PATENT DOCUMENT

Publication Number: US-9851613-B2
Application Number: US-201414257803-A
Country: US
Kind Code: B2

Title: Electro-optic variable aperture lens

Abstract:
A variable aperture lens and methods of forming such lenses are disclosed. More particularly, embodiments of the variable aperture lens include an electro-optic aperture sandwiched between a front lens and a rear lens along an optical axis. The front lens or the rear lens may include multiple lens layers having different optical properties to provide for a low z-height, optically aligned, variable aperture lens.

Claims:
What is claimed is: 
     
       1. An optical element, comprising:
 an electro-optic aperture including an electrochromic element mounted on a substrate, wherein the electrochromic element is an electrically variable pupil, and wherein the electro-optic aperture includes a flat front surface and a flat rear surface; 
 a front lens having a flat front lens surface attached to the flat front surface of the electro-optic aperture, wherein the front lens is a first portion of an achromatic lens to limit chromatic aberration; and 
 a rear lens having a flat rear lens surface attached to the flat rear surface of the electro-optic aperture, wherein the rear lens is aligned with the front lens along an optical axis, and wherein the rear lens is a second portion of the achromatic lens; 
 wherein at least one of the front lens or the rear lens includes a plurality of lens layers, wherein the plurality of lens layers include a first lens layer laminated on a second lens layer, wherein the plurality of lens layers have different optical properties, wherein the achromatic lens is an achromatic doublet, wherein the front lens is a positive element of the achromatic doublet, and wherein the rear lens is a negative element of the achromatic doublet. 
 
     
     
       2. The optical element of  claim 1 , wherein the electro-optic aperture and the substrate are aligned along the optical axis between the front lens and the rear lens. 
     
     
       3. The optical element of  claim 2 , wherein the electro-optic aperture, the front lens, and the rear lens are aligned along the optical axis. 
     
     
       4. The optical element of  claim 1 , wherein the plurality of lens layers include a resin material. 
     
     
       5. The optical element of  claim 4 , wherein the resin material is configured to be cured by ultraviolet radiation. 
     
     
       6. The optical element of  claim 1 , wherein the electrochromic element includes at least one of a liquid, a crystalline material, or a non-crystalline material. 
     
     
       7. The optical element of  claim 1  further comprising an electro-optic filter between the front lens and the rear lens. 
     
     
       8. The optical element of  claim 1  further comprising an electrical contact on the substrate, wherein the electrical contact is exposed from the front lens and the rear lens. 
     
     
       9. The optical element of  claim 1  further comprising a dielectric film between the first lens layer and the second lens layer. 
     
     
       10. The optical element of  claim 1 , wherein the first lens layer and the second lens layer include a same lens material. 
     
     
       11. A method of producing a mobile lens assembly, comprising:
 attaching a flat front lens surface of a front lens to a flat front surface of an electro-optic aperture, wherein the electro-optic aperture includes an electrochromic element mounted on a substrate, and wherein the electrochromic element is an electrically variable pupil, and wherein the front lens is a positive element of an achromatic doublet to limit chromatic aberration; 
 attaching a flat rear lens surface of a rear lens to a flat rear surface of the electro-optic aperture to form a variable aperture lens, wherein the rear lens is aligned with the front lens along an optical axis, and wherein the rear lens is a negative element of the achromatic doublet; and 
 combining the variable aperture lens with a lens stack to form a mobile lens assembly, wherein the lens stack includes one or more aberration-correction lenses to limit monochromatic aberrations; 
 wherein at least one of the front lens or the rear lens includes a plurality of lens layers, and wherein the plurality of lens layers include a first lens layer laminated on a second lens layer. 
 
     
     
       12. The method of  claim 11  further comprising:
 molding a first resin into the second lens layer; and 
 overmolding a second resin into the first lens layer over the second lens layer to form the one or more of the front lens or the rear lens. 
 
     
     
       13. The method of  claim 12 , wherein the first resin and the second resin have different optical properties. 
     
     
       14. The method of  claim 13  further comprising molding a third resin into one or more of the front lens or the rear lens. 
     
     
       15. The method of  claim 14 , wherein at least one of the first resin, the second resin, or the third resin is configured to be cured by ultraviolet radiation. 
     
     
       16. The method of  claim 12  further comprising depositing a film between the first lens layer and the second lens layer. 
     
     
       17. The method of  claim 11 , wherein the attaching further includes aligning the front lens, the rear lens, and the electro-optic aperture along the optical axis. 
     
     
       18. The method of  claim 17 , wherein the attaching further includes molding at least one of the front lens or the rear lens directly over the electro-optic aperture. 
     
     
       19. The method of  claim 18 , wherein the molding includes introducing a lens resin in an uncured state and curing the lens resin into a cured state.

Description:
RELATED APPLICATIONS 
     Applicant claims the benefit of priority of prior, provisional application Ser. No. 61/943,151 filed Feb. 21, 2014, the entirety of which is incorporated by reference. 
    
