Camera modules designed to capture images of objects that emit near-infrared (near-IR) light are used in automotive applications and endoscopy. For example,
Effectiveness of endoscope 110 depends on its ability to meet performance specifications at a wavelength and temperature range characteristic of its application. A wavelength range is, for example, the visible wavelength range (free-space wavelength λ0∈[0.40 μm, 0.65 μm]) or the near infrared wavelength range (λ0∈[0.60 μm, 1.0 μm]). A typical temperature range for the aforementioned applications is 20° C. to 60° C. Hence, the performance of a camera that includes lens 100 depends in part on imaging lens 100 being athermalized such that it forms a clear image on image sensor 132 within the temperature range associated with its application. For example, imaging lens 100 images light 192 propagating from a point 190P on lesion 190 to a point 102. Light 192 is for example near-IR light. Point 102 is located a field height x1 from optical axis 100X and a focal shift Δz1 from pixel array 132. Focal shift Δz1=0 corresponds to when imaging lens 100 forms an in-focus image of point 190P on image sensor 132. The magnitude of focal shift Δz1 as a function of field height x1 and ambient temperature T is an athermalization metric for lens 100. For a prior-art lens, at visible and near-IR wavelengths the on-axis focal length shifts by Δz1=9.2 μm between 20° C. and 60° C., or
Embodiments of the systems and methods disclosed herein provide an athermal compound lens system. Embodiments of the athermal compound lens herein may be suitable for the above-mentioned endoscopic imaging application, as well as any other application with athermal imaging requirements.
In an embodiment, an athermal compound lens includes a plano-concave lens and a plano-convex lens. The plano-concave lens has a first focal length, a first refractive index n1, and planar object-side surface opposite a concave image-side surface. The plano-convex lens is axially aligned with the plano-concave lens and has (i) a second focal length, (ii) a second refractive index n2, (iii) a planar image-side surface, and (iv) a convex object-side surface between the planar image-side surface and the concave image-side surface. In a free-space wavelength range and temperature range: (a) the first focal length divided by the second focal length is less than −0.68, and (b) first and second refractive indices n1 and n2 have respective temperature dependences
that satisfy
Athermal compound lens 200 also may include a cover glass 260. When included in athermal compound lens 200 or an imaging system therewith, cover glass 260 covers a pixel array of an image sensor (not shown) located at an image plane 278. Cover glass 260 has a front surface 261 and a back surface 262. The specific type of pixel array and image sensor may vary and is thus not discussed in detail herein.
In an embodiment, at least part of the manufacturing of athermal compound lens 200 is performed at the wafer-level using a wafer-level optics replication process. In this embodiment, lenses 230 and 250 are molded on substrate 240 and, when the embodiment includes substrate 210, lens 220 is molded thereon. Wafer-level replication processes enable lenses 230 and 250 to be formed of materials with different respective refractive indices, which enables greater flexibility in designing athermal compound lens 200 to minimize focal shift Δz1.
The cross section of elements of athermal compound lens 200 may be rectangular or square. For example, if produced via wafer-level optics replication, each of lenses 230 and 250 and substrate 240 may have the same square cross section resulting from a dicing operation performed after molding lenses 230 and 250 on substrate 240.
Lenses 220, 230, and 250 may be formed of a solder-reflow compatible material via a wafer-level optics replication process. A solder-reflow compatible material for example withstands surface-mount technology (SMT) reflow soldering processes occurring at temperatures exceeding 250° C. Examples of such material include NT-UV Series UV-curing resins by Nitto Denko Corporation (Osaka, Japan). It should be appreciated that additional or alternative materials may be used without departing from the scope hereof.
Lenses 220, 230, and 250 may also be formed via injection molding or other methods known in the art. Alternatively, lenses 220, 230, and 250 may be formed of glass via precision glass molding (also known as ultra-precision glass pressing) or other methods known in the art.
