WO2013024733A1 - ハイブリッドレンズの製造方法 - Google Patents
ハイブリッドレンズの製造方法 Download PDFInfo
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- WO2013024733A1 WO2013024733A1 PCT/JP2012/069964 JP2012069964W WO2013024733A1 WO 2013024733 A1 WO2013024733 A1 WO 2013024733A1 JP 2012069964 W JP2012069964 W JP 2012069964W WO 2013024733 A1 WO2013024733 A1 WO 2013024733A1
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- lens
- glass
- resin
- parallel plate
- hybrid
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D11/00—Producing optical elements, e.g. lenses or prisms
- B29D11/00009—Production of simple or compound lenses
- B29D11/00403—Producing compound lenses
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D11/00—Producing optical elements, e.g. lenses or prisms
- B29D11/00009—Production of simple or compound lenses
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D11/00—Producing optical elements, e.g. lenses or prisms
- B29D11/00009—Production of simple or compound lenses
- B29D11/00432—Auxiliary operations, e.g. machines for filling the moulds
- B29D11/00442—Curing the lens material
Definitions
- the present invention relates to a method of manufacturing a hybrid lens that can be manufactured at low cost and easily in a hybrid lens using optical glass and resin.
- Hybrid lenses with a thin aspheric resin layer formed on the curved surface of a spherical glass lens have long been used in situations where a complex aspherical shape that is difficult to handle with a glass lens, a large-aperture lens, or an aspheric meniscus lens is required. It's being used.
- glass lenses have excellent environmental characteristics, and optical performance deterioration with respect to temperature, humidity, ultraviolet rays, etc. is less than resin lenses.
- an aspherical lens is made of glass, there are many restrictions. Therefore, a hybrid lens using a spherical glass lens that can be manufactured relatively easily is widely used.
- hybrid lenses are used as an alternative to aspheric glass lenses, but lead-free solder reflow in electronic component mounting is an example of actively adopting hybrid lenses to solve the problem of heat resistance.
- An imaging hybrid lens that can withstand the process is disclosed in Patent Document 1.
- This hybrid lens is a glass-resin hybrid lens formed of optical glass and energy-curable resin having high heat resistance.
- a large amount of resin layer lens surfaces are collectively formed on a several inch parallel flat glass wafer, and then these wafers are bonded to a sensor wafer, and then cut into a camera module.
- This method is disclosed in Patent Document 2.
- Such a camera module is called a wafer scale camera module.
- the lens produced in this way is called a wafer scale lens.
- hybrid lenses are used in situations where it is difficult to apply resin lenses, such as solder reflow, in combination with energy curable resins with excellent heat resistance in addition to environmental stability. Yes.
- resin lenses such as solder reflow
- the hybrid lens uses a spherical glass lens, it is less expensive than an aspherical glass mold lens, but very expensive for a thermoplastic resin lens formed by injection molding.
- the outer diameter of the cylindrical glass becomes the reference for the lens coaxial, and in order to make this lens into a lens unit, when incorporated in an elastic member called a lens barrel that blocks light other than the design, the outer diameter Therefore, strict dimensional accuracy and roundness are required.
- a hybrid lens can be produced at a lower cost than when a spherical glass lens is used. However, it is still more expensive than a resin lens.
- a wafer scale lens has been proposed as a method for producing a hybrid lens at low cost and in large quantities.
- This method can form a large number of resin lenses on a glass wafer of several inches, and then create individual hybrid lenses by means such as dicing. Therefore, the lens can be provided at a very low cost.
- the lens after cutting becomes a quadrangle, when incorporated into a lens barrel or the like, assembling is worse than a lens having a circular outer shape, and the assembling accuracy is also inferior.
- the cutting dimension error in dicing is about 0.05 to 0.1 mm, which is about 5 to 10 times larger than 0.01 mm, which is generally required for an optical lens, so that precise optical
- precise alignment adjustment such as XY position control by image processing or alignment joining must be performed at the time of assembly. Therefore, when considered as a lens unit, an expensive adjustment process is required, and the provided lens becomes expensive.
- the resin lens is collectively formed on a large parallel plate having a size of several inches, the glass wafer may be warped or cracked due to resin curing shrinkage during lens formation. Therefore, in order to regulate warping and cracking, it is necessary to increase the thickness of the glass wafer. For this reason, restrictions are imposed on the lens design, and the design performance may be inferior.
