U.S. patent application number 13/318559 was filed with the patent office on 2012-08-09 for camera module with tolerance adjustment using embedded active optics.
This patent application is currently assigned to LENSVECTOR INC.. Invention is credited to Bahram Afshari, Peter P Clark, Samuel Wennyann Ho, John Toor.
Application Number | 20120200764 13/318559 |
Document ID | / |
Family ID | 42735392 |
Filed Date | 2012-08-09 |
United States Patent
Application |
20120200764 |
Kind Code |
A1 |
Afshari; Bahram ; et
al. |
August 9, 2012 |
CAMERA MODULE WITH TOLERANCE ADJUSTMENT USING EMBEDDED ACTIVE
OPTICS
Abstract
A focus free camera module uses fixed lenses within a housing
that are combined with an electrically controllable active optical
element, such as a tunable liquid crystal lens. The fixed lenses
provide a desired amount of optical power, but the manufacturing
tolerances of the module are insufficient to ensure a proper focus
of an image on an image sensor. The active optical element is
therefore used to compensate for any variations in the optical
power to achieve the desired focus. To ensure an effective
compensation, the module may be constructed so that, when the
variation in optical power due to manufacturing tolerances is at a
maximum, the desired focus is achieved when the active optical
element is at zero optical power. All other variations may then be
compensated by adjusting the active optical element to increase its
optical power.
Inventors: |
Afshari; Bahram; (Los Altos,
CA) ; Toor; John; (Palo Alto, CA) ; Clark;
Peter P; (Boxborough, MA) ; Ho; Samuel Wennyann;
(Foster City, CA) |
Assignee: |
LENSVECTOR INC.
Mountain View
CA
|
Family ID: |
42735392 |
Appl. No.: |
13/318559 |
Filed: |
May 3, 2010 |
PCT Filed: |
May 3, 2010 |
PCT NO: |
PCT/US2010/033357 |
371 Date: |
January 18, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61175025 |
May 3, 2009 |
|
|
|
Current U.S.
Class: |
348/345 ;
29/592.1; 29/593; 348/E5.045 |
Current CPC
Class: |
Y10T 29/49004 20150115;
Y10T 29/49002 20150115; H04N 5/2257 20130101; H04N 5/2254 20130101;
H04N 5/2251 20130101 |
Class at
Publication: |
348/345 ;
29/592.1; 29/593; 348/E05.045 |
International
Class: |
G03B 13/00 20060101
G03B013/00; H05K 13/00 20060101 H05K013/00; H04N 5/232 20060101
H04N005/232 |
Claims
1. A camera module comprising: a fixed focus optical lens assembly
through which an optical signal passes; an electrically
controllable active optical element, the active optical element
changing its optical characteristics from a first state to a second
state in response to an input electrical signal, such that the
active optical element exerts a different optical influence on the
optical signal in the first state than in the second state; an
image sensor; and a mounting for the fixed focus optical lens
assembly, the image sensor and the active optical element, wherein
the camera module has a manufacturing tolerance insufficient to
ensure a desired precision of focus of an image on said image
sensor when said active optical element is at a nominal optical
power, and wherein the optical characteristic of the active optical
element may be adjusted to achieve said desired precision of focus
of said image on the image sensor.
2. A camera module according to claim 1 wherein the active optical
element comprises a tunable liquid crystal lens for which the
optical power changes in response to said input electrical
signal.
3. A camera module according to claim 2 wherein the nominal optical
power of the active optical element is substantially zero
diopters.
4. A camera module according to claim 1, wherein a potential
variation in optical power of the camera module due to said
manufacturing tolerance ranges between two predetermined extremes,
and wherein the camera module is constructed such that, when said
variation in optical power is at one of said extremes, said desired
precision of focus is achieved with the active optical element at
said nominal optical power.
5. A camera module according to claim 1 wherein the fixed focus
optical lens assembly comprises a plurality of fixed focus optical
lenses.
6. A camera module according to claim 5 wherein the active optical
element is located between two fixed focus optical lenses of the
fixed focus optical lens assembly.
7. A camera module according to claim 5 wherein the active optical
element is located at one end of the fixed focus optical lens
assembly.
8. A camera module according to claim 1 further comprising a
mechanical adjustment mechanism that allows manual adjustment of a
distance between the fixed focus optical lens assembly and the
image sensor.
9. A camera module according to claim 2 wherein the tunable liquid
crystal lens has a tunable range to provide focusing power for near
focus and infinity focus.
