Wafer-Level Aspheric Lens System for Aberration Control
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Solution Overview
Problem
Conventional wide-angle lens systems for large field-of-view camera modules are costly due to the high production costs of molded glass or plastic lenses, and there is a need for compact, cost-effective solutions that can provide high-quality, wide-angle optics for applications like machine vision and capsule endoscopes.
Innovation Solution
A wide-angle lens system comprising wafer-level lenses replicated on a substrate, with a configuration of three lenses (first, second, and third lenses) that include aspheric surfaces and a stop to control aberrations, allowing for mass production and flexibility in material choice, resulting in an ultra-short and compact camera module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If molded glass or plastic lenses are used in conventional wide-angle lens systems, then optical quality can be achieved, but manufacturing cost increases significantly
Solution Approach 1:
The patent uses wafer-level lens replication technology to create multiple identical lenses simultaneously on a substrate. This copying approach allows mass production of precise optical elements without the high per-unit cost of molded lenses, directly resolving the contradiction between optical quality and manufacturing cost
Solution Approach 2:
The patent changes the manufacturing method from traditional molding to wafer-level replication, and specifies precise parameter ranges for lens curvature (e.g., -5 < f1/f < -2, 0.5 < f2/f < 1.5) to achieve optimal optical performance while enabling cost-effective mass production
2Manufacturing precision
If conventional molded lenses are used, then lens performance can be maintained, but the camera module size increases
Solution Approach 1:
The patent integrates multiple lens elements (first lens with negative power, second lens with positive power, and third lens) in a compact nested arrangement within a short total track length (TTL), enabling high-performance wide-angle optics in an ultra-compact camera module form factor
Solution Approach 2:
The patent employs aspheric surfaces on the lenses to control aberrations in multiple dimensions simultaneously, achieving superior optical performance while reducing the axial length of the camera module compared to conventional spherical lens designs
3Ease of manufacture
If wafer-level lenses are used for mass production, then manufacturing cost decreases, but achieving high optical quality becomes more difficult
Solution Approach 1:
The patent applies aspheric surfaces specifically to the wafer-level lenses to correct local aberration problems, and optimizes the local curvature radii and thickness of each lens element to achieve high optical quality that would otherwise be difficult with standard wafer-level replication
Solution Approach 2:
The patent uses different glass materials (e.g., LaK33, LAK27, LAL11) with specific refractive indices and Abbe numbers for different lens elements in the wafer-level assembly, combining materials to achieve superior chromatic and spherical aberration correction while maintaining mass production feasibility
4Area of stationary object
If a wide field-of-view is achieved with conventional lenses, then large FOV is obtained, but aberration control becomes difficult
Solution Approach 1:
The patent employs aspheric surfaces on the wafer-level lenses to control off-axis aberrations across a wide field-of-view (≥80 degrees). The aspheric curvature profiles correct field curvature, distortion, and astigmatism that would otherwise be difficult to control in wide-angle designs
Solution Approach 2:
The patent introduces a stop (aperture) as an intermediary element in the optical path to control the angular aperture and reduce the angle of incident rays, thereby improving aberration control and enabling a practical wide field-of-view with manageable optical performance
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
The wafer-level lens system achieves a balance of aberrations and compactness, reducing manufacturing costs while providing high-quality images with improved spherical aberration, field curvature, distortion, and lateral color aberration correction, suitable for large field-of-view applications.
Implementation Method 1
A wide-angle lens system comprising wafer-level lenses replicated on a substrate, with a configuration of three lenses (first, second, and third lenses) that include aspheric surfaces and a stop to control aberrations
Data Source
AI summary
A wide-angle lens system comprises a first lens having a concave aspheric surface and a planar surface, a second lens having a convex aspheric surface and a planar surface, a substrate, wherein the planar surface of the first lens is adjacent to a first side of the substrate and the planar surface of the second lens is adjacent to a second side of the substrate, a third lens behind the second lens having a concave aspheric surface and a planar surface, and a stop disposed between the first lens and the substrate. The planar surface of the third lens is secured to an outermost surface of an image sensor.