U.S. patent application number 13/466130 was filed with the patent office on 2012-08-30 for lens assembly and lens assembly array.
This patent application is currently assigned to HON HAI PRECISION INDUSTRY CO., LTD.. Invention is credited to SEI-PING LOUH.
Application Number | 20120218642 13/466130 |
Document ID | / |
Family ID | 42164976 |
Filed Date | 2012-08-30 |
United States Patent
Application |
20120218642 |
Kind Code |
A1 |
LOUH; SEI-PING |
August 30, 2012 |
LENS ASSEMBLY AND LENS ASSEMBLY ARRAY
Abstract
A first lens having a first bottom surface and a first top
surface at opposite sides thereof; and a first supporter having a
first supporting surface and a second supporting surface at
opposite sides thereof, the first supporting surface being flat,
the second supporting surface being in contact with the first
bottom surface, the first supporter being made of transparent
material, and a refraction index of the first supporter being
different from a refraction index of the first lens. A lens
assembly array and method of making the lens assembly array are
also provided.
Inventors: |
LOUH; SEI-PING; (Tu-Cheng,
TW) |
Assignee: |
HON HAI PRECISION INDUSTRY CO.,
LTD.
Tu-Cheng
TW
|
Family ID: |
42164976 |
Appl. No.: |
13/466130 |
Filed: |
May 8, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12537355 |
Aug 7, 2009 |
8202451 |
|
|
13466130 |
|
|
|
|
Current U.S.
Class: |
359/619 ;
359/723; 359/811 |
Current CPC
Class: |
Y10S 425/808 20130101;
G02B 3/0031 20130101; B29D 11/0073 20130101 |
Class at
Publication: |
359/619 ;
359/811; 359/723 |
International
Class: |
G02B 7/02 20060101
G02B007/02; G02B 5/20 20060101 G02B005/20 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 12, 2008 |
CN |
200810305502.X |
Claims
1. A lens assembly, comprising: a first lens having a first bottom
surface and a first top surface at opposite sides thereof; and a
first supporter having a first supporting surface and a second
supporting surface at opposite sides thereof, the first supporting
surface being flat, the second supporting surface being in contact
with the first bottom surface, the first supporter being made of
transparent material, and a refraction index of the first supporter
being different from a refraction index of the first lens.
2. The lens assembly according to claim 1, wherein the first lens
and the first supporter are coaxially arranged, and a maximum
diameter of the first lens is equal to a diameter of the first
supporter.
3. The lens assembly according to claim 1, wherein a refraction
index of the first lens is in the range from 1.55 to 1.60, and a
refraction index of the first supporter is in the range from 1.45
to 1.49.
4. The lens assembly according to claim 1, wherein a refraction
index of the first lens is in the range from 1.45 to 1.49, and a
refraction index of the first supporter is in the range from 1.55
to 1.60.
5. The lens assembly according to claim 1, further comprising a
second supporter, the second supporter having a third supporting
surface and a fourth supporting surface at opposite sides thereof,
the third supporting surface being in contact with the first top
surface, and the fourth supporting surface being flat.
6. The lens assembly according to claim 1, further comprising a
filter formed on the first supporting surface of the first
supporter.
7. The lens assembly according to claim 1, further comprising a
second supporter and a second lens, the second supporter having a
third supporting surface and a fourth supporting surface at
opposite sides thereof, the second lens having a second bottom
surface and a second top surface at opposite sides thereof, the
third supporting surface being in contact with the first top
surface, and the fourth supporting surface being in contact with
the second bottom surface.
8. The lens assembly according to claim 7, further comprising a
third supporter, the third supporter having a fifth supporting
surface and a six supporting surface at opposite sides thereof, the
fifth supporting surface being in contact with the second top
surface, and the six supporting surface being flat.
9. A lens assembly array, comprising: a lens array having a first
bottom surface and a first top surface at opposite sides thereof;
and a supporter array having a first supporting surface and a
second supporting surface at opposite sides thereof, the first
supporting surface being flat, the second supporting surface being
in contact with the first bottom surface, a refraction index of the
supporter array being different from a refraction index of the lens
array.