10. A camera module according to claim 9 further comprising an
autofocus processor for adjusting said input electrical signal,
said autofocus processor having an offset value for infinity
focus.
11. A camera module according to claim 1 wherein said active
optical element is a liquid crystal lens with liquid crystal
polymerized while said lens is controlled to be between said first
state and said second state.
12. A method of manufacturing a fixed focus camera module
comprising: providing an image sensor, a fixed focus optical lens
assembly and a tunable liquid crystal optical device; mounting the
image sensor and the fixed focus optical lens assembly in such a
way that manufacturing tolerances of the camera module are
insufficient to ensure a desired precision of focus of an image on
the image sensor when said active optical element is at a nominal
optical power; and providing an electrical signal to the tunable
liquid crystal optical device to modify the camera module and
establish said desired precision of focus of the image on the image
sensor.
13. A method according to claim 12 wherein the active optical
element comprises a tunable liquid crystal lens for which the
optical power changes in response to said input electrical
signal.
14. A method according to claim 13 wherein the nominal optical
power of the active optical element is substantially zero
diopters.
15. A method according to claim 12, wherein a potential variation
in optical power of the camera module due to said manufacturing
tolerance ranges between two predetermined extremes, and wherein
the method further comprises constructing the camera module such
that, when said variation in optical power is at one of said
extremes, said desired precision of focus is achieved with the
active optical element at said nominal optical power.
16. A method according to claim 15 wherein the nominal optical
power of the active optical element is substantially zero
diopters.
17. A method according to claim 12 wherein providing a fixed focus
optical lens assembly comprises providing a plurality of fixed
focus optical lenses.
18. A method according to claim 17 wherein the active optical
element is located between two fixed focus optical lenses of the
fixed focus optical lens assembly.
19. A method according to claim 17 wherein the active optical
element is located at one end of the fixed focus optical lens
assembly.
20. A method according to claim 12 further comprising adjusting a
mechanical adjustment mechanism that changes a distance between the
fixed focus optical lens assembly and the image sensor.
21. A method according to claim 13 wherein the tunable liquid
crystal lens has a tunable range to provide focusing power for near
focus and infinity focus.
22. A method according to claim 21 wherein said providing an
electrical signal to the tunable liquid crystal optical device
comprises using an autofocus processor for adjusting said
electrical signal, said autofocus processor having an offset value
for infinity focus.
23. A method according to claim 13 further comprising including a
monomer in a liquid crystal material of said liquid crystal lens
and polymerizing said monomer once a desired optical power is set
by said electrical signal.
Description
[0001] This application claims priority of U.S. provisional patent
application 61/175,025 filed May 3, 2009.
FIELD OF THE INVENTION
[0002] This invention relates generally to optical devices and
assemblies and, more specifically, to lenses having active optical
control.
BACKGROUND OF THE INVENTION
[0003] Lens structures for optical devices such as cameras consist
of multiple lens elements assembled in a single barrel or stacked
in a wafer form, utilizing spacers, to create fixed focus lens
assemblies. These lens structures have a fixed focal plane and are
mechanically moved to focus on objects in varying distances to the
camera system.
[0004] Tunable liquid crystal lenses (TLCL) that have a flat layer
construction are known in the art, as described in PCT patent
application WO 2007/098602, published on Sep. 7, 2007, as well as
in PCT patent application publication WO 2009/153764 published Dec.
23, 2009, the specifications of which are hereby incorporated by
reference as if fully set forth herein.
SUMMARY OF THE INVENTION
[0005] In accordance with the present invention, an electrically
controllable optical lens apparatus is provided that has a first
optical lens and a second optical lens fixed in position relative
to each other such that an optical signal can pass through both
lenses. Located at a fixed position within the apparatus, which in
a first embodiment is a position between the first and second
lenses, is an electrically controllable active optical element. The
active optical element which may be, for example, a tunable liquid
crystal lens (TLCL), changes its optical characteristics from a
first state to a second state in response to an input electrical
signal, such that it exerts a different optical influence on the
optical signal in the first state than in the second state. In the
case of a tunable lens, the active optical element may change
between many states, changing the overall optical power of the
entire lens apparatus.
