configured to control the actuator responsive to output of the alignment-sensing system, so as to bring the objective and sensor portions into alignment. The retaining member is configured to couple the objective portion to the sensor portion when the objective and sensor portions are aligned and when the objective portion is separated from the sensor portion.