- the present invention has been made to solve such problems, and it is possible to inexpensively manufacture a hybrid lens that can control the coaxiality of the lens with high accuracy, has excellent integration accuracy during assembly, and has few lens design constraints. It is an object.
- a guide component 1 having a through hole 13 and a glass parallel plate G formed of optical glass are prepared, and (b) at least one surface of the guide component 1 is prepared.
- an energy curable resin is applied and cured to form the resin lens L.
- a method for manufacturing a hybrid lens is provided. Manufacture hybrid lenses.
- the guide parts can be manufactured by a method that can obtain a large amount of inexpensive and high-precision parts such as metal cutting, plastic injection molding, metal plate etching, and plastic plate or metal plate punching.
- the outer diameter accuracy in these means can be controlled from about 0.001 mm to 0.01 mm.
- a hybrid lens can be manufactured using high-precision guide parts manufactured by these methods.
- the outer diameter of the guide component 1 can be used as the coaxial reference of the lens. Therefore, the coaxial accuracy with respect to the outer shape 12 of the resin lens L is parallel flat glass. Regardless of the shape of G, the dimensional error accuracy can be suppressed to about 0.01 mm.
- the outer diameter of the guide part 1 can be used as a concentric reference at the time of incorporation, so that it does not depend on the shape of the parallel flat glass G and has a concentric error of about 0.01 mm. High-precision lens integration is possible.
- the size of the parallel flat glass G may be any size as long as light rays necessary for optical design can pass therethrough. Therefore, the size of the glass can be reduced, and the member cost can be kept low.
- a hybrid lens using a piece of glass can use a thin glass that is less susceptible to glass breakage and warpage than a wafer scale lens. For this reason, the size of the glass can be further reduced. Therefore, even when a thin glass is used, warping or breakage of the glass due to shrinkage of the curable resin can be suppressed.
- Generally distributed lens units are configured by fixing one or more lenses inside a component formed of an elastic member called a lens barrel that blocks light other than the design.
- an elastic member called a spacer for controlling the lens interval may be used in addition to the lens barrel.
- Examples of the method of fixing the lens to the lens barrel include a method of fitting with a resilient member having a hole in the center, which is called fitting press-fitting, adhesion, welding, heat caulking, or lens pressing.
- fitting press-fit is the easiest to ensure accuracy, but fitting stress is applied to the lens, birefringence and the like are often generated, and the lens performance is often deteriorated.
- the parallel flat glass G and the resin lens L are not subjected to stress after being press-fitted into the lens barrel when assembled into the lens barrel, and thus are thin. Even if glass is used, glass breakage does not occur. Further, since the outer diameter 12 is press-fitted into the lens barrel, the parallel flat glass G and the energy curable resin are not subjected to the stress due to the fitting, so that birefringence that deteriorates the optical characteristics occurs in both the glass and the resin. There is nothing.
- the external shape and external dimension of the parallel flat glass G can pass the light beam required for optical design, and should just be smaller than the outer diameter of the guide component 1, after glass dicing Even a scrap that is usually discarded can be used for manufacturing a hybrid lens if it meets a predetermined size.
- the glass edge portion can be used for manufacturing a hybrid lens without any problem as long as it does not penetrate inside a predetermined size. Furthermore, even if it is cut obliquely during dicing, it can be used as long as it satisfies a predetermined size. Therefore, since it is a halfway size and shape, it is possible to use even discarded glass, so there is almost no need to consider glass loss.
- the dimensional tolerance can be extremely loose, even glass parallel plates manufactured through a high-speed cutting process with an inexpensive manufacturing facility can be used without using high-precision dicing equipment that can achieve a dimensional accuracy of around 0.05 mm.
- the hybrid lens can be manufactured at low cost.
- the energy curable resin used here refers to a material that undergoes a crosslinking reaction or a polymerization reaction by receiving energy from the outside.
- the external energy include heat, ultraviolet rays, and electron beams.
- Examples of such energy curable resins include thermosetting, ultraviolet curable, and electron beam curable types, depending on the type of energy. Silicone, epoxy, and acrylic types are common as material types.
- transparent here means that the light absorption and scattering of the material is small enough to withstand use in the wavelength range of use.
- the guide component 1 can be formed as a lens unit by an elastic member having a light shielding property with a transmittance at a predetermined wavelength of 1% or less and a surface reflectance of 5% or less.