[0006] In one particular embodiment of the present invention, a
tunable liquid crystal optical device is used to compensate for
variances in the focal length of the lens stack that occur due to
manufacturing tolerances of a lens and imaging sensor assembly,
such as the optical core of a fixed focus digital camera. Such an
embodiment may include a fixed focus optical lens assembly, having
one or more fixed focus optical lenses, through which an optical
signal passes, as well as an electrically controllable active
optical element, such as a TLCL. The active optical element changes
its optical characteristics from a first state to a second state
(e.g., from a first optical power to a second optical power) in
response to an input electrical signal. This changes the influence
that the element has on the optical signal, and may change the
focusing power of the overall device. A mounting for the lens
assembly, the image sensor and the active optical element supports
these devices in their predetermined relative positions, but the
optical and physical manufacturing tolerances are insufficient to
ensure a desired precision of focus of an image on an image sensor
of the device when the active optical element is at a nominal
optical power. However, by controlling the active optical element,
this tolerance inaccuracy can be compensated for to allow the image
to be correctly focused on the image sensor. Thus, the task of
adjusting mechanically the lens assembly with respect to the image
sensor plane may be augmented by making focus adjustments using the
active optical element.
[0007] In a variation of this embodiment, the module is constructed
so as to allow adjustment of the active optical element to cover
the entire range of possible optical power variations due to
manufacturing tolerances. Where a potential variation in optical
power of the camera module due to manufacturing tolerances ranges
between two extremes, the module may be constructed so that, when
the variation in optical power is at one of the extremes, the
desired precision of focus is achieved with the active optical
[0008] The camera module may also include a mechanical adjustment
mechanism for making focus adjustments of the camera during
assembly. For example, a barrel lens structure may be used that is
threaded and which can be screwed into a receiving space of a
device to which it is mounted, and the position change of the
module while being turned may change the focus setting. This type
of manual adjustment may be combined with the active optical
element to provide two complementary way of compensating for minor
misalignment in the components. The active optical element may also
function as a focusing mechanism for the final camera apparatus, in
addition to being used to compensate for tolerance variations.
[0009] The lens apparatus may have the active optical element
positioned within a lens stack. In this configuration, by applying
a required electrical signal to the active element, the optical
properties of the lens assembly are modified without any mechanical
movement. In case of a TLCL as the active optical element, the
focal plane of the lens structure could be moved, thus creating a
variable focus (e.g. auto focus) device. By including other
features into the active element, this active element can also
function as an aperture stop, shutter, IR cut filter or other
mechanism in the lens stack, resulting in a possibly shorter and
improved overall lens design.
[0010] A lens mounting structure having a barrel shape may also be
used to enable easy assembly of the active element into the lens
stack. In this embodiment, a lens barrel is split into two sections
at the active optical element plane. Mechanical features on the
fixed focus lens elements are used to establish assembly spacing
and alignment. In this configuration, the active optical element is
designed to be integrated into the stack without interfering with
precise alignment and spacing of other optical elements within the
stack. A special feature on the fixed elements is used to align and
space these elements without interference from the active optical
element. The active optical element may have a substantially planar
shape and, in one embodiment, is roughly square. With such a square
shape, extra space around the active optical element may be used to
provide alignment and spacing, which is required in conventional
fixed lens systems to achieve acceptable optical performance.
[0011] An integrated electrical connection structure and method is
also provided to enable electrical contacts as part of the lens
barrel assembly. At least one electrical contact provides an
electrically conductive path between an outer surface of the lens
mounting structure and the active optical element. The contact may
be a stamped metallic piece with an incorporated spring element to
ensure reliable electrical connection to a contact on a receiving
device to which the lens apparatus is mounted. Alternatively, a
molded interconnect device (MID) also may be used to create a
connection between the active optical element and camera housing or
surrounding devices. An MID would be used in place of lead frames
in the device. Connection to the embedded active optical element
may be achieved by means of conductive adhesives.
[0012] Two different barrel assembly methods and structures are
proposed. The first is a threaded barrel with appropriate matching
threads on the housing of a receiving device to which the lens
apparatus is mounted. In a second variation, a ramp design is used
to ensure proper positioning of the contacts with respect to
corresponding contacts on the camera housing. In this approach a
single thread is created with a locking stop mechanism to define
the distance of lens barrel from the sensor in a deterministic way.
In the ramp design no focusing operation is required at assembly
and optical device relies solely on the active optical element for
proper focusing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The following figures show features and different embodiment
of the proposed design.
[0014] FIG. 1 is a cross sectional view of a first embodiment of a
lens structure according to the present invention.
[0015] FIG. 2 is a perspective view of the lens structure of FIG.
1.
[0016] FIG. 2A is an isolated view of an outer portion of the lens
structure of FIG. 1 showing an active optical element adjacent
thereto.