    
     BACKGROUND 
     Field 
     Embodiments related to optical elements having electro-optic variable apertures, are disclosed. More particularly, an embodiment related to an electro-optic variable aperture lens for use in a camera, is disclosed. 
     Background Information 
     Camera modules have been incorporated in a variety of consumer electronics devices, including smart phones, mobile audio players, personal digital assistants, and both portable and desktop computers. A typical camera module includes an optical system used to collect and transmit light from an imaged scene to an image sensor. The optical system generally includes at least one lens associated with one aperture. The lens collects and transmits light. The aperture limits the light collected and transmitted by the lens, and is therefore termed the stop aperture, or alternatively, the entrance pupil) aperture. The effective diameter of the stop aperture combined with the lens focal length determines the “F number” of the lens. A lens with a lower F number produces a brighter image than a lens with a larger F number and, as a result, reduces the image noise in a low light scene. However, as the F number is reduced, the lens depth of field decreases and, as a result, lens aberrations increase. Thus, there is an optimal stop aperture diameter, dependent on the lens and the scene being imaged, to minimize image noise and maximize image resolution. 
     In most portable consumer electronics devices, minimizing device profile is an important design goal. Accordingly, device profile requirements generally prohibit the use of an iris diaphragm as a variable stop aperture. Thus, product designs often aim to minimize the device profile, known as z-height, by fixing the aperture diameter in the optical system for a particular zoom factor. This design choice minimizes the F number without noticeably affecting achievable resolution, both from design and manufacturing standpoints. As a result of this design paradigm, users have been unable to adjust and optimize the F number for a particular scene in a mobile application. 
     SUMMARY 
     Optical elements having electro-optic variable apertures, particularly for use in portable consumer electronics device applications, are disclosed. In an embodiment, an optical element is provided having a front lens, a rear lens, and an electro-optic aperture. The rear lens may be aligned with the front lens along an optical axis and the electro-optic aperture may be coupled, e.g., joined, attached, fixed, or otherwise secured, to at least one of the front lens or the rear lens. In an embodiment, the front lens is attached to the electro-optic aperture and the electro-optic aperture is between the front lens and the rear lens. 
     The electro-optic aperture may include an electrochromic element coupled with a substrate. For example, the electro-optic aperture may include a variable pupil aligned with the front lens and the rear lens along the optical axis. The electrochromic element of the electro-optic aperture may include at least one of a liquid, a crystalline material, or a non-crystalline material. 
     In an embodiment, at least one of the front lens or the rear lens includes a plurality of lens layers. For example, the plurality of lens layers may be formed from a plurality of resins having different optical properties and at least one of the resins may be curable by ultraviolet radiation. The front lens and the rear lens may combine to form an achromatic lens. 
     The optical element may include other components. For example, in an embodiment, the optical element may include an electro-optic filter between the front lens and the rear lens. Additionally, the optical element may include an electrical contact on the substrate, and the electrical contact may be exposed from the front lens and the rear lens. 
     In an embodiment, a method of producing a mobile lens assembly is provided. The method includes attaching a front lens to a front surface of an electro-optic aperture. The electro-optic aperture may include an electrochromic element coupled with a substrate. The method may also include attaching a rear lens to a rear surface of the electro-optic aperture to form a variable aperture lens. The attaching may include aligning the front lens, the rear lens, and the electro-optic aperture along an optical axis. The attaching may further include molding at least one of the front lens or the rear lens directly over the electro-optic aperture. For example, the molding may include introducing a lens resin in an uncured state and curing the lens resin into a cured state. The method may further include combining the variable aperture lens with a lens stack to form a mobile lens assembly, forming a hybrid system. The lens stack may include one or more aberration-correction lenses. 
     In an embodiment, the method may include molding a first resin into a first lens layer and overmolding a second resin into a second lens layer over the outer lens layer to form the front lens. The first resin and the second resin may have different optical properties. In an embodiment, a film may be deposited between the front surface and at least one of the front lens or the rear lens. Furthermore, the method may include molding a third resin into the rear lens. At least one of the first resin, the second resin, or the third resin may be configured to be cured by ultraviolet radiation. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a pictorial view of a portable consumer electronics device having a camera module. 
         FIG. 2  is a side view of a mobile lens assembly. 
         FIG. 3  is a schematic view of a mobile lens assembly having an electro-optic aperture in front of a doublet. 
         FIG. 4  is a schematic view of a mobile lens assembly having an electro-optic aperture behind a first lens element of a doublet. 
         FIG. 5  is a cross-sectional view of a variable aperture lens in accordance with an embodiment. 
         FIG. 6  is a side view of a mobile lens assembly having a variable aperture lens in accordance with an embodiment. 
         FIG. 7  is a schematic view of camera related elements including a camera module having a variable aperture lens in accordance with an embodiment. 
         FIG. 8  is a cross-sectional view of an electro-optic aperture in accordance with an embodiment. 
         FIG. 9  is a flowchart of a method of producing a mobile lens assembly in accordance with an embodiment. 
         FIGS. 10-17  are pictorial views illustrating operations in forming a variable aperture lens in accordance with an embodiment. 
         FIG. 18  is a flowchart of a method of producing a mobile lens assembly in accordance with an embodiment. 
         FIGS. 19-23  are pictorial views illustrating operations in forming a variable aperture lens in accordance with an embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Embodiments describe optical elements having electro-optic variable apertures, particularly for use in portable consumer electronics device applications. However, while some embodiments are described with specific regard to integration within mobile electronics device, the embodiments are not so limited and certain embodiments may also be applicable to other uses. For example, an optical element having an electro-optic variable aperture may be incorporated into camera modules that remain at fixed locations, e.g., traffic cameras, or used in relatively stationary applications, e.g., as a lens in a multimedia disc player. 