- Examples of such light shielding members include thermoplastic resins and energy curable resins to which pigments and dyes such as carbon black are added.
- thermoplastic resins and energy curable resins to which pigments and dyes such as carbon black are added.
- the metal material hardly transmits light, since the reflection on the surface of the member is large, surface reflection can be suppressed by applying a matte black alumite treatment or blackening treatment to the surface.
- At least one of the glass parallel flat plates G may be subjected to a coating treatment so that the transmittance at a predetermined wavelength is 20% or less.
- the glass member used for the hybrid lens in advance, it is not necessary to prepare a separate filter part for cutting a specific wavelength, so the number of parts can be reduced, and the hybrid lens can be reduced. It can be provided at low cost.
- CCD and CMOS image sensors have sensitivity outside the visible light range, it is known that image quality deteriorates when infrared rays are incident on the image sensor as they are. Therefore, an infrared cut filter is inserted in the lens unit in order to cut unnecessary infrared rays.
- an infrared cut filter is inserted in the lens unit in order to cut unnecessary infrared rays.
- a film for cutting infrared rays can be formed on any surface of the parallel flat glass G used for the hybrid lens by vapor deposition, it is not necessary to prepare an infrared cut filter.
- An antireflection treatment may be performed on at least one of the glass parallel flat plates G so that the transmittance at a predetermined wavelength is 80% or more.
- a transparent solid In a transparent solid, it is known that reflection occurs at the interface between air and the solid due to the refractive index inherent to the material. For example, in a glass member having a refractive index of 1.5, about 4% of light is reflected with respect to a light beam incident vertically. When there are many air / solid interfaces, the number of interfaces is reflected to reduce the amount of light. Further, it is known that in the imaging lens unit, when reflected light is incident on the image sensor, defects such as flare and ghost that deteriorate image quality occur. When light that is not condensed due to multiple reflections enters the image sensor, the noise of the image sensor increases, and the contrast of the image decreases. This is a defect called flare.
- the reflectance increases in proportion to the refractive index difference between glass and resin.
- the flare and the ghost defect as described above occur.
- the antireflection structure can be provided on the surface of the parallel flat glass G, if an antireflection film corresponding to the refractive index of the resin and the glass is formed, even if the refractive index difference between the resin and the glass is large. It becomes possible to suppress the reflected light.
- these film formations can be handled with large format glass, so that a hybrid lens unit having an antireflection function can be provided at low cost.
- the curved surface side of the resin lens L is preferably aspherical.
- the surface of the resin layer in contact with air can be aspherical as in the case of the conventional hybrid lens with respect to the formation of the resin lens.
- the refractive index and the Abbe number of the glass parallel plate G and the energy curable resin satisfy the following expressions (1) to (2).
- Ng is the d-line refractive index of the parallel plate glass parallel plate G
- Nr is the d-line refractive index at the wavelength used of the energy curable resin
- ⁇ g is the Abbe number of the parallel plate glass G based on the d-line
- ⁇ r is the energy It is the Abbe number on the d-line basis of the curable resin.
- flare and ghost can be suppressed without performing antireflection treatment on the glass-resin interface.
- the manufacturing method proposed by the present invention in the hybrid lens using glass and resin, the coaxial is controlled with high accuracy without depending on the size and accuracy of the parallel plate glass, and the mounting accuracy is improved.
- An excellent hybrid lens can be manufactured at low cost. Furthermore, since the number of parts can be reduced and thin glass can be used, a high-quality, low-cost and high-accuracy hybrid lens unit with few design constraints can be provided.
- FIG. 15A It is a longitudinal spherical aberration diagram of the lens unit. It is a distortion aberration figure of the said lens unit.
- the outer diameter 12 of the guide component 1 having a through hole 13 in the center is controlled to a dimensional error of 0.01 mm.
- the outer shape of the parallel flat glass G formed of optical glass may be a dimension that fits inside the guide component 1 and allows light rays necessary for optical design to pass therethrough. No. Furthermore, there is no restriction
- a parallel plate glass G is fixed to one surface of the guide component 1 by means such as adhesion, and a resin lens L is formed on one surface of the glass parallel plate G with an energy curable resin.
- the strength is such that it does not fall off from the guide component 1 due to the external environment when the lens is formed and assembled and then becomes a product, and the method used is UV adhesive or thermosetting adhesive.