[0017] FIG. 3 is a perspective view of a lens structure according
to the present invention that uses a ramp structure and electrical
connections near a top of a barrel portion of the lens
structure.
[0018] FIG. 4 is a perspective view of a lens structure according
to the present invention that uses electrical connections on an
inner surface of an inner portion of the lens structure.
[0019] FIG. 5 is a cross sectional view of a lens structure
according to the present invention in which fixed lenses are formed
on the surfaces the upper and lower substrates of an active optical
element.
[0020] FIG. 6 is a perspective view of a lens structure according
to the present invention in which a molded interconnect device is
used to provide electrical connection between an active optical
element and an inner surface of an outer portion of the lens
structure.
[0021] FIG. 6A is a perspective view of an interior of an outer
portion of the structure of FIG. 6 showing the location of
electrical contact points.
[0022] FIG. 6B is a top view of an interior of the lens structure
of FIG. 6 showing an active optical element in place adjacent to
the electrical contact points of the lens structure.
[0023] FIG. 7 is a perspective view of a lens structure according
to the present invention in which a molded interconnect device is
used to provide electrical connection between an active optical
element and an inner surface of an inner portion of the lens
structure.
[0024] FIG. 7A is a perspective view of an interior of an inner
portion of the lens structure of FIG. 7 showing the location of
electrical contact points.
[0025] FIG. 8 is a perspective view of a lens structure according
to the present invention showing gaps via which an electrically
conductive adhesive may be applied to the connection points between
an active optical element and the electrical contacts of the lens
structure.
[0026] FIG. 9 is a perspective view of a single barrel
configuration in which the present invention may be used, the
figure depicting a socket flange base in an exploded view showing
the image sensor, circuit board and the various optical
elements.
[0027] FIG. 10A is a top view of an assembly including a unitary
image sensor and barrel lens mounting that has a tunable liquid
crystal device to provide a tunable focus camera.
[0028] FIG. 10B is a cross sectional side view of the assembly of
FIG. 10A.
[0029] FIG. 11A is a top view of an assembly including a unitary
image sensor, a barrel lens mounting and a tunable liquid crystal
device, and that functions as a fixed focus camera.
[0030] FIG. 11B is a cross sectional side view of the assembly of
FIG. 11A.
[0031] FIG. 12A is a top view of an assembly similar to that of
FIGS. 11A and 11B, but that has the tunable liquid crystal device
located between two lens elements of the structure.
[0032] FIG. 12B is a cross sectional side view of FIG. 12A.
[0033] FIG. 13A is a cross sectional view of a unitary image sensor
and barrel lens mounting that has a top cavity for receiving the
tunable liquid crystal lens device after assembly of the image
sensor and barrel lens.
[0034] FIG. 13B is a perspective view of the assembly of FIG. 13A
with a top cover of the assembly removed.
DETAILED DESCRIPTION
[0035] The present invention is directed to an optical lens
apparatus that uses fixed lenses in combination with an
electrically controllable liquid crystal optical device. Depending
on the specific configuration, the apparatus may be directed to one
of several applications. In each of these embodiments, the
apparatus uses the optical properties of the fixed lenses in
combination with the electrically controlled optical properties of
the liquid crystal device.
[0036] Shown in FIG. 1 is a schematic view of a first embodiment of
the invention in which a variable focus lens 10 has a barrel
structure consisting of two portions, an outer portion 12 and an
inner portion 14. The lens may be used in a variety of different
applications, including compact digital cameras, such as might be
integrated into a portable telephone. Each of the two portions
includes a fixed lens, lens 16 in the outer portion 12, and lens 18
in the inner portion 14. Each of the lenses in this embodiment are
an integral part of a supporting structure, and may be formed
together with a substrate material, although those skilled in the
art will understand that other lens structures may be used as well.
Light from a subject in front of the outer portion 12 is collected
via aperture 20 and focused by the outer portion fixed lens 16.
This focused light is refocused by the fixed lens 18 of the inner
portion to form an image on a desired imaging device, such as a
CMOS or a charge-coupled device type detector, etc. (not shown).
The overall focusing of the variable focus lens 10 is, however,
adjustable by way of a tunable lens 22 positioned between the fixed
lens 16 and the fixed lens 18.
[0037] In the present embodiment, the tunable lens 22 is a tunable
liquid crystal lens (TLCL), such as that discussed PCT patent
application publication WO 2009/153764 published Dec. 23, 2009, the
substance of which is incorporated herein by reference. As is
discussed in this and other disclosures, a TLCL is a liquid crystal
based lens structure for which the focusing power changes with
changes to an applied electric field. As the electric field is
typically generated by an input electrical signal, variation of
that signal may be used to change the tuning of the lens. The
tuning range of the TLCL may include a zero optical power level at
which it adds no focusing effect to the overall lens structure.