10. The lens assembly array according to claim 9, wherein the lens
array comprises a plurality of lens portions, the supporter array
comprises a plurality of supporter portions, and each lens portion
is coaxially arranged with a corresponding supporter portion.
11. The lens assembly array according to claim 9, wherein a
refraction index of the lens array is in the range from 1.55 to
1.60, and a refraction index of the supporter array is in the range
from 1.45 to 1.49.
12. The lens assembly array according to claim 9, wherein a
refraction index of the lens array is in the range from 1.45 to
1.49, and a refraction index of the supporter array is in the range
from 1.55 to 1.60.
Description
[0001] This application is a divisional application of a
commonly-assigned application entitled "METHOD OF MAKING A LENS
ASSEMBLY ARRAY", filed on Aug. 7, 2009 with application Ser. No.
12/537,355. The disclosure of the above-identified application is
incorporated herein by reference.
BACKGROUND
[0002] 1. Technical Field
[0003] The present disclosure relates to lens assemblies, lens
assembly arrays and methods of manufacturing the lens assemblies
and lens assembly arrays by press molding.
[0004] 2. Description of Related Art
[0005] Wafer-level optical lenses are usually manufactured by
press-molding a plurality of optical lenses on one or both sides of
a transparent substrate.
[0006] A lens assembly is usually formed by combining a plurality
of single lenses with other optical components, such as a filter
and a spacer, for example. It is required that the individual
lenses be coaxially arranged. However, a coaxial lens assembly is
often hard to achieve by assembling the lenses one by one.
[0007] What is needed, therefore, is a lens assembly and a method
of making the lens assembly which can overcome the above
shortcomings
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Many aspects of the present lens assembly, lens assembly
array, and methods of making the lens assembly and lens assembly
array can be better understood with reference to the following
drawings. The components in the drawings are not necessarily drawn
to scale, the emphasis instead being placed upon clearly
illustrating the principles of the present lens assembly, lens
assembly array and methods. Moreover, in the drawings, like
reference numerals designate corresponding parts throughout the
several views.
[0009] FIG. 1 is cross-sectional view of a lens assembly in
accordance with a first embodiment, showing a central axis thereof
as a broken line.
[0010] FIG. 2 is cross-sectional view of a lens assembly in
accordance with a second embodiment, showing a central axis thereof
as a broken line.
[0011] FIG. 3 is cross-sectional view of a lens assembly in
accordance with a third embodiment, showing a central axis thereof
as a broken line.
[0012] FIG. 4 is cross-sectional view of a lens assembly array in
accordance with a fourth embodiment.
[0013] FIGS. 5-14 are cross-sectional views showing successive
stages in a method of making a lens assembly in accordance with a
fifth embodiment; and
[0014] FIGS. 15-18 are cross-sectional views showing successive
stages in a method of making a lens assembly array and a
corresponding plurality of lens assemblies in accordance with a
sixth embodiment.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0015] A lens assembly 100 in accordance with a first embodiment is
shown in FIG. 1. The lens assembly 100 includes a first lens 110,
and a first supporter 120 integrally formed with the first lens
110. The first lens 110 has a bottom surface 111 and a top surface
112 at opposite sides thereof, and a peripheral first side surface
113 interconnecting the bottom surface 111 and the top surface 112.
In this embodiment, the first lens 110 is a biconvex lens. In other
embodiments, the first lens can be a biconcave lens or a positive
meniscus lens. The supporter 120 has a first surface 121 and a
second surface 122 at opposite sides thereof, and a peripheral
first sidewall 123 interconnecting the first surface 121 and the
second surface 122. The first surface 121 is flat. The second
surface 122 is fully in contact with the bottom surface 111. That
is, a shape of the second surface 122 matches a shape of the bottom
surface 111.
[0016] The first lens 110 is coaxial with the first supporter 120.
The first lens 110 and the first supporter 120 are each
substantially circular or disk shaped. A maximum diameter of the
first lens 110 is equal to that of the first supporter 120, in
order to ensure that the first side surface 113 of the first lens
110 can be aligned with the first sidewall 123 of the first
supporter 120.