     In various embodiments, description is made with reference to the figures. However, certain embodiments may be practiced without one or more of these specific details, or in combination with other known methods and configurations. In the following description, numerous specific details are set forth, such as specific configurations, dimensions, and processes, in order to provide a thorough understanding of the embodiments. In other instances, well-known processes and manufacturing techniques have not been described in particular detail in order to not unnecessarily obscure the description. Reference throughout this specification to “one embodiment,” “an embodiment”, or the like, means that a particular feature, structure, configuration, or characteristic described is included in at least one embodiment. Thus, the appearance of the phrase “one embodiment,” “an embodiment”, or the like, in various places throughout this specification are not necessarily referring to the same embodiment. Furthermore, the particular features, structures, configurations, or characteristics may be combined in any suitable manner in one or more embodiments. 
     In an aspect, a camera module incorporates a variable aperture lens such that a user may vary a lens F number without significantly increasing the space required for the optical system. In an embodiment, the variable aperture lens includes an electro-optic aperture sandwiched between a front lens and a rear lens. Furthermore, the front lens or the rear lens may include a multi-layered construction, allowing the variable aperture lens to replace an achromatic doublet without increasing the z-height. The multiple layers may, for example, both spherical and aspherical contours and different optical properties. 
     In an aspect, a camera module incorporates a variable aperture lens such that a user may vary a lens F number without degrading the system optics. In an embodiment, the variable aperture lens incorporates multiple lens layers having different optical properties that create the functionality of an achromatic doublet. Furthermore, the variable aperture lens includes an electro-optic aperture between the lens layers in an optimized position in the optical system such that vignetting is avoided. Furthermore, the variable aperture lens components may be fixed relative to each other along an optical axis such that the variable aperture lens remains optically aligned throughout use. 
     Referring to  FIG. 1 , a pictorial view of a portable consumer electronics device having a camera module is shown. A portable consumer electronics device  100 , e.g., a smartphone, is being held by a user. As mentioned above, portable consumer electronics device  100  may be another, not necessarily portable, device. In an embodiment, portable consumer electronics device  100  includes an integrated camera module  102  that incorporates a mobile lens assembly. 
     Referring to  FIG. 2 , a side view of a mobile lens assembly is shown. A mobile lens assembly  200  may be considered to be typical of portable consumer electronics devices  100  having camera module  102  with a fixed aperture. The mobile lens assembly  200  may incorporate a doublet  202  and a lens stack  204 . One or more filters, such as infrared filter  206 , may also be aligned with mobile lens assembly  200  to reflect or block certain wavelengths of light that a user does not wish to transmit to an image sensor  208 . Thus, mobile lens assembly  200  may include numerous lenses, filters, and other optical components aligned along an optical axis  210  between an external window  212  and image sensor  208 . External window  212  may, for example, be a transparent glass or polymer window located substantially coplanar with a mobile device housing. 
     The various optical components of mobile lens assembly  200  may be paired or grouped to achieve various optical functionalities. For example, doublet  202  may function as an achromatic lens to limit the effects of chromatic aberration. More specifically, doublet  202  may be an achromatic doublet  202  having lens one  214  and lens two  216 . Lens one  214  may be a positive element and lens two  216  may be a negative element. The lenses may be formed and mounted such that the chromatic aberration of lens one  214  is counterbalanced by the chromatic aberration of lens two  216 . More specifically, the shape and materials of the lens one  214  and lens two  216  may be varied to complement each other and achieve the desired chromatic aberration correction. 
     In an embodiment, lens stack  204  functions to limit the effects of monochromatic aberrations. More specifically, lens stack  204  may include lens three  218 , lens four  220 , and lens five  222 , each of which is formed and mounted to correct optical aberrations caused by the geometry of the lenses. The number and shapes of the hybrid lenses is shown by way of example, and other numbers or shapes of the lenses may be used to correct the targeted optical aberrations, such as spherical aberrations. 
     Still referring to  FIG. 2 , in an embodiment, a plurality of image rays  230  are reflected or emitted from a scene and transmit through external window  212 , mobile lens assembly  200 , and infrared filter  206 , to image sensor  208 . A relative illumination of image sensor  208  by image rays  230  may depend on both placement of an aperture and an angle of incidence of image rays  230  relative to optical axis  210 , i.e., the object angle. For example, as the distance between an aperture and lens one  214  is increased or as the object angle is increased, relative illumination of image sensor  208  decreases. This drop in relative illumination indicates vignetting, a generally undesirable phenomenon that is an important consideration when incorporating a variable aperture into an optical system. Thus, incorporation of a variable aperture along the optical path may require that the variable aperture be located to limit vignetting, as well as z-height. 
     The incorporation of a variable aperture in an imaging system has been suggested to improve focusing and depth of field. Technologies exist to realize such a variable aperture, such as artificial muscles or electro-optic apertures. Electro-optic apertures may include, for example, an electrochromic medium to attenuate light from a scene as it passes through the aperture. The stop aperture diameter may be varied based on a voltage applied to the electro-optic aperture components. However, such solutions suffer from integration problems. 
     Referring to  FIG. 3 , a schematic view of a mobile lens assembly having an electro-optic aperture in front of a doublet is shown. Introducing an electro-optic aperture  300  in front of doublet  202 , such as when it is mounted on external window  212 , results in several trade-offs. First, since electro-optic aperture  300  must be spaced apart from lens one  214 , relative illumination of image sensor  208 , i.e., vignetting, is increased. To mitigate such vignetting, the semi-diameters of doublet  202  lenses may be increased. However, this increase in lens thickness, as well as the fact that electro-optic aperture  300  requires its own plane, results in an overall increase in system z-height. Furthermore, given the spacing between system optics, alignment of electro-optic aperture  300  with doublet  202  lenses along optical axis  210  can be difficult to perfect, and thus, overall lens performance may be degraded. Finally, in an optical system that utilizes autofocus, complexities in changing the F number in relation to focus make overall system management difficult to achieve. 