However, as the electrical signal supplied to the TLCL changes, the
optical power of the lens changes with it, causing an overall
change in the focal length of the variable focus lens 10.
[0038] The two portions of the variable focus lens 10 are shown
separated from each other in FIG. 1, but are part of a single
integral component during operation. In the present embodiment, the
two portions are separate and are joined together near the position
of the active optical plane, i.e., the location of the TLCL. When
assembled, the variable focus lens has a "barrel" shape, as is
evident in the perspective view of FIG. 2. In the present
embodiment, the barrel shape has a thread 24 along its curved outer
surface, allowing the variable lens to be screwed into a threaded
hole on an apparatus (such as a camera) on which it is installed,
although other connection means may be used instead.
[0039] Also shown in FIG. 2 are a set of electrical contacts 26 by
which electrical connection with the TLCL may be made. These
contacts can be stamped metallic pieces with incorporated spring
elements that help ensure reliable electrical connection.
Corresponding electrical contacts on the apparatus to which the
lens is mounted allow convenient electrical signal routing. The
relative positioning of the TLCL 22, which in this embodiment has a
generally square shape, and the outer portion 12 of the barrel
structure is shown in the isolated view of FIG. 2A. This figure
provides a view of the interior of the barrel structure, and shows
how electrical contacts located in the corners of the TLCL 22 make
contact with the electrical contacts 26 of the barrel structure.
Thus, electrical continuity is provided from a surface of the
apparatus to which the lens is mounted to the
electrically-activated TLCL 22 on the interior of the lens
structure.
[0040] An alternative arrangement for assembly of the system uses a
ramp or cam surface 28 on the barrel of the lens 10, as is shown in
FIG. 3. This ramp allows for barrel adjustment during assembly. The
ramp is essentially a circumferential lip that extends radially
from an outer surface of the barrel, and that includes a flat
surface 29 that functions as a stop mechanism during rotation of
the barrel. When the barrel is inserted into a mounting socket of a
device to which the barrel is attached, the ramp 28 makes contact
with a corresponding ramp on an inner surface of the mounting
socket (not shown). As the barrel is rotated counter-clockwise
(relative to a view facing an outer surface of outer portion 12),
the two ramps slide against each other until the flat surface 29 of
the ramp 28 meets a corresponding flat surface of the mounting
socket. Thus, when the barrel is attached to the housing of the
corresponding optical device using the ramp method, the barrel
stops in a predetermined position with respect to an internal
component of the device, such as a CMOS sensor. The barrel may then
be permanently attached to the device using, for example, adhesive
or ultrasonic welding, or any other technique known in the art.
Using this arrangement, no focusing operation is required at
assembly, and the optical variable lens 10 relies solely on the
TLCL for proper focusing. Those skilled in the art will recognize
that other ways of providing assembly may also be used.
[0041] Another embodiment of the present invention is shown in FIG.
4, and makes use of electrical contacts located at the innermost
surface of the barrel structure. This is in contrast to the
positioning of the contacts on an inner surface of the outer
portion 12, as shown, for example, in FIG. 2. In both embodiments,
the electrical contacts 26 pass between the outer portion 12 and
the inner portion 14 to make contact with the TLCL. However, while
the contacts of the FIG. 4 embodiment extend to a surface of the
inner portion 14, where they will make contact with corresponding
contacts of the apparatus to which the variable lens is mounted 10,
those of the FIG. 2 embodiment are extended to the aforementioned
inner surface of the outer portion. The particular configuration of
the contacts in one of these two arrangements is a matter of design
convenience.
[0042] In still another embodiment of the invention, a fixed lens
integral with the TLCL is used. As shown in FIG. 5, the TLCL
includes a fixed lens 30 molded onto its surface. Further
disclosure of such a lens construction set out in PCT patent
application publication WO/2010/022503 published Mar. 4, 2010, the
specification of which is hereby incorporated by reference.