[0017] The first lens 110 as well as the first supporter 120 can be
made of thermosetting material or thermoplastic material, either of
which has properties of high transmittance and a low light
absorption rate. The refraction index of the first lens 110 is
different from that of the first supporter 120. For example, the
refraction index of the first lens 110 can either be higher than
that of the first supporter 120, or lower. The high refraction
index range is from 1.55 to 1.60. The low refraction index range is
from 1.45 to 1.49. For example, the high refraction index material
is polycarbonate, and the low refraction index material is
polymethyl methacrylate. Due to the refractivity difference between
the first lens 110 and the first supporter 120, the inherent
optical properties of the bottom surface 111 and the top surface
112 can be maintained. That is, the first supporter 120 being in
intimate contact with the first lens 110 does not adversely impact
the performance characteristics of the first lens 110.
[0018] A lens assembly 200 according to a second embodiment is
shown in FIG. 2. The lens assembly 200 is essentially similar to
the lens assembly 100 of the first embodiment. However, the lens
assembly 200 further has a second supporter 230 in addition to a
first lens 210 and a first supporter 220.
[0019] The second supporter 230 has a third surface 231 and a
fourth surface 232 at opposite sides thereof, and a peripheral
second sidewall 233 interconnecting the third surface 232 and the
fourth surface 232. The third surface 231 is fully in contact with
the first lens 210. The fourth surface 232 is flat. The first
supporter 220 has a peripheral first sidewall 223.
[0020] The refraction index of the first lens 210 is different from
that of each of the first supporter 220 and the second supporter
230. The first lens 210, the first supporter 220, and the second
supporter 230 are coaxially arranged. The diameters of the first
lens 210, the first supporter 220, and the second supporter 230 are
the same, to ensure that the first side 213 of the first lens 210,
the first sidewall 223 of the first supporter 220 and the second
sidewall 233 of the second supporter 230 can be aligned.
[0021] A lens assembly 300 in accordance with a third embodiment is
shown in FIG. 3. The lens assembly 300 is essentially similar to
the lens assembly 100 of the first embodiment. However, the lens
assembly 300 further has a filter 310, a second supporter 340, a
second lens 350, and a third supporter 360, in addition to a first
lens 330 and a first supporter 320.
[0022] The filter 310 includes a transparent substrate 311, and a
filter film 312 deposited on the transparent substrate 311. An
outer surface 314 of the filter 310 is in contact with a first
surface 321 of the first supporter 320. The substrate 311 is able
to transmit visible light, as well as reflect ultraviolet rays or
infrared rays or both ultraviolet and infrared rays.
[0023] The second supporter 340 has a third surface 341 and a
fourth surface 342 at opposite sides thereof, and a peripheral
sidewall 343 interconnecting the third surface 341 and the fourth
surface 342. The third surface 341 is in intimate contact with a
first top surface 332 of the first lens 330. A first bottom surface
(not labeled) of the first lens 330 is in intimate contact with a
second surface 322 of the first supporter 320.
[0024] The second lens 350 has a second bottom surface 351 and a
second top surface 352 at opposite sides thereof, and a peripheral
second side surface 353 interconnecting the second bottom surface
351 and the second top surface 352. In this embodiment, the second
lens 350 is a biconvex lens. In other embodiments, the second lens
350 can be a biconcave lens or a positive meniscus lens. The second
bottom surface 351 is in intimate contact with the fourth surface
342 of the second supporter 340.
[0025] The third supporter 360 has a fifth surface 361 and a sixth
surface 362 at opposite sides thereof, and a third sidewall 363
interconnecting the fifth surface 361 and the sixth surface 362.
The fifth surface 361 is in intimate contact with the second top
surface 352. The sixth surface 362 is flat.
[0026] The refraction index of the first lens 330 is different from
that of each of the first supporter 320, the second supporter 340,
and the third supporter 360. The refraction index of the second
lens 350 can be the same as that of the first lens 330. The first
lens 330, the second lens 350, the first supporter 320, the second
supporter 340, and the third supporter 360 are coaxially arranged,
and have the same diameter to ensure that all of these components
can be aligned.