     Referring to  FIG. 4 , a schematic view of a mobile lens assembly having electro-optic aperture behind a first lens element of a doublet is shown. Introducing electro-optic aperture  300  behind lens one  214  results in similar trade-offs to those discussed in relation to  FIG. 3 . For example, placing electro-optic aperture  300  between doublet  202  lenses requires an increase in lens one  214  and lens two  216  separation, resulting in increased z-height. Additionally, alignment between lens one  214  and lens two  216  along optical axis  210  is critical to overall lens performance and thus, since placement of electro-optic aperture  300  between doublet  202  lenses may promote misalignment, image degradation may result. 
     Referring to  FIG. 5 , a cross-sectional view of a variable aperture lens is shown in accordance with an embodiment. In an embodiment, a variable aperture lens  500  may include an electro-optic aperture  300  and one or more lenses integrated into a single optical element. For example, electro-optic aperture  300  may be located between a front lens  502  and a rear lens  504 . Thus, in an embodiment, variable aperture lens  500  replaces doublet  202  and electro-optic aperture  300  in mobile lens assembly  200  of  FIGS. 3 and 4 . 
     In an embodiment, electro-optic aperture  300  includes an electrochromic element  506  on a substrate  508 . Electro-optic aperture  300  effectively provides a pupil whose width or size is electrically variable. When the pupil has been electrically controlled into a small or narrow opening, highly collimated image rays  230  are admitted toward image sensor  208 . By contrast, when the pupil is configured into a large or wide opening, un-collimated rays are admitted toward image sensor  208 . As previously discussed, the pupil size controls the stop aperture, and thus, influences image quality. Various embodiments of electro-optic aperture  300  are described below, but in at least one embodiment, electro-optic aperture  300  includes front surface  510  on electrochromic element  506  and rear surface  512  on substrate  508 . 
     Although not evident in  FIG. 5 , electrochromic element  506  may include multiple component layers that combine to create an electrically variable pupil  513 . For example, an ion source, an ion conduction layer, and an active electrochromic layer may be arranged between substrate  508  and one or more transparent conductors electrically connected to a variable voltage source, as described further below. By varying the voltage supplied to the transparent conductors, an effective diameter of the active electrochromic layer may be varied to provide a desired pupil  513  size. 
     Substrate  508  may be any material having structural and optical characteristics suitable for the present application. More specifically, substrate  508  may be adequately rigid to support electrochromic element  506 . Furthermore, substrate  508  may be adequately transparent to permit light passing from front lens  502  through electrochromic element  506  to transmit onward toward rear lens  504 . Accordingly, substrate  508  material candidates may include glass, sapphire, or polycarbonate, to name a few. Thus, substrate  508  may include a rigid, transparent, film or cylindrical object with one or more flat surface. In an embodiment, a diameter or maximum dimension of substrate  508  is greater than a diameter of front lens  502  or rear lens  504 , such that an edge of electro-optic aperture  300  extends laterally beyond an edge of front lens  502  and/or rear lens  504 . 
     In an embodiment, front lens  502  and/or rear lens  504  may include a multi-layered structure. For example, front lens  502  may include an outer lens layer  514  and an inner lens layer  516 . The layers may have a laminate structure. The multiple layers may be shaped to achieve the desired optical characteristics, e.g., chromatic aberration correction or focal properties. As an example, outer lens layer  514  may include a convexity near optical axis  210  and inner lens layer  516  may include a meshing concavity in the same region. Furthermore, each of the multiple layers, e.g., outer lens layer  514  and inner lens layer  516 , may have be formed from the same or different materials and those materials may include the same or different optical characteristics, e.g., indices of refraction. Accordingly, the complementary geometries and optical properties of outer lens layer  514  and inner lens layer  516  may form a composite lens structure that provides a positive element of a doublet lens, like lens one  214 . 
     In an embodiment, front lens  502 , electro-optic aperture  300 , and rear lens  504  may be aligned along optical axis  210 . More specifically, an optical axis  210  of each of front lens  502 , electro-optic aperture  300 , and rear lens  504  may be coaxially arranged along optical axis  210 . Since front lens  502 , rear lens  504 , and electro-optic aperture  300  may be fixed relative to each other, this coaxial arrangement may be maintained regardless of system movement. Furthermore, since the interfacing surfaces of front lens  502 , electro-optic aperture  300 , and rear lens  504  may be fixed relative to each other in a coplanar fashion at front surface  510  and rear surface  512 , respectively, the angular alignment between variable aperture lens  500  components may be maintained regardless of system movement. Accordingly, optical alignment between variable aperture lens  500  components, once set, may remain stable throughout system use. 
     Variable aperture lens  500  may be constructed in numerous fashions within the scope of this disclosure. In an embodiment, each of front lens  502 , electro-optic aperture  300 , and rear lens  504  may be formed separately and then aligned and integrated with each other using thermal or adhesive bonding processes. In another embodiment, variable aperture lens  500  may be formed through a single process that includes a plurality of overmolding or replication steps in which front lens  502  is formed, electro-optic aperture  300  is deposited on front lens  502 , and rear lens  504  is formed over electro-optic aperture  300 . Molding of lenses on electro-optic aperture may be performed directly, i.e., uncured resin may be introduced over a surface of electro-optic aperture and cured to a cured state in order to form an integrated body having an electro-optic aperture and a lens. In an alternative embodiment, a hybrid process of molding and bonding steps may be used. In other embodiments, press fits, mechanical fasteners, or other known fastening techniques may be used to physically connect variable aperture lens  500  components. Examples of such processes are described in more detail with respect to  FIGS. 9-23  below. Thus, it will be appreciated that variable aperture lens  500  may be manufactured according to numerous methods. 