[0043] FIG. 6 shows another variation of the present invention in
which a molded interconnect device (MID) approach is used to create
a connection between the active optical element and the camera
housing or surrounding devices. This embodiment is similar to that
shown in FIG. 2, but in place of stamped metal contact pieces, MID
elements 32 are used. As with the contacts of the FIG. 2
embodiment, The MID elements pass in between the inner portion 14
and the outer portion 12 of the barrel and make electrical
connection to the embedded active optical element by way of
conductive adhesives. In this embodiment, the MID elements may form
contact surfaces 34 on an interior of the outer portion 12 of the
barrel, as is shown in FIG. 6A. These contact surfaces 34 allow for
an easy means of making an electrical connection to the active
optical element such as a TLCL 22. FIG. 6B, for example, is a view
of the outer portion 12 with a TLCL 22 having the corners of its
square shape positioned adjacent to the contact surfaces 34.
Surface electrical contacts located in the corners of the TLCL 22
thereby make electrical contact with the contact surfaces 34 of the
outer portion. When the outer portion 12 is assembled with the
inner portion 14 of the barrel, the corners of the TLCL 22 rest
between surfaces of the two portions, and may be thereby held in
place in the barrel.
[0044] As with the stamped metal contact embodiment, the MID
contacts may also extend to an inner surface of the inner portion
14. In the embodiment shown in FIG. 7, the MID contacts 36 are
positioned to make contact with corresponding contacts on a surface
of the device to which the lens structure is attached. The MID
contacts 36 in this embodiment extend along an interior surface of
the inner portion 14 to locations adjacent to the active optical
element. This is shown more clearly in FIG. 7A, which is an
isolated view of the inner portion 12 of FIG. 7 as seen from the
opposite side. While the active optical element (such as a TLCL 22)
is not shown in this figure, those skilled in the art will
understand that such an element with a square shape could rest
within the barrel with corresponding electrical contacts located in
the corners of the square shape located adjacent to the interior
surfaces of the MID contacts 36.
[0045] In each of the embodiments having an active optical element
within the barrel making contact with electrical contacts located
substantially between an inner portion and an outer portion of a
barrel structure, the two portions may be constructed such that,
when assembled together, small gaps remain between them in the
vicinity of the electrical contacts. Such gaps 38 are shown in the
perspective view of FIG. 8, although it will be understood by those
skilled in the art that such gaps may be used with any of the
embodiments described herein. Since the electrical contacts of the
active optical element will reside adjacent to the electrical
contacts of the barrel assembly, gaps 38 may serve as access points
by which to apply a conductive adhesive that both secures the
electrical components together and provides a more robust
electrical connection between them.
[0046] It will be appreciated that the barrel can be provided with
a base, for example incorporating a flange, and that electrical
connections between the active embedded optical element and the
circuit board may be through the barrel base. The barrel body
incorporates the required conductors to conduct signals from the
circuit board to the contacts on the barrel body in contact with
the active element. FIG. 9 illustrates a conventional single barrel
having a socket flange base in an exploded view showing the image
sensor 40, circuit board 42 and the various optical elements,
including fixed lenses 44, IR glass 46 and TLCL 47, which is
protected by barrel cover 48. The base contacts and integration of
the conductors and embedded active optical element contacts are not
detailed in FIG. 9. An arrangement such as shown in this figure may
be used with the present invention. In such a case, the barrel body
shown in FIG. 9 would be one of those presented in the foregoing
embodiments, with the active optical element positioned therewithin
between the two barrel portions.
[0047] The present invention also includes the possibility of using
active optical devices other than lenses in a configuration such as
that presented herein. For example, in an arrangement similar to
that shown in FIG. 1, in place of TLCL 22, an electrically
activated shutter may be provided.
[0048] In the embodiment of FIGS. 10A and 10B, there is shown a
design for incorporation of a barrel with an active optical element
(in this case a TLCL) into a camera module unit. FIG. 10A is a top
view of the device, and indicates the section line corresponding to
the cross-sectional view of FIG. 10B. As shown, the barrel (i.e.,
lens/TLCL assembly) 50 fits within housing assembly 52, which is
mounted to PC board substrate 54, which also supports image sensor
56. It is beneficial in this, and other, embodiments that the two
fixed lens components make contact with each other to ensure a
proper alignment and orientation between them. In this embodiment,
the housing is threaded to receive the threaded barrel assembly,
and includes four metallic inserts 58, such as lead frames, for
completing connection from the barrel assembly 50 to the camera
substrate. Since the barrel assembly 50 includes conductive
contacts 51 that are electrically connected to the active optical
element 53, the metallic inserts 58 provide the necessary
electrical pathways to the substrate. Thus, this configuration
allows electrical connection between the active optical element 53
and the substrate 54, despite the fact that the barrel assembly may
have imprecise height and rotational angle relative to the
housing.