[0027] A lens assembly array 400 in accordance with a fourth
embodiment is shown in FIG. 4. The lens assembly array 400 is
similar in principle to the lens assemblies 100, 200, 300. The lens
assembly array 400 comprises a filter 410, a supporter array 420,
and a lens array 430 arranged in that order from bottom to top. The
lens array 430 has a plurality of biconvex lenses 431. The
supporter array 420 is arranged between the filter 410 and the lens
array 430. The filter 410 comprises a transparent substrate 411,
and a filter film 412 formed on the substrate 411. Each lens of the
lens array 430 is coaxially aligned with a corresponding supporter
portion of the supporter array 420. The lens assembly array 400 can
be diced into a plurality of lens assemblies by cutting along a
plurality of broken lines 450. In alternative embodiments, the lens
assembly array 400 can further include another supporter array on
the lens array 430 and another lens array on the additional
supporter array.
[0028] A method of making a lens assembly (such as the lens
assembly 300) in accordance with a fifth embodiment is described
below.
[0029] In step 1, as shown in FIG. 5, a platform 10 and a hollow
cylindrical barrel 20 are provided. The platform 10 has a flat
supporting surface 11 and an annular side surface 13. The hollow
cylindrical barrel 20 has a cylindrical inner surface 22. The
platform 10 is set inside the hollow cylindrical barrel 20, with
the side surface 13 movably contacting the inner surface 22. The
platform 10 is connected to and controlled by a driving shaft 12,
so that the platform 10 can linearly move up and down inside the
hollow cylindrical barrel 20. The hollow cylindrical barrel 20 has
an annular first end surface 201 and an opposite annular second end
surface 202. The distance that the platform 10 ascends or descends
can be precisely controlled. In this way, the flat supporting
surface 11 of the platform 10 and the inner surface 22 of the
hollow cylindrical barrel 20 can cooperatively form a molding
cavity 21 (see FIG. 6). The platform 10 is capable of moving inside
the hollow cylindrical barrel 20 under a pushing force or a pulling
force provided by the driving shaft 12, such that the molding
cavity 21 can be enlarged or contracted.
[0030] In step 2, as shown in FIG. 6, the filter 310 is put on the
flat supporting surface 11. At least one first alignment mark 313
is provided on or in the filter 310. The number and the position(s)
of the at least one alignment mark 313 depend on, inter alia, the
size and form of the lenses that are to be made. In the illustrated
embodiment, there are two first alignment marks 313.
[0031] In step 3, the first supporter 320 is formed on the top
surface 314 of the filter 310 by press molding, as shown in FIGS. 6
through 8.
[0032] Firstly, the position of the platform 10 is adjusted by
moving the driving shaft 12 in order that the distance between the
top surface 314 of the filter layer 312 and the first end surface
201 is equal to the maximum thickness of the first supporter
320.
[0033] Secondly, a molding material in a liquid, viscous, or
plastically deformable state for making the first supporter 320 is
provided. The molding material is arranged on the top surface 314,
and is pressed by a first mold 30 to form the first supporter 320.
The first mold 30 is transparent. The first mold 30 has a first
pattern surface 31 that is complementary to the second surface 322
of the first supporter 320. At least one second alignment mark 34
is marked on the first mold 30. In the illustrated embodiment,
there are two first alignment marks 34. The first mold 30 is placed
above the first end surface 201, and the first alignment marks 313
are aligned with the second alignment marks 34. Then, the first
mold 30 is pressed into the molding material until the first mold
30 contacts the first end surface 201. Excess molding material
flows out from one or more gaps (not shown) between an edge of the
first pattern surface 31 and a corresponding edge of the first end
surface 201.
[0034] Thirdly, the uncured first supporter 320 is cured by thermal
treatment or with ultraviolet (UV) rays. In the illustrated
embodiment, UV rays are applied from above the first mold 30.
[0035] Fourthly, the first mold 30 and the first supporter 320 are
separated from each other.
[0036] In step 4, the first lens 330 is formed on the cured first
supporter 320 by press-molding, as shown in FIGS. 9 through 11.
[0037] Firstly, the position of the platform 10 is adjusted in
order that the distance between the first end surface 201 and the
second surface 322 of the first supporter 320 is equal to a
thickness of a peripheral side surface (not labeled) of the first
lens 330. Secondly, a molding material in a liquid, viscous, or
plastically deformable state for making the first lens 330 is
provided. The molding material is put onto the second surface 322.