     Referring to  FIG. 6 , a side view of a mobile lens assembly having a variable aperture lens is shown in accordance with an embodiment. Variable aperture lens  500  may replace doublet  202  in mobile lens assembly  200 . That is, as a result of the multi-layered structural shape and optical properties, front lens  502  may effectively replace the function of lens one  214  in mobile lens assembly  200 . For example, front lens  502  having one or more layers may provide a positive element. Similarly, the shape and optical properties of rear lens  504  may be such that rear lens  504  may effectively replace the function of lens two  216  in mobile lens assembly  200  described above. For example, rear lens  504  may provide a negative element. The geometry and optical properties of each lens, as well as each layer in each lens, of variable aperture lens  500 , may be varied to complement each other and achieve the desired chromatic aberration correction. Furthermore, given that variable aperture lens  500  components mate with each other and remain robustly aligned, the integration of electro-optic aperture  300  does not require additional physical separation between front lens  502  and rear lens  504  or introduce alignment instabilities. Thus, variable aperture lens  500  may be used in mobile lens assembly  200  without appreciably increasing device z-height or degrading optical system performance. 
     Referring to  FIG. 7 , a schematic view of camera related elements including a camera module having a variable aperture lens is shown in accordance with an embodiment. In an embodiment, portable consumer electronics device  100  includes camera module  102  having mobile lens assembly  200  axially aligned with image sensor  208 . In an embodiment, mobile lens assembly  200  includes variable aperture lens  500 , which includes front lens  502 , electro-optic aperture  300 , and rear lens  504 , physically connected and axially aligned with each other. Variable aperture lens  500  and lens stack  204 , as well as each sub-component or sub-element of variable aperture lens  500  and lens stack  204  may be optically aligned along optical axis  210 . However, in some embodiments, rather than each optical element being physically located along a straight line, one or more mirrors or optical deflectors may be used to allow one or more of the optical elements to be physically arranged in a non-linear fashion. Nonetheless, given that image rays  230  may propagate from a scene along optical axis  210  through such optical elements and mirrors, variable aperture lens  500  and lens stack  204  may be considered to be optically aligned along optical axis  210  in any case. 
     Although discussion to this point has focused primarily on the function of mobile lens assembly  200  to correct chromatic and monochromatic aberrations, it will be appreciated that the various lenses ultimately function to focus image rays  230  from a scene onto image sensor  208 . More specifically, some portion of mobile lens assembly  200  may include either a fixed focus optical subsystem or a variable focus subsystem that implements an autofocus mechanism. There may also be an optical zoom mechanism as part of mobile lens assembly  200 . Thus, one or more of front lens  502 , rear lens  504 , or various lenses of lens stack  204  function to produce an optical image on an active pixel array portion of image sensor  208 . Accordingly, image sensor  208  may be any conventional solid-state imaging sensor such as a complimentary metal-oxide-semiconductor (CMOS) sensor chip, able to capture the focused optical image. 
     Image capture may be affected by an exposure controller  706  interfaced with image sensor  208  and various mechanisms used to adjust mobile lens assembly  200 . Image sensor  208  may receive certain parameters for determining an exposure for taking a picture from exposure controller  706 . The sensor parameters may include pixel integration time, which may be set by exposure controller  706  in accordance with any suitable exposure control algorithm that considers various input variables (e.g., level of scene illumination and the availability of a flash or strobe illumination). Exposure controller  706  may automatically perform the algorithm to determine an appropriate exposure setting and then signal image sensor  208  to update its parameters in response to actuation of a shutter release  708 . Exposure controller  706  may be implemented as a programmed processor or as a completely hardwired logic state machine together with stored parameter options. In an embodiment, exposure controller  706  sets parameters for lens position that can be used to drive mechanisms to control an optical zoom lens or an autofocus mechanism. 
     Once a digital image representing image rays  230  is captured by image sensor  208  under the chosen exposure setting, the digital image may be transferred to an image storage  710 . Image storage  710  may be a solid state volatile or non-volatile memory. Digital images stored in image storage  710  may be accessed for further processing and analysis by higher layer camera functions  712 . Such processing may yield, by way of example, a compressed image file in a JPEG format or a compressed video file in an MPEG format. 
     In an embodiment, a driver circuit  714  controls the effective pupil size of electro-optic aperture  300 . Driver circuit  714  may receive a control signal or command from exposure controller  706 , which represents the desired pupil size. In response to this command, driver circuit  714  may output an appropriate drive voltage to electrical contacts on electro-optic aperture  300  in variable aperture lens  500  in order to create the desired stop aperture for the image being shot. 
     In addition to the functionality described above, portable consumer electronics device  100  may include numerous other functions implemented with components not shown. For example, portable consumer electronics device  100  may include a communication network interface, a display screen, a touch screen, a keyboard, or an audio transducer, to name a few. Thus, the system configuration of portable consumer electronics device  100  described above is not restrictive. 
     Referring to  FIG. 8 , a cross-sectional view of an electro-optic aperture is shown in accordance with an embodiment. It will be appreciated that  FIG. 8  represents an embodiment of electro-optic aperture  300 , but there are many different embodiments of electrically variable apertures that may be integrated in variable aperture lens  500 , including both solid-state and liquid-state electro-optic apertures  300 . Several of such embodiments are described in U.S. patent application Ser. No. 14/146,259, titled “Electro-Optic Aperture Device”, filed on Jan. 2, 2014, which is incorporated herein by reference. The range of electro-optic apertures that are contemplated to be within the scope of this disclosure include electro-optic apertures that are apodized, continuously variable, or discretely variable. Thus, the aperture may be formed from multiple discrete steps of electrochromic layers placed on any and all surfaces of a substrate  508 . A general description of one such embodiment follows. 
     Electro-optic aperture  300  may have a stack including electrochromic element  506  on substrate  508 . Electrochromic element  506  may include: a front transparent conductor  802 , an ion source  804 , an ion conduction layer  806 , an active electrochromic layer  808 , and a rear transparent conductor  810 . Each stack element may be in physical contact with an adjacent stack element. In an embodiment, ion source  804  may be fully separated from active electrochromic layer  808  by ion conduction layer  806 . The ion source  804  layer may store suitable ions, for example, lithium ions to activate the electrochromic layer  808  when a sufficient charge field is generated between front transparent conductor  802  and rear transparent conductor  810 . Accordingly, ion conduction layer  806  may allow ions that have been generated by ion source  804  to transmit toward and enter active electrochromic layer  808 . 
