Stacked-Lens Assembly Spacer Alignment Mechanism
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Solution Overview
Problem
The incorporation of alignment structures in wafer-level lens assemblies for camera modules increases manufacturing costs and complexity.
Innovation Solution
A stacked-lens assembly is developed, featuring a lower substrate with a lower element and inner spacer, and an upper substrate with an upper element and outer spacer, where the upper spacer is attached to the inner spacer and at least partially surrounds the upper element, allowing for reduced manufacturing complexity by eliminating the need for additional alignment structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If alignment structures are incorporated into substrates and lenses, then axial alignment of lenses is ensured, but manufacturing costs and complexity increase
Solution Approach 1:
The patent removes alignment structures from substrates and lenses, extracting the alignment function to a dedicated alignment mechanism that coordinates wafer stacking. This eliminates the complexity of incorporating alignment structures into each component while maintaining precise axial alignment through the alignment mechanism's control of wafer positions and orientations.
2Manufacturing precision
If alignment structures are incorporated into substrates and lenses, then axial alignment of lenses is ensured, but manufacturing costs increase
Solution Approach 1:
The alignment function is extracted from individual components (substrates and lenses) and consolidated into a dedicated alignment mechanism. This reduces the total number of alignment structures needed across all components, lowering manufacturing costs while maintaining precise axial alignment through centralized control.
Solution Approach 2:
The alignment mechanism serves as a universal solution for aligning multiple lenses across multiple wafers, replacing the need for individual alignment structures in each substrate and lens. This multi-functional approach reduces overall manufacturing complexity and cost.
3Manufacturing precision
If multiple alignment structures are used across substrates and lenses, then axial alignment is achieved, but the number of components and fabrication steps increase
Solution Approach 1:
The alignment function is extracted from multiple components and consolidated into a single alignment mechanism, reducing the total number of components and fabrication steps. This centralized approach improves manufacturing efficiency by eliminating redundant alignment structures while maintaining precise axial alignment.
Data Source
AI summary
A stacked-lens assembly includes a lower substrate and an upper substrate. The lower substrate includes a lower-substrate top surface having thereon a lower element and an inner spacer, the inner spacer at least partially surrounding the lower element. The upper substrate includes an upper-substrate bottom surface opposite the lower-substrate top surface and having thereon an upper element and an outer spacer, the outer spacer (i) being attached to the inner spacer and (ii) at least partially surrounding the upper element. In any cross-section of the stacked-lens assembly parallel to the upper substrate and including both the inner spacer and the outer spacer, the entirety of the inner spacer is within a perimeter of the outer spacer.