While each of lenses 220, 230, and 250 is illustrated as a singlet lens in
Athermal compound lens 200 satisfies the following limitations, which enable it to have an athermalization metric Δz1/ΔT<0.15 μm/° C. at temperatures between 20° C. and 60° C. Herein, temperature ranges such as ΔT have units of degrees Celsius, or equivalently degrees Kelvin. The following limitations are satisfied at free-space wavelengths in a wavelength range including at least one of the visible and near-IR wavelength range.
Lenses 220 and 230 have respective focal lengths f220 and f230, which satisfy f220/f230<−0.68. Lenses 220 and 230 have respective refractive indices n2 and n3, which satisfy n3≥n2 for enabling the athermalization metric while maintaining sufficient image equality. Refractive indices n2 and n3 have respective temperature dependences
that satisfy
For example,
Athermal compound lens 300 includes a plano-concave lens 220(1), a plano-convex lens 230(1), an image-side lens 250(1), and substrates 210(1), 240(1), 360, and 370. Substrates 360 and 370 have respective object-side surfaces 361 and 371, and respective image-side surfaces 362 and 372. Surfaces 362 and 371 are adjoining; as such, substrates 360 and 370 are denoted herein as cover glass 260(1). Image-side lens 250(1) is plano-convex. Substrate 240(1) includes substrates 342 and 344, and an aperture stop 343 therebetween. Herein, a figure element denoted by a reference numeral suffixed by a parenthetical numeral indicates an example of the element indicated by the reference numeral. For example, lens 220(1) is an example of lens 220.
Column 426 indicates the minimum diameter of each surface sufficient for a ray incident on substrate 210(1) that passes through aperture stop 343 to also pass through that surface. Aperture stop 343 has a diameter Ø343=0.192 mm. It should be appreciated that imaging system 301 need not include cover glass 260(1), in which case image plane 278(1) shifts toward athermal compound lens 300.
Surfaces 222(1), 231(1), and 252(1) are defined by surface sag zsag, shown in Eqn. 1.
In Eqn. 1, zsag is a function of radial coordinate r, where directions z and r are shown in a coordinate system 298 of
Column 422 of Table 400 lists rc values for surfaces 222(1), 231(1), and 252(1). Parameter k denotes the conic constant, shown in column 427. Columns 404, 406, 408, 410, 412, and 414 contain values of aspheric coefficients α4, α6, α8, α10, α12, and α14 respectively. The units of quantities in table 400 are consistent with zsag in Eqn. 1 being expressed in millimeters.
Column 424 lists values of material refractive index nd at free-space wavelength λ0=587.5 nm (at temperature T1), and column 425 lists the corresponding Abbe numbers Vd. The refractive index and Abbe number values corresponding to a surface characterize the material between the surface and the surface in the row beneath. For example, the refractive index and Abbe number between surface 221(1) and 222(1) are 1.511 and 57.0, respectively.
Table 1 shows the refractive index n and focal lengths f of lenses 220(1) and 230(1). Focal lengths f are approximated using the lensmaker's equation and lens parameters of table 400 (λ0=587.5 nm, T=20° C.). The ratio of the focal lengths of lens 220(1) to that of lens 230(1) is −0.73 at 587.5 nm and −0.72 at 850 nm.
Athermal compound lens 600 includes a plano-convex lens 610, a plano-concave lens 220(2), a plano-convex lens 230(2), an image-side lens 250(2), and substrates 210(2), 240(2), and 260(2). Image-side lens 250(2) is plano-concave. Plano-convex lens 610 has an object-side surface 611 and an image-side surface 612, which corresponds to an axial location of an aperture stop 643 of athermal compound lens 600.
Column 726 indicates the minimum diameter of each surface sufficient for a ray incident on substrate 210(2) that passes through aperture stop 643 to also pass through that surface. Aperture stop 643 has a diameter Ø643=0.32 mm. It should be appreciated that imaging system 601 need not include cover glass 260(2), in which case image plane 278(2) shifts toward athermal compound lens 600.
