Wafer Scale Camera Module Optical Trim Element
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Solution Overview
Problem
Manufacturing of miniature camera modules with fixed focus lens structures faces challenges due to assembly and optical errors within manufacturing tolerances, leading to distortions, aberrations, and focus issues, which are typically addressed through mechanical adjustments that complicate the process and increase bulk.
Innovation Solution
Employing an optical trim element, such as a tunable liquid crystal lens, within the lens structure that can be electrically controlled to adjust optical properties without mechanical movement, compensating for assembly and optical errors by modifying its focal length to ensure accurate focusing on the image sensor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical adjustment structures (screws, adjustment mechanisms) are used to compensate for assembly errors and optical errors, then focus accuracy is improved, but device complexity and manufacturing overhead increase
Solution Approach 1:
The patent replaces mechanical adjustment structures (screws, levers, moving parts) with an optical trim element that uses optical properties to compensate for assembly errors. The trim element modifies the optical path and focal plane through optical means rather than mechanical movement, thereby maintaining focus accuracy while eliminating complex mechanical adjustment mechanisms.
Solution Approach 2:
The patent extracts the adjustment function from mechanical components and transfers it to an optical element. By removing the need for mechanical adjustment structures entirely, the design simplifies the device while preserving the ability to compensate for manufacturing tolerances through optical trimming.
2Manufacturing precision
If mechanical adjustment structures are used to compensate for assembly errors, then focus accuracy is improved, but manufacturing time and overhead increase
Solution Approach 1:
The optical trim element is pre-configured with specific optical properties during manufacturing to compensate for anticipated assembly errors. This preliminary configuration eliminates the need for time-consuming mechanical adjustments during final assembly, as the trim element is already optimized to correct for manufacturing tolerances.
Solution Approach 2:
By replacing mechanical adjustment mechanisms with a pre-configured optical trim element, the patent eliminates manual manipulation and mechanical positioning steps, thereby reducing manufacturing time and overhead while maintaining focus accuracy.
3Manufacturing precision
If mechanical adjustment structures are used to compensate for optical errors, then focus accuracy is improved, but the bulk and size of the camera module increase
Solution Approach 1:
The patent removes mechanical adjustment structures (screws, adjustment mechanisms, moving components) that occupy physical space within the camera module. By extracting these bulky mechanical elements and replacing them with a compact optical trim element, the overall volume and bulk of the device are reduced while maintaining focus correction capability.
Solution Approach 2:
The substitution of mechanical adjustment structures with an optical trim element eliminates the need for bulky mechanical components. The optical element achieves the same focus correction function in a more compact form factor, thereby reducing the overall bulk of the camera module.
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 eliminates the need for mechanical adjustments, enhances manufacturing yields, and reduces bulk by allowing precise focus adjustments within manufacturing tolerances, ensuring accurate image focus without mechanical screws or additional components.
Implementation Method 1
The optical properties of the liquid crystal lens can be configured to meet the needs of the imaging system to compensate for optical errors such as defects in lens components or assembly errors
Data Source
AI summary
Methods are provided for wafer scale manufacturing camera modules without adjustment components to compensate for assembly errors and optical errors incurred within manufacturing tolerances. Camera modules are assembled in wafer arrays from arrays of image sensors, arrays of lens structures and arrays of optical trim elements. At least one of the arrays is a wafer. Lens structures are configured to provide less optical power than necessary to focus an image at infinity on image sensors without trim elements. A test performed during the wafer scale assembly of camera modules, after at least the sensor array and the lens structure array assembled, determines optical errors by identifying optical distortions and aberrations quantified in terms of optical power, astigmatism, coma, optical axis shift and optical axis reorientation deficiencies. Corresponding trim elements are configured to counteract distortions and aberrations prior to singulating useful camera modules from the array.