Image Sensor Alignment Using Transverse Test Image Projection
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Solution Overview
Problem
Conventional alignment apparatuses are unsuitable for aligning image sensors with certain lens modules due to complexities in optical path orientation, particularly in folded camera configurations where the second optical path is perpendicular to the first, making precise alignment difficult and impractical for achieving optimal image quality.
Innovation Solution
A method involving the use of a test image projected along a first optical path, which is then manipulated to align transversely with the image sensor, allowing for the determination of a corrected orientation of the lens module relative to the image sensor, enabling precise alignment and fixing of the lens module to the image sensor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional alignment apparatuses are used with complex lens modules having transverse optical paths, then the alignment process becomes difficult and impractical, but using specialized apparatuses increases device complexity and cost
Solution Approach 1:
The patent uses a test image as a virtual copy of the final image to perform alignment operations. By projecting a known test pattern through the lens module and analyzing its position and orientation on the image sensor, the system determines alignment parameters without requiring complex mechanical alignment apparatuses. The test image serves as a reference model that simplifies the alignment process.
Solution Approach 2:
The patent replaces mechanical alignment apparatuses with an optical-computational system. Instead of using complex mechanical devices to physically align components, the system projects test images optically and uses image processing algorithms to calculate alignment parameters. This substitution of mechanical systems with optical and computational methods simplifies the overall apparatus while maintaining alignment precision.
2Volume of moving object
If the optical path is folded to achieve compact imaging modules, then the device size is reduced, but the alignment between lens module and image sensor becomes more difficult
Solution Approach 1:
The patent addresses the alignment challenge in folded optical paths by introducing a test image projection approach that operates in the image space rather than directly in the optical path space. By projecting test images along both the first optical path (through the folded optics) and the second optical path (directly to the sensor), the system creates a reference framework that accounts for the folded geometry without requiring direct mechanical alignment along the folded path.
Solution Approach 2:
The alignment method combines multiple approaches: optical projection of test images, computational analysis of image positions, and iterative adjustment of alignment parameters. This composite methodology integrates optical, computational, and mechanical elements to achieve precise alignment in compact folded configurations, where each component addresses a specific aspect of the alignment challenge.
3Manufacturing precision
If precise alignment is achieved through manual adjustment, then image quality improves, but the alignment time and labor cost increase
Solution Approach 1:
The patent implements an automated feedback-based alignment system. Test images are projected through the lens module, captured by the image sensor, and analyzed to determine the current alignment state. Based on the analysis results, the system automatically adjusts alignment parameters and repeats the measurement until optimal alignment is achieved. This closed-loop feedback process eliminates manual trial-and-error adjustment, reducing both time and labor while maintaining high precision.
Solution Approach 2:
The alignment system performs self-alignment through automated image capture and analysis. The test image projection and sensor capture system automatically determines alignment parameters without requiring external manual intervention. The system serves itself by using its own imaging capability to measure and correct its alignment, eliminating the need for separate alignment tools or skilled operators.
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 method effectively addresses the challenge of aligning image sensors with complex lens modules by allowing for accurate optical alignment, even in folded camera configurations, thereby improving image quality and facilitating the attachment process by maintaining the image sensor on a horizontal plane, which simplifies glue dispensing and ensures correct orientation.
Implementation Method 1
an orientation of the second optical path with respect to the first optical path is due to reflection by at least one optical element comprised in the lens module
Data Source
AI summary
A method for aligning an image sensor relative to a lens module, the method comprising the steps of: receiving a test image along a first optical path with the lens module and projecting the test image along a second optical path transverse to the first optical path with the lens module; manipulating an orientation of the lens module with respect to the image sensor to project the test image along the second optical path onto the image sensor; using the test image received by the image sensor along the second optical path to determine a corrected orientation of the lens module with respect to the image sensor, so as to align the lens module with respect to the image sensor; and thereafter fixing the aligned lens module to the image sensor.