Thirdly, the molding material is pressed by a second mold 40 to
form the first lens 330. The second mold 40 has a second pattern
surface 41 that is complementary to the first top surface 332 of
the first lens 330.
[0038] In step 5, the second supporter 340 is formed on the first
top surface 332 by press-molding, as shown in FIG. 12 and FIG.
13.
[0039] The position of the platform 10 is adjusted in order that
the distance between the first top surface 332 of the first lens
330 and the first end surface 201 is equal to a maximum thickness
of the second supporter 340. Then a molding material in a liquid,
viscous, or plastically deformable state for making the second
supporter 340 is provided. The molding material is put onto the
first top surface 332, and is pressed by a third mold 50 to form
the second supporter 340. The third mold 50 has a third pattern
surface 51 that is complementary to the second surface 342 of the
second supporter 340. In the illustrated embodiment, there are two
third alignment marks 52 on or in the third mold 50. The third
alignment marks 52 are aligned with the first alignment marks 313.
The third mold 50 is pressed into the molding material until the
third mold 50 contacts the first end surface 201. The second
supporter 340 is cured by thermal treatment or ultraviolet rays,
and then the third mold 50 and the second supporter 340 are
separated from each other.
[0040] In step 6, the second lens 350 is formed on the fourth
surface 342 of the second supporter 340 in much the same way as the
first lens 330 is formed (see above).
[0041] In step 7, the third supporter 360 is formed on the second
top surface 352 of the second lens 350, as shown in FIG. 14. The
third supporter 360 is formed in much the same way as the first
supporter 320 is formed (see above). The lens assembly 300 can then
be separated from the platform 10 and taken out of the hollow
cylindrical barrel 20. Formation of the lens assembly 300 is thus
completed.
[0042] FIGS. 15 to 18 show successive stages in a method of making
a lens assembly array and a corresponding plurality of lens
assemblies in accordance with a sixth embodiment. The lens assembly
array may for example be similar to the lens assembly array 400,
but without the filter 410. The method employs techniques similar
to the method of the fifth embodiment described above. Accordingly,
a full description of such techniques is not provided herein, for
the sake of brevity.
[0043] In step 1, a platform 60 having a flat supporting surface 61
is provided.
[0044] In step 2, a molding material in a liquid, viscous, or
plastically deformable state is provided. The molding material is
put onto the supporting surface 61 and is pressed by a mold (not
labeled) to form the supporter array 610. After curing the
supporter array 610, molding material is put onto the supporter
array 610 for making a lens array 620. The integrally formed
supporter array 610 and lens array 620 is finally taken out of a
cylindrical barrel (not labeled). Thus, a lens assembly array 600
is obtained.
[0045] In step 3, the lens assembly array 600 is diced into a
plurality of lens assemblies 500, one of which is shown in FIG. 18.
The lens assembly 500 is comprised of a lens 520 and a supporter
510, which are coaxially stacked one on the other. A central axis
of the lens assembly 500 is shown in a broken line.
[0046] In alternative embodiments, another supporter array and
another lens assembly can be formed on the lens assembly array 600.
The steps and techniques for forming the additional supporter array
and lens assembly are similar to corresponding steps and techniques
in the above-described method for making the lens assembly 300.
Accordingly, a full description of such steps and techniques is not
provided herein, for the sake of brevity.
[0047] According to the above-described method of making a lens
assembly array, each lens portion (not labeled) of the lens array
620 is coaxial with a corresponding supporter portion (not labeled)
of the supporter array 610. This is achieved by alignment marks
(not shown) provided on the mold (not labeled), at least one of the
supporter array 610 and the lens array 620, and the platform (not
labeled). Unlike in a conventional method, the above-described
method obviates the need for, e.g., producing a plurality of
individual first optical components and a plurality of individual
second optical components and then combining one first optical
component with one second optical component to obtain each lens
assembly.
[0048] It is understood that the above-described embodiments are
intended to illustrate rather than limit the invention. Variations
may be made to the embodiments without departing from the spirit of
the invention. Accordingly, it is appropriate that the appended
claims be construed broadly and in a manner consistent with the
scope of the invention.
* * * * *