[0049] As indicated in the drawing, the metallic inserts 58 are
electrically connected to the board 54 using conductive glue 60,
although solder could also be used. The housing 52 itself is also
connected to the substrate 54 using glue (typically
non-conductive), but bumps 62 are provided on the bottom of the
housing surface which extend beyond the glue to make contact with
the substrate 54. In this way, a precise distance is maintained
between the housing 52 and the substrate 54 which is not affected
by the thickness or flatness of the glue layer.
[0050] In the embodiment of FIGS. 11A and 11B, there is shown a
fixed focus camera module. FIG. 11A is a top view of the device,
and shows a section line along which the cross section of FIG. 11B
is taken. Two lens elements 64 are permanently mounted within a
housing 66 with no adjustability for focus. A TLCL 68 is located at
the side of the housing opposite PC board substrate 70, to which is
mounted image sensor 72. As in the embodiment of FIGS. 10A and 10B,
electrical connection is made between the substrate and the TLCL
via metallic inserts 74 that run vertically in the corners of the
housing, being connected to the substrate via conductive glue 76.
In the same manner as the embodiment of FIGS. 10A and 10B, the
housing 66 also makes use of bumps at its base to provide a precise
setoff between the housing and the substrate 70. A top cover 78 of
the housing blocks light except that in the main optical path, and
provides mechanical protection to TLCL 68, which is mounted at the
top of the device, above the fixed lenses.
[0051] Normally, most miniature cameras consist of a separate
housing and a lens barrel, among other parts. One important
operation during construction is to thread the lens barrel into the
housing, activate the sensor, and adjust the focus by turning the
barrel to achieve the best focus for camera system. This operation
requires special equipment and is costly due to extra operation and
may reduce yield by creating particles due to rubbing of barrel
surface against the housing thread surface.
[0052] A focus-free camera module refers to a camera module that is
constructed utilizing a camera housing with lenses integrated into
the housing permanently before attachment to the sensor substrate.
Thus, for a configuration such as that shown in FIGS. 11A and 11B,
there will be no adjustment of focus during the assembly process.
The main issue with such a construction is that the tolerances of
the assembly (physical and optical) may not be tight enough to
ensure a precise focus at the sensor surface, and an out-of-focus
image may result. However, in the present embodiment, minute focus
errors may be compensated for by adjusting the optical power of the
TLCL 68.
[0053] In some embodiments, the TLCL is used to add an optical
power to achieve infinity focus. Thus, the fixed lens assembly is
designed to have an optical power that ranges in accordance with
manufacturing tolerances between an extreme of infinity focus and
another extreme of an amount optical power that is insufficient to
achieve infinity focus when the fixed lens assembly is mounted in a
fixed manner to the image sensor. The TLCL provides the variable
shortfall. Optionally, one or more further TLCLs could be used for
variable focus or zoom functions.
[0054] In other embodiments, the TLCL is able to provide sufficient
optical power to replace one lens within the fixed lens assembly.
In these embodiments, the TLCL has its value set to provide the
desired fixed focus, such as infinity focus under the conditions of
the individual assembly of the camera having mounting and fixed
lens tolerance variations. The optical power of the TLCL can be
fixed.
[0055] In other embodiments, the TLCL is able to provide sufficient
optical power for variable focus between far field or infinity and
near field, and part of this tunable range is set aside for
compensating for the fixed lens assembly tolerance errors. For
example, autofocus can be implemented using a TLCL as described in
commonly assigned PCT application publication WO/2010/022080
published on Feb. 25, 2010. FIG. 2 of the publication shows a block
diagram of the autofocus system. With the TLCL also compensating
for tolerance errors, an offset value can be used in the processor
10 so that the far field focus value is correctly adjusted.
[0056] The optical power of a TLCL can be fixed by setting the
control signal with a programmable memory, resistor trimming,
etc.
[0057] For a fixed optical power TLCL, it is also possible to
include a monomer within the liquid crystal mixture of the TLCL,
and once the desired optical power is determined, to cause
polymerization (e.g. using light initiation or temperature) of the
monomer to fix the liquid crystal.
[0058] In the embodiment of FIGS. 12A-12B, a focus-free camera
module uses an active optical element (TLCL 80) located between
primary lens 82 and secondary lens 84 of the lens stack. This
configuration is similar to that of FIG. 11, except for the
location of the TLCL. A focus plane of the lens structure can be
actively adjusted by changing the optical power of the TLCL 80 to
compensate for an improper distance of the lens stack from the
sensor 85, or for focusing errors due to the focal length
tolerances of the primary and secondary lenses. As with the
embodiment of FIGS. 11A and 11B, this design enables construction
of cheaper cameras, allowing the use of parts with non-precision
tolerances and avoiding the need for a physical focus adjustment
operation.