Surfaces 222(2), 231(2), and 252(2) are defined by surface sag zsag, shown in Eqn. 1. Column 722 of Table 700 lists rc values for surfaces 222(2), 231(2), and 252(2). Parameter k denotes the conic constant, shown in column 727. Columns 704, 706, 708, 710, 712, 714, and 716 contain values of aspheric coefficients α4, α6, α8, α10, α12, α14, and α16 respectively. The units of quantities in table 700 are consistent with zsag in Eqn. 1 being expressed in millimeters.
Column 724 lists values of material refractive index nd at free-space wavelength λ0=587.5 nm, and column 725 lists the corresponding Abbe numbers Vd. Table 2 shows the refractive index n at λ0=587.5 nm and focal lengths f of lenses 610, 220(2), 230(2), and 250(2). Focal lengths f are approximated using the lensmaker's equation and lens parameters of table 700 (λ0=587.5 nm, T=20° C.). The ratio of the focal lengths of lens 220(2) to that of lens 230(2) is −0.965 at both λ0=587.5 nm and λ0=850 nm.
Features described above as well as those claimed below may be combined in various ways without departing from the scope hereof. The following examples illustrate some possible, non-limiting combinations:
(A1) An athermal compound lens includes a plano-concave lens and a plano-convex lens. The plano-concave lens has a first focal length, a first refractive index n1, and planar object-side surface opposite a concave image-side surface. The plano-convex lens is axially aligned with the plano-concave lens and has (i) a second focal length, (ii) a second refractive index n2, (iii) a planar image-side surface, and (iv) a convex object-side surface between the planar image-side surface and the concave image-side surface. In a free-space wavelength range and temperature range: (a) the first focal length divided by the second focal length is less than −0.68, and (b) first and second refractive indices n1 and n2 have respective temperature dependences
that satisfy
(A2) In the athermal compound lens denoted by (A1), the free-space wavelength range may include wavelengths from 400 nm to 650 nm.
(A3) In any athermal compound lens denoted by one of (A1) and (A2), the free-space wavelength range may include wavelengths from 600 nm and 1,000 nm.
(A4) In any athermal compound lens denoted by one of (A1) through (A3), the temperature range may be from 20° C. to 60° C.
(A5) Any athermal compound lens denoted by (A4) may have a temperature-dependent focal length shift
within the free-space wavelength range and the temperature range.
(A6) In any athermal compound lens denoted by one of (A1) through (A5),
may be greater than or equal to 10−4/° C. and
may be greater than or equal to 0.5×10−4/° C.
(A7) In any athermal compound lens denoted by one of (A1) through (A6), the second refractive index may be greater than or equal to the first refractive index.
(A8) Any athermal compound lens denoted by one of (A1) through (A7) may further include a third lens, axially aligned with the plano-convex lens, and having a planar object-side surface, and a biplanar substrate between the plano-convex lens and the third lens.
(A9) In any athermal compound lens denoted by (A8), the third lens may have a convex image-side surface.
(A10) Any athermal compound lens denoted by one of (A8) and (A9) may further include an aperture stop between the third lens and the plano-convex lens.
(A11) In any athermal compound lens denoted by one of (A8) through (A10), the third lens may have a concave image-side surface.
(A12) In any athermal compound lens denoted by one of (A8) through (A11), wherein the plano-convex lens is formed of a first material and the third lens is formed of a third material, the first material may differ from the third material.
(A13) Any athermal compound lens denoted by one of (A1) through (A12) may further include a fourth lens, axially aligned with the plano-concave lens, and having a planar image-side surface, and a second biplanar substrate between the plano-concave lens and the fourth lens.
Changes may be made in the above methods and systems without departing from the scope hereof. It should thus be noted that the matter contained in the above description or shown in the accompanying drawings should be interpreted as illustrative and not in a limiting sense. The following claims are intended to cover all generic and specific features described herein, as well as all statements of the scope of the present method and system, which, as a matter of language, might be said to fall therebetween.
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