- Various means such as adhesion, welding using laser and ultrasonic waves, heat caulking, and press fitting can be used.
- FIG. 4 is a cross-sectional view showing a method of manufacturing a hybrid lens using the above-described member.
- FIG. 4 is a cross-sectional view when the mold of FIG. 5 is closed. 4 and 5, the glass parallel plate G1 is fixed to only one surface of the guide component 1 by UV bonding, and the resin lens L is formed only to one surface of the fixed glass parallel plate G.
- the surface on which the resin lens of the glass parallel plate G1 used at this time is formed is subjected to silane coupling treatment in order to improve the interfacial adhesion strength between the glass and the resin.
- the glass parallel flat plate G when the number of glass parallel flat plates is increased, numbers are added after alphabetic characters in the order of addition, such as G1, G2, G3,.
- the resin lens L when the number of resin lenses increases, numbers are added after letters in the order of addition, such as L1, L2, L3,.
- the outer diameter 12 of the guide part 1 is inserted into the first inner diameter 23 of the holding mold 2.
- the UV curable resin is dropped on the lens curved surface portion 34 of the first lens mold 3 having a spherical or aspherical shape
- the outer diameter 32 is inserted into the first inner diameter 23 of the holding mold 2 and UV cured.
- the flat resin is brought into contact with the parallel flat glass G1 while being spread and stopped.
- UV light is irradiated through the second inner diameter 22 of the holding mold 2, the UV curable resin is cured, and the resin lens L1 is formed on the glass parallel plate G1.
- FIG. 6 is a cross-sectional view when the first resin lens L1 and the second resin lens L2 are formed on both surfaces of the parallel flat glass G1.
- 7 and 8 are sectional views showing an example of the manufacturing method at this time.
- the guide component 1 in which the parallel flat glass G1 is fixed to the first inner diameter 23 of the holding mold 2 is inserted. Thereafter, a thermosetting resin is dropped into the lens curved surface portion 34 of the first lens mold 3 and the through hole 13 of the guide component 1. After this operation, the outer diameter 32 of the first lens mold 3 is inserted along the first inner diameter 23 of the holding mold 2 and abuts against the glass parallel plate G1, and the first lens mold 3 stops.
- thermosetting resin is used.
- UV curable resin is used. It can also be used.
- both surfaces of the glass parallel flat plate G1 are thinly coated with a UV adhesive having good adhesion to the glass and high adhesion to the resin.
- the example described with reference to FIGS. 6, 7, and 8 is a method of forming the resin lens L1 on both sides of one parallel flat glass G1, but the parallel flat glass G1 and the parallel flat glass G2 as shown in FIG. 9 are used.
- a lens can be formed on one surface in the same manner.
- FIG. 10 after the first resin lens L1 and the second resin lens L2 are formed on both sides of the parallel flat glass G1, another parallel flat glass G2 is fixed to the guide component 1,
- the third resin lens L3 can be formed on the surface.
- two glass parallel plates and three resin lenses exist in one guide component 1.
- FIG. 12 is a cross-sectional view of the lens unit when a heat-resistant nylon black grade, which is an injection molding resin widely used for a lens barrel member of a camera module, is used.
- a heat-resistant nylon black grade which is an injection molding resin widely used for a lens barrel member of a camera module
- FIG. 13 is a cross-sectional view of a lens unit in which a resin lens L1 is formed on one surface 71 of a glass parallel plate 7 on which an infrared cut coating film is deposited.
- a filter component that has been subjected to a process of cutting infrared rays is often inserted immediately before the image sensor.
- FIG. 13 since infrared rays can be cut by one surface 71 of the glass parallel 7, an infrared cut filter is not necessary, the parts cost can be reduced, and the assembly process can be reduced.
- a vapor deposition film reflecting infrared rays is taken as an example, and the means and structure are not limited as long as the film or structure can be processed on the glass surface.
- FIGS. 14A and 14B show design data when the first resin lens L1 and the second resin lens L2 of the parallel flat glass G1 are aspherical in the structure of the present invention.
- Back focus bf 0.72
- Sensor diagonal length IH 1.4mm
- 15A is a sectional view of the lens unit in the optical design data of FIGS. 14A and 14B
- FIG. 15B is an enlarged view of a portion A in FIG. 15A.
- the aperture stop surface S1 that determines the entrance pupil is placed in front of the first resin lens L.