[0059] When compensating for focus variations due to manufacturing
tolerances, it is important to consider the optical power that may
be contributed using a TLCL. In a typical TLCL, the nominal optical
power is zero diopters, corresponding to the non-powered stated of
the device. The optical power of the TLCL may thereafter be
increased by providing an electrical signal that powers the
electric field of the device to reorient the liquid crystal. Thus,
if the camera module uses a TLCL that has a zero diopter nominal
optical power, the TLCL may be used to change the overall optical
power of the module in only one direction. That is, the overall
optical power may only be increased by providing an electrical
signal to the TLCL. Thus, the compensation of optical power
variation due to manufacturing tolerance is only effective if the
variation is in a negative optical power sense, which would allow
the additional optical power of the TLCL to bring the image into
proper focus.
[0060] In one embodiment of the invention, therefore, optical power
of the fixed lenses is selected so that the camera module is in
proper focus when the variation due to the manufacturing tolerances
is at the maximum expected value. Thus, if the overall variation
due to tolerances was at the highest expected optical power, the
focus of the camera module would be correct when the TLCL was at
its nominal (e.g., zero) optical power. This would mean that all
other possible optical power variations due to manufacturing
tolerances would be lower, and the adjustment to a desired focus
would require the addition of optical power, which could be
provided by powering the TLCL. Although this means that the overall
optical range of the camera module would be reduced, it ensures the
ability to compensate for manufacturing tolerances using the
TLCL.
[0061] The top view of FIG. 12A shows the location of metallic
inserts 86 along the side edges of the lens housing 88. Unlike the
FIG. 11A, 11B embodiment, the metallic inserts do not run all the
way to the top of the housing but, rather, only to the vertical
position of the TLCL 80. This is shown in the cross section of FIG.
12B, which is taken along the section line shown in FIG. 12A and
which shows the relative positions of the fixed lenses and the TLCL
within the housing. The inserts 86 are connected to the substrate
87 using conductive glue 90, and the housing has a setoff bump, as
in the previous embodiments. This configuration, along with the
capability of the embedded TLCL to adjust the focus plane, can
enable proper camera focus without adjustment of the barrel.
[0062] In the embodiment of FIGS. 13A-13B, the camera need not be a
fixed-focus camera. This design shows an easy and low cost way of
incorporating a TLCL 94 into a conventional camera module. In this
configuration, a camera housing 96 is designed and molded in such a
way that there is a cavity on the top of the housing to receive the
TLCL, while allowing for a barrel-type lens to be inserted into a
socket in the housing before inserting the TLCL. Once assembled,
the TLCL 94 resides directly adjacent to the lens barrel 98, in
close proximity to the lens elements. Connection is provided by
metallic inserts 100, as apparent from FIG. 13B, which shows the
housing with top cover 95 removed. These connectors can also be
seen in the cross sectional view of FIG. 13A which, as in previous
embodiments, is taken along a diagonal section line. This
embodiment may also use a conductive glue to connect the metallic
inserts to the substrate 102 and the setoff bumps that function as
in the previous embodiments.
[0063] This camera module can include a conventional lens barrel 98
that is threaded into the housing. One possible assembly sequence
for the assembly of this embodiment is to attach the housing,
including the lens barrel, to the substrate 102 that supports the
CMOS sensor 104. At this time, the electrical contacts 100 in the
housing can be connected to the substrate by the conductive
adhesive over the connection pads on the camera substrate. After
attachment, the lens barrel 98 is turned and focused, as is done in
conventional camera modules, and glue added to the threads to fix
the barrel in the desired position. After this camera is tested,
the bare TLCL 94 (TLCL part with no housing or FPC) is placed into
the top cavity and aligned with respect to the lens barrel
aperture. At this time, conductive adhesive is applied to connect
the contacts on the TLCL to the electrical contacts in the housing,
after which the top cover 95 is placed over the TLCL 94 to close
the housing. In an arrangement such as this, therefore, focus
tuning of the device can be done manually and by adjustment of the
TLCL.
[0064] It will be appreciated that in various embodiments, the
active optical element can be placed on the top, in the middle, or
on the bottom of other lens elements depending on the optical
design of the fixed element
* * * * *