     Rear transparent conductor  810  may be formed directly on substrate  508 . The other elements of electro-optic aperture  300  may be sequentially formed over rear transparent conductor  810 . In other embodiments, a second substrate (not shown) may be located above front transparent conductor  802 , and in some cases, front transparent conductor  802  may be formed directly on the second substrate. In still other embodiments, such as in a liquid-state electro-optic aperture, the second substrate may be a coverslip, such as a thin layer of glass, which retains a liquid electrochromic material. 
     The transparent conductors may include a layer of indium tin oxide or other transparent conductive material formed into a thin layer. The transparent conductors may provide a conductive path for charge from driver circuit  714  to be applied to ion source  804  while at the same time allowing free passage of image rays  230 . Accordingly, front transparent conductor  802  and rear transparent conductors  810  may be electrically connected with respective electrical contacts  812 . Likewise, each of electrical contacts  812  may be electrically connected with driver circuit  714 , which may provide appropriate input charge. 
     In an embodiment, electrical contacts  812  may be formed on front surface  510 , rear surface  512 , or a sidewall of electro-optic aperture  300 . For example, electrical contacts  812  may be sputtered, printed, soldered, or otherwise deposited on respective transparent conductors  802 ,  810 . Alternatively, electrical contacts  812  may be formed on substrate  508  and appropriate electrical connections, e.g., leads or vias, may be routed to corresponding transparent conductors  802 ,  210 . Furthermore, electrical contacts  812  may be accessibly located. For example, in an embodiment, electrical contacts  812  may be located on electro-optic aperture  300  such that they are visibly exposed or at least not covered by front lens  502 , rear lens  504 , or any other film or coatings of variable aperture lens  500 . 
     In an embodiment, active electrochromic layer  808  tapers from an outer edge toward optical axis  210 . In other words, a thickness of active electrochromic layer  808  may decrease in a gradual or step-like fashion from the outer edge toward optical axis  210 . As a result, active electrochromic layer  808  may have a thickness of essentially zero at optical axis  210 . In operation, the tapered profile of active electrochromic layer  808  creates an aperture opening of a maximum size when no voltage is applied from driver circuit  714 , but as driver circuit  714  increases the charge in the transparent conductors, the tapered layer will cause the aperture opening to gradually decrease in diameter toward a minimum. Thus, stop aperture of electro-optic aperture  300  may be reversibly varied by increasing and decreasing charge supplied by driver circuit  714  to the transparent conductors  802 ,  810 . In an embodiment, an activation voltage may be between zero volts and 2 volts. Such activation voltage may result, for example, in a gradated voltage of between about 2 volts at the outer edge of active electrochromic layer  808  to zero volts at the location coincident with the aperture diameter in the active electrochromic layer  808 . 
     In other embodiments, electro-optic aperture  300  may include a plurality of stacked electrochromic elements  506  that are independently driven to achieve different effects. For example, a front electrochromic element  506  may be driven by a first driver circuit  714  and a second electrochromic element (not shown) may be driven by a second driver circuit (not shown). In this manner, electro-optic aperture  300  as a whole may be controlled to act as a neutral density filter that exhibits substantially homogeneous reduction in intensity of light from an imaged scene across all visible colors or wavelengths of interest. In other applications, electro-optic aperture  300  may be controlled to provide polarization detection. Thus, electro-optic aperture  300  may be varied within the scope of this disclosure to provide optical effects beyond stop aperture control. 
     Referring to  FIG. 9 , a flowchart of a method of producing a mobile lens assembly is shown in accordance with an embodiment. The operations of  FIG. 9  are described below with specific reference to  FIGS. 10-17 , which provide pictorial views illustrating operations in forming a variable aperture lens  500  in accordance with an embodiment. 
     At operation  900 , outer lens layer  514  may be formed in a molding process. Referring to  FIG. 10 , an outer layer resin  1000  may be injected, poured, or otherwise loaded into one or more outer layer recess  1002  formed in a first mold drag  1004 . Outer layer resin  1000  may be introduced into first mold drag  1004  as a liquid. Outer layer recess  1002  may have a curvature corresponding to the desired shape of outer lens layer  514 . For example, outer layer recess  1002  may have a spherical contour. The finish of outer layer recess  1002  may be important to achieving an acceptable lens finish, and thus, outer layer recess  1002  may be formed in first mold drag  1004  using tool machining or electrical discharge machining processes followed by chemical or electropolishing processes. Alternatively, lens surface finish may be changed after lens formation, e.g., by vapor polishing. 
     Referring to  FIG. 11 , a film may optionally be placed over outer layer resin  1000 . Film  1100  may be flexible and provide a transparent barrier between outer layer resin  1000  and subsequently added lens resins to avoid mixing of resins prior to lens curing. Film  1100  may be any material and size that provides adequate transparency and flexibility so as not to interfere with the function and formation of outer lens layer  514  and inner lens layer  516 . As an example, film  1100  may be polycarbonate, polyvinyl butyral, polyester, or polyurethane having a thickness of about 200 μm. 
     In an embodiment, film  1100  may include optical properties that provide certain optical characteristics to a cured lens. For example, film  1100  may include a material that includes anti-reflection and/or infrared filter properties. Thus, infrared filter  206  in mobile lens assembly  200  may be effectively relocated to coincide with front lens  502 . 
     Referring to  FIG. 12 , a first mold cope  1200  may be brought toward first mold drag  1004  to squeeze outer layer resin  1000  into the desired shape of outer lens layer  514 . More specifically, an outer layer boss  1202  of first mold cope  1200  may come toward outer layer recess  1002  of first mold drag  1004 , forming a cavity having the shape of outer lens layer  514 . For example, the cavity may exhibit a generally spherical outer curvature and an inner curvature having a convexity near optical axis  210 , or another aspherical contour. 
