Webcam Lens Cap Design for Shock Absorption and Yield
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Solution Overview
Problem
Webcams are susceptible to damage during manufacture due to exposure of delicate auto focus elements, which can be easily damaged by physical contact or contamination from dust particles, leading to reduced yield of usable units.
Innovation Solution
A cap apparatus and method that includes a lens cap with a coupling system to protect the lens system and an auto focus actuator, featuring a gap to absorb shocks and an aperture for light transmission, and screw bosses on the PCB to prevent particle accumulation on the image sensor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the lens system and auto focus elements are exposed during manufacture for assembly and testing, then manufacturing efficiency and ease of assembly are improved, but the elements are susceptible to damage from physical contact and dust particle contamination
Solution Approach 1:
A protective cap is pre-installed on the lens system before the webcam assembly process begins. This cap remains in place throughout manufacturing operations, allowing workers to handle and assemble the webcam without risking damage to the exposed lens and auto focus elements. The cap is designed to be easily installed in advance and removed only when absolutely necessary for final testing.
Solution Approach 2:
The protective cap serves as an intermediary barrier between the delicate lens system/auto focus elements and the potentially harmful manufacturing environment. This intermediate protective layer allows manufacturing operations to proceed while preventing direct contact and dust contamination, thus resolving the contradiction between ease of manufacture and protection from harmful factors.
2Object-affected harmful factors
If a protective cap is added to cover the lens system during manufacture, then protection from damage and contamination is improved, but the device complexity and number of components increase
Solution Approach 1:
The protective cap is designed as a simple, inexpensive component that can be easily manufactured and disposed of if necessary. Rather than creating a complex permanent protective system, this disposable cap provides effective protection during manufacture while adding minimal complexity. If damaged during assembly, it can be replaced without affecting other components.
Solution Approach 2:
The protective function is segmented into a separate, removable cap component rather than being integrated into the main webcam structure. This segmentation allows the cap to be added only when needed for protection during manufacture, without permanently increasing the complexity of the webcam itself. The cap can be independently manufactured and attached only during the manufacturing process.
3Volume of moving object
If the gap between the lens cap and lens system is minimized to reduce size, then compactness is improved, but shock absorption capability is reduced
Solution Approach 1:
The gap between the lens cap and lens system is not uniformly distributed but is strategically designed with varying dimensions in different locations. Critical areas that require enhanced shock absorption have larger gaps, while non-critical areas have minimal gaps to maintain compactness. This local variation in gap size optimizes both protection and size requirements.
Solution Approach 2:
The gap design incorporates pre-planned cushioning space around the lens system within the cap structure. This beforehand cushioning allows the lens to move slightly upon impact without direct contact with the cap, absorbing shock energy before it reaches the delicate optical elements. The cushioning effect is built into the cap's geometry rather than requiring additional active components.
Data Source
AI summary
A webcam includes an external housing; a lens system disposed in the external housing; and a lens cap disposed in the external housing and configured to at least partially surround the lens system, wherein a gap is formed between the lens system and the lens cap.