Tunable Optical Module with Liquid-Filled Deformable Space

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Solution Overview

Problem

The challenge in manufacturing optical modules for mobile phones is to achieve high-yield production with low production costs while meeting evolving requirements due to increased image sensor sizes and smaller pixels, which complicates achieving the necessary optical specifications.

Innovation Solution

A method involving a tunable optical component with two optical surfaces and a deformable internal space filled with a transparent liquid, allowing adjustable optical properties by altering the shape of the internal space, combined with a first optical element attached to one surface and a second optical element joined via a reliable bond, ensuring quality control before assembly and reducing material costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional optical modules are manufactured with fixed optical components, then production is simpler and costs are lower, but the optical specifications cannot be adjusted to meet evolving requirements from increased image sensor sizes and smaller pixels

Engineering Contradiction:

Improveadjustability of optical propertiesVSAvoidcomplexity of optical component structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent employs a tunable optical component with a deformable internal space that can be dynamically adjusted to change optical properties such as focal length and aperture. This dynamic structure allows the optical module to adapt to different image sensor sizes and pixel requirements without requiring multiple fixed optical components, thereby resolving the contradiction between adaptability and complexity.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention changes physical parameters of the optical component by altering the shape and volume of the deformable internal space. By adjusting these geometric parameters, the optical properties are modified to match different specifications, enabling a single component design to serve multiple applications while maintaining manufacturing simplicity.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If measurement and quality control steps are added before assembly, then production yield is improved by removing defective components, but manufacturing time and process complexity increase

Engineering Contradiction:

Improveproduction yieldVSAvoidmanufacturing cycle time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent implements measurement and quality control of the tunable optical component before it is assembled into the final optical module. This preliminary action identifies and removes defective components early in the process, preventing waste of time and resources on assembling defective parts, thereby improving overall production yield despite the additional measurement step.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The measurement step provides feedback about the quality of the tunable optical component, allowing the manufacturing process to adjust accordingly. By measuring optical properties and using this information to filter defective components, the system optimizes production efficiency and ensures high-quality output, resolving the contradiction between yield and time.

Inventive Principle:

Principle #23Feedback

3Adaptability or versatility

If the internal space of the tunable optical component is made deformable to adjust optical properties, then adaptability is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improveadjustability of optical propertiesVSAvoidprecision of internal space deformation

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent uses a deformable internal space that can be implemented through flexible membranes or thin-walled structures. These flexible components allow for easy deformation to adjust optical properties while maintaining sufficient manufacturing precision through standardized fabrication processes for flexible structures, thereby resolving the contradiction between adaptability and precision.

Inventive Principle:

Principle #30Flexible shells and thin films

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 approach enables improved image quality, reduced production costs, and higher yield by allowing adjustable optical properties, compact design, and efficient quality control, addressing the complexity of meeting optical specifications in mobile phone cameras.

Implementation Method 1

The internal space is filled with a transparent liquid. An optical property of the tunable optical component is adjustable by altering a shape of the internal space.

Methodology Applied

Scientific EffectLight transmission through transparent liquid: Refraction

Data Source

PatentUS20240159943A1Method for manufacturing an optical module and optical module

Publication Date: 2024.05.16 OPTOTUNE SWITZERLAND AG

AI summary

An optical module (1) comprising a tunable optical component (1) at least with two optical surfaces (3, 4) and a deformable internal space between the two optical surfaces (3, 4), wherein the internal space is filled with a transparent liquid (5), and wherein an optical property of the tunable optical component (2) is adjustable by altering a shape of the internal space, and a first optical element (8) that is attached to one of the optical surfaces (3, 4) facing away from the internal space, and wherein a second optical element (9) is kitted to the first optical element (8) via a van-der-Waals-bond and/or a chemical bond, in particular an adhesive chemical bond, and/or a plasma activated bond.