     After outer layer resin  1000  is squeezed within the cavity between outer layer boss  1202  and outer layer recess  1002 , any residual inclusions trapped within outer layer resin may be extracted. For example, the resin-filled first mold drag  1004  may be maintained under vacuum for a time period sufficient to allow trapped gas bubbles to escape. The outer layer resin  1000  may then be cured to form outer lens layer  514  of front lens  502 . 
     At operation  902 , inner lens layer  516  may be formed over the cured outer lens layer  514  in an overmolding or replication process. Referring to  FIG. 13 , inner layer resin  1300  may be injected or poured over the cured outer lens layer  514  still located within first mold drag  1004 . As described above, outer layer resin  1000  and inner layer resin  1300  may be different resins and/or may have different optical properties. For example, outer layer resin may include polycarbonate and inner layer resin may include polystyrene. Alternatively, both outer layer resin and inner layer resin may include polycarbonate, however the polycarbonates included in the resins may have different optical properties, e.g., refractive indices. 
     In an embodiment, a second mold cope  1302  having a generally flat lower surface may be brought toward the first mold drag  1004  to spread and squeeze inner layer resin  1300  against first mold drag  1004 . As above, inner layer resin  1300  may be placed under vacuum and cured such that the cured resin forms inner lens layer  516  shape, e.g., having a concavity near optical axis  210 . Referring to  FIG. 14 , after curing inner layer resin  1300  and removing second mold cope  1302 , front lens  502  may be integrally formed and include outer lens layer  514 , inner lens layer  516 , and optionally, film  1100 . 
     At operation  904 , front lens  502  may be bonded to electro-optic aperture  300 . For example, referring to  FIG. 15 , electro-optic aperture  300  may be picked and placed such that front surface  510  contacts inner lens layer  516 . Prior to placement, an adhesive may be added to electro-optic aperture  300  or inner lens layer  516  to form a chemical bond between the components. The adhesive layer may include a radiation-activated or thermosetting adhesive that cures to form a substantially transparent thin layer having a thickness of about 5 to 150 μm. Alternatively, the contacting components may be heated to form a thermal bond therebetween, or otherwise attached, joined, fixed, secured, or fastened. 
     In an alternative embodiment, front lens  502  may be separated prior to being bonded to electro-optic aperture  300 . For example, the plurality of front lenses  502  shown in first mold drag  1004  may be separated from each other before or after being removed from first mold drag  1004 . Separation may be made by laser cutting, e.g., excimer laser cutting using a mask, or any other known technique. After the front lenses  502  are separated, they may be bonded to electro-optic aperture  300  using adhesives, e.g., ultraviolet radiation, thermal, or chemically activated adhesives. 
     At operation  906 , rear lens  504  may be formed using a similar methodology used to form front lens  502 . Referring to  FIG. 16 , a second mold drag  1601  may include one or more recesses having the shape of rear lens  504  in an upper surface. Thus, rear lens  504  may be formed in second mold drag  1601  by pouring or injecting an appropriate resin into the recesses, optionally flattening the resin and placing the resin under vacuum, and then curing the rear lens  504  into the desired final form. In an embodiment, rear lens  504  is not flattened, e.g., by another mold cope, prior to curing, and in such case, shrinkage of resin material may be accommodated for by filling recesses in second mold drag  1601  to include a convex meniscus prior to curing. The meniscus may shrink to a flattened surface after curing. The rear lens  504  may be formed from a rear lens  504  resin that is the same or different than outer layer resin  1000  and inner layer resin  1300 . Thus, front lens  502  and rear lens  504  may include different indices of refraction and/or other material or optical properties consistent with an intended lens design. 
     At operation  908 , rear lens  504  may be bonded to rear surface  512  of electro-optic aperture  300  to form variable aperture lens  500 . Referring to  FIG. 17 , in an embodiment, second mold drag  1601  having cured rear lens  504  may be brought toward first mold drag  1004  to bring rear lens  504  and rear surface  512  of electro-optic aperture  300  into contact. An adhesive may be placed on either of the mating surfaces prior to bringing them into contact, or the surface may be subjected to thermal heating to form a bond therebetween. Thus, a vertical stack may be formed having front lens  502 , electro-optic aperture  300 , and rear lens  504 . More specifically, variable aperture lens  500  may be integrally formed. Alignment between each of the components of variable aperture lens  500  may be controlled during bonding to ensure that each is substantially aligned, and fixed relative to each other, along optical axis  210 . 
     Referring to  FIG. 18 , a flowchart of a method of producing a mobile lens assembly is shown in accordance with an embodiment. The operations of  FIG. 18  are described below with specific reference to  FIGS. 19-23 , which provide pictorial views illustrating operations in forming a variable aperture lens  500  in accordance with an embodiment. 
     At operation  1800 , inner lens layer  516  may be formed in a molding process. Referring to  FIG. 19 , a plurality of electro-optic apertures  300  may be provided. For example, electro optic apertures  300  may be provided on a sheet or wafer  1900 . In an embodiment, electro-optic apertures include film  1100  laminated on front surface  510  and/or rear surface  512 . Film  1100  may be, for example, a dielectric material that is sputtered, grown, or otherwise deposited. 
     An inner layer resin  1300  may be injected, poured, or otherwise loaded over electro-optic apertures  300  in an uncured state. For example, inner layer resin  1300  may be introduced as a liquid. 
     Referring to  FIG. 20 , a first mold cope  1200  may be brought toward electro-optic apertures  300  to squeeze inner layer resin  1300  into the desired shape of inner lens layer  516 . More specifically, an outer layer boss  1202  of first mold cope  1200  may come toward electro-optic aperture  300 , forming a replicated cavity having the shape of inner lens layer  516 . For example, the cavity may exhibit a concavity near optical axis  210 , or another aspherical contour. 
     After inner layer resin  1300  is squeezed within the cavity between outer layer boss  1202  and electro-optic aperture  300 , any residual inclusions trapped within inner layer resin  1300  may be extracted under vacuum. The inner layer resin  1300  may then be cured to form inner lens layer  516  of front lens  502 . 
