Lens assembly and method of manufacture
First Claim
Patent Images
1. A method of forming a lens module array for an image sensor array comprising a plurality of image sensors on a sensor substrate that are spaced apart by a spacing distance, the method comprising:
- (a) providing an alignment tool comprising an array of alignment holes that are separated from one another by the spacing distance of the image sensors;
(b) placing at least one lens in each alignment hole of the alignment tool to form a lens filled alignment tool, each lens having an outer circumference;
(c) providing a spacer plate comprising;
(i) first and second surfaces, and(ii) an array of lens barrels that each comprise a lens opening extending inward from the first surface of the spacer plate, and a sensor cavity extending inward from the second surface of the spacer plate to meet the lens opening;
(d) aligning the lens filled alignment tool onto the first surface of the spacer plate such that each lens is aligned to a lens opening of a lens barrel in the spacer plate;
(e) attaching outer circumferences of the lenses to the first surface of the spacer plate; and
(f) removing the alignment tool from the spacer plate to form a lens module array comprising a plurality of lens modules that each comprise a lens in a lens barrel of the spacer plate.
1 Assignment
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Accused Products
Abstract
A lens assembly comprises a spacer plate having first and second surfaces, and an array of lens barrels that each comprise a lens opening extending inward from the first surface of the spacer plate and a sensor cavity extending inward from the second surface of the spacer plate. An alignment tool comprising an array of alignment holes or prongs is used to align the lens to the orifices of the lens openings.
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Citations
54 Claims
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1. A method of forming a lens module array for an image sensor array comprising a plurality of image sensors on a sensor substrate that are spaced apart by a spacing distance, the method comprising:
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(a) providing an alignment tool comprising an array of alignment holes that are separated from one another by the spacing distance of the image sensors; (b) placing at least one lens in each alignment hole of the alignment tool to form a lens filled alignment tool, each lens having an outer circumference; (c) providing a spacer plate comprising; (i) first and second surfaces, and (ii) an array of lens barrels that each comprise a lens opening extending inward from the first surface of the spacer plate, and a sensor cavity extending inward from the second surface of the spacer plate to meet the lens opening; (d) aligning the lens filled alignment tool onto the first surface of the spacer plate such that each lens is aligned to a lens opening of a lens barrel in the spacer plate; (e) attaching outer circumferences of the lenses to the first surface of the spacer plate; and (f) removing the alignment tool from the spacer plate to form a lens module array comprising a plurality of lens modules that each comprise a lens in a lens barrel of the spacer plate. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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17. A lens module array comprising:
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(a) a spacer plate comprising; (i) first and second surfaces, and (ii) an array of lens barrels that each comprise a lens opening extending inward from the first surface of the spacer plate, and a sensor cavity extending inward from the second surface of the spacer plate to meet the lens opening; and (b) at least one lens positioned over each lens opening of a lens barrel, the outer circumference of the lens being attached to the spacer plate. - View Dependent Claims (18, 19, 20, 21, 22, 23, 24, 25, 26, 27)
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28. A method of forming a lens module array for an image sensor array comprising a plurality of image sensors on a sensor substrate that are spaced apart by a spacing distance, the method comprising:
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(a) forming a spacer plate comprising first and second surfaces, and an array of lens barrels that each comprise (i) a lens opening that extends inward from a first surface of the spacer plate to end in an orifice having a circumferential edge, the lens openings separated from one another by a lens spacing distance that corresponds to the sensor spacing distance, and (ii) a sensor cavity that extends inward from a second surface of the spacer plate to meet the lens opening; (b) applying an adhesive to the circumferential edge of the orifice of the lens opening; (c) placing a lens in each orifice of each lens opening; (d) providing an alignment tool comprising an array of alignment prongs that are separated from one another by the lens spacing distance; (e) inserting the alignment prongs of the alignment tool into the lens openings of the lens barrels, wherein each alignment prong aligns a lens to an orifice of a lens opening of a lens barrel; and (f) removing the alignment tool from the spacer plate to form a lens module array comprising a plurality of lens modules that each comprises a lens adhered to an orifice of a lens opening of a lens barrel of the spacer plate. - View Dependent Claims (29, 30, 31, 32, 33, 34, 35, 36, 37)
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38. A lens module array comprising:
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(a) a spacer plate comprising first and second surfaces, and an array of lens barrels that each comprise (i) a lens opening that extends inward from a first surface of the spacer plate to end in an orifice having a circumferential edge, the lens openings separated from one another by a lens spacing distance, and (ii) a sensor cavity that extends inward from a second surface of the spacer plate to meet the lens opening; (b) at least one lens in each lens opening of a lens barrel, each lens having an outer circumference that is adhered to a circumferential edge of an orifice of a lens opening of a lens barrel of the spacer plate with an adhesive. - View Dependent Claims (39, 40, 41, 42, 43)
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44. An image capturing unit comprising:
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(a) a spacer plate comprising; (i) first and second surfaces, and (ii) an array of lens barrels that each comprise a lens opening extending inward from the first surface of the spacer plate, and a sensor cavity extending inward from the second surface of the spacer plate to meet the lens opening; (b) a lens positioned in each lens opening of a lens barrel, each lens having an outer circumference that is attached to the spacer plate; and (c) a sensor positioned within each sensor cavity of a lens barrel to be under a lens. - View Dependent Claims (45, 46, 47, 48, 49, 50, 51, 52, 53, 54)
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Specification