     At operation  1802 , outer lens layer  514  may be formed over the cured inner lens layer  516  in an overmolding or replication process. Referring to  FIG. 21 , outer layer resin  1000  may be injected or poured over the cured inner lens layer  516 . Referring to  FIG. 22 , in an embodiment, a second mold cope  1302  having a generally flat lower surface may be brought toward electro-optic aperture  300  to spread and squeeze outer layer resin  1000  against inner lens layer  516 . As above, outer layer resin  1000  may be placed under vacuum and cured such that the cured resin forms outer lens layer  514  shape, e.g., having a generally spherical outer surface and a convexity near optical axis  210 . After curing outer layer resin  1000 , front lens  502  may be integrally formed and include outer lens layer  514  and inner lens layer  516 . In an embodiment, film  1100  is located between outer lens layer  514  and inner lens layer  516 . For example, in substitution for or in addition to film  1100  over electro-optic aperture  300  surfaces, film  1100  may be deposited over cured inner lens layer  516  prior to introducing and curing outer lens resin  1000 . Thus, a dielectric film layer may be provided between outer lens layer  514  and inner lens layer  516 . 
     At operation  1804 , rear lens  504  may be formed using a similar methodology used to form front lens  502 . Referring to  FIG. 23 , electro-optic apertures  300  may be removed from wafer  1900 . For example, front lens  502  may remain engaged with second mold cope  1302  and lifted away from wafer  1900 . Second mold cope  1302  may then be turned over such that electro-optic apertures  300  have rear surface  512  facing upward, although the directionality of the surfaces is not restrictive. An appropriate rear lens resin may be poured over electro-optic apertures, and a third mold cope  2300  having recesses corresponding to a shape of rear lens  504  may be brought toward electro-optic apertures  300 . Thus, the rear lens resin may be squeezed into the shape of rear lens  504 . The rear lens resin may then be placed under vacuum and cured to form rear lens  504 . Thus, a vertical stack may be formed having front lens  502 , electro-optic aperture  300 , and rear lens  504 . More specifically, variable aperture lens  500  may be integrally formed. Alignment between each of the components of variable aperture lens  500  may be controlled during the molding and overmolding processes to ensure that each is substantially aligned, and fixed relative to each other, along optical axis  210 . 
     In an embodiment, the curable resins may include curable resins that maintain transparency upon curing. Examples of such resins include compositions that are curable by ultraviolet radiation, such as: polycarbonates, polystyrenes, polyacrylates, polyester compounds, silicones, acrylic resin, urethane resin, epoxy resin, enthiol resin, or thiourethane resin or photopolymer. In an embodiment, curing of outer layer resin  1000  and inner layer resin  1300  may involve exposure of the uncured resin to ultraviolet radiation having an intensity of between about 100 to 2,000 W/cm 2  over a period of approximately one minute. Portions of the mold may be transparent, or special transmissive inserts may be used, to allow the ultraviolet radiation to irradiate the lens resins. In other embodiments, resins may be cured at according to predetermined time and temperature profiles. The cured lenses may also be post-cured. For example, the lenses may be stabilized at high temperatures for a period of time, e.g., between about 100 to 150 degrees Celsius for 6 to 12 hours. 
     The lenses and/or electro-optic aperture  300  may be further treated to introduce additional optical characteristics to variable aperture lens  500 . For example, one or more surfaces of front lens  502 , rear lens  504 , or electro-optic aperture  300  may be coated with anti-reflective coating or optical filter material, e.g., infrared filter  206  material, to provide variable aperture lens  500  with optical filtering capabilities. As described above, in an embodiment, film  1100  may be layered over any and all surfaces of electro-optic aperture to provide additional optical characteristics. 
     The manufacturing process may also account for the introduction of additional features not directly addressed above. For example, it may be necessary to form electrical contacts  812  on electro-optic aperture  300  at locations that are accessible to allow for electrical connections to be provided for varying the voltage to electrochromic elements. Thus, electrical contacts  812  may be placed on front surface  510 , rear surface  512 , or on a sidewall of electro-optic aperture  300 , and on substrate  508  in particular, to allow such electrical connections to be formed. Accordingly, electrical contacts  812  may be formed prior to lens overmolding. Alternatively, locations dedicated to the formation of contacts after overmolding may be exposed to view and/or accessible through front lens  502  or rear lens  504  of variable aperture lens  500 . 
     After forming a sheet or wafer of variable aperture lenses  500  by bonding the front lens  502 , electro-optic aperture  300 , and rear lens  504  into a final assembly, each of the variable aperture lenses  500  may be separated using known separation techniques. For example, various chemical, laser, mechanical, etc., cutting operations may be used to separate the variable aperture lenses  500  into individual parts. Separation may be performed before or after removing the mold drags from the variable aperture lenses. 
     After forming variable aperture lens, for example, at operations  910  or  1806 , variable aperture lens  500  may be combined with a lens stack  204  to from a camera lens assembly. More particularly, variable aperture lens  500  may be physically associated with one or more optical components, such as lens stack  204 , infrared filter  206 , image sensor  208 , etc., to form mobile lens assembly  200  for use in portable consumer electronics device  100 . Such physical association may be made by incorporating variable aperture lens  500  within a chassis, barrel, frame, or other mechanical holder or carrier that supports and positions variable aperture lens  500  relative to other lenses in mobile lens assembly  200 . In an embodiment, the holder or carrier does not need to be rotated in order to focus an image on image sensor  208 . 
     In the foregoing specification, the invention has been described with reference to specific exemplary embodiments thereof. It will be evident that various modifications may be made thereto without departing from the broader spirit and scope of the invention as set forth in the following claims. The specification and drawings are, accordingly, to be regarded in an illustrative sense rather than a restrictive sense.

Metadata:
Filing Date: 20140421
Publication Date: 20171226
Grant Date: 20171226
Priority Date: 20140221
Inventors: NOBLE HANNAH DUSTAN
MCALLISTER IAIN ALEXANDER
Assignee: APPLE INC
CPC Classifications: [{"code": "G02B27/58", "inventive": true, "first": false, "tree": "[]"}, {"code": "G03B9/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02F1/157", "inventive": true, "first": true, "tree": "[]"}, {"code": "Y10T29/49826", "inventive": false, "first": false, "tree": "[]"}, {"code": "G02B5/005", "inventive": true, "first": false, "tree": "[]"}, {"code": "G03B9/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B27/58", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B5/005", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B5/005", "inventive": true, "first": true, "tree": "[]"}, {"code": "Y10T29/49826", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49826", "inventive": false, "first": false, "tree": "[]"}, {"code": "G02F1/157", "inventive": true, "first": true, "tree": "[]"}, {"code": "G03B9/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B27/58", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 52472619