- a straight line passing through the center of the aperture stop S1 and passing through the center of the focal plane S8 is used as an optical axis, and a sign is taken so as to have a positive sign from the aperture stop plane S1 toward the focal plane S8.
- lenses are formed on both surfaces of the glass parallel flat plate G1, but the bonded resin and the glass plane are treated as separate surfaces for convenience. That is, in this example, the plane of the resin plano-convex lens L1 is treated as S3, and the plane of the parallel flat glass G1 is treated as S4. The plane is expressed as a curvature radius ⁇ .
- the sign of the radius of curvature is expressed as plus when the surface is convex with respect to the direction of the optical axis and minus when the surface is concave.
- the surface spacing means the distance between the surfaces, and the refractive index and Abbe number are numerical values based on the d-line.
- the focal plane is a point where the light beam passing through the lens is collected, and a detection device such as an image sensor is usually installed at this position. Since the detection device is often a flat surface, it is described as a curvature radius ⁇ in this example.
- the focal length f is a calculated value for the d line
- the total lens length TL is the distance calculated along the optical axis from the S2 surface to the focal plane S8 of the first resin lens L1
- the back focus bf is the second focus bf. This is a distance calculated along the optical axis from the surface S7 to the focal plane S8 of the resin lens L2.
- the aspherical surface used in the present invention is given by the following equation.
- the numerical value indicating the aspheric coefficient is an exponential display.
- e ⁇ 1 means “10 to the power of ⁇ 1”.
- FIG. 16 is a spherical aberration diagram of the lens unit shown in FIGS. 14A and 14B
- FIG. 17 is a distortion diagram. 16 and 17, it can be seen that the spherical aberration is within 0.1 mm, the distortion is within 2%, and good optical characteristics are obtained.
- a lens unit having a hybrid structure of glass and resin can be manufactured at a low cost with a hybrid lens unit having excellent dimensional error accuracy and ease of incorporation. Is possible.
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Abstract
Description
焦点距離f=1.062mm レンズ全長TL=1.525mm
バックフォーカス bf=0.72 センサー対角長IH=1.4mm
図15Aは図14A、図14Bの光学設計データでのレンズユニットの断面図、図15Bは図15AにおけるA部の拡大図である。入射瞳を確定する開口絞り面S1は第1樹脂レンズLの前におかれている。開口絞りS1の中心を通り、焦点面S8の中心を通る直線を光軸とし、開口絞り面S1から焦点面S8に向かって正の符号となるように符合が取られている。本例では、ガラス平行平板G1の両面にレンズを形成しているが、接合されている樹脂とガラス平面については、便宜上別の面として扱う。つまり、本例では、樹脂平凸レンズL1の平面をS3として扱い、平行平板ガラスG1の平面はS4として扱う。また、平面は曲率半径∞として表現している。曲率半径の符号は、光軸の方向に対して凸面となった場合はプラス、凹面となった場合はマイナスで表記している。また面間隔は、面と面の間の距離を意味し、屈折率とアッベ数はd線基準の数値を使用している。焦点面は、レンズを通した光線が集光する点であり、通常はこの位置にイメージセンサー等の検出装置が設置される。検出装置は平面であることが多いので、本例では曲率半径∞として記載してある。焦点距離fはd線での計算値を適用しており、レンズ全長TLは第1樹脂レンズL1のS2面から焦点面S8までの光軸に沿って計算された距離、バックフォーカスbfは第2樹脂レンズL2のS7面から焦点面S8までの光軸に沿って計算された距離である。
12 ガイド部品部材の外径
13 ガイド部品の貫通穴
14 ガイド部品の底面
2 保持金型
22 保持金型の第2内径
23 保持金型の第1内径
24 保持金型の位置決め面
3 第1レンズ金型
32 第1レンズ金型の外径
34 第1レンズ金型のレンズ曲面
4 第2レンズ金型
42 第2レンズ金型の位置決め段差面
45 第2レンズ金型の第2外径
7 赤外線カット蒸着膜つきガラス平行平板
71 赤外線カット蒸着膜
G ガラス平行平板
G1 第1ガラス平行平板
G2 第2ガラス平行平板
G3 第3ガラス平行平板
L 樹脂レンズ
L1 第1樹脂レンズ
L2 第2樹脂レンズ
L3 第3樹脂レンズ
L4 第4樹脂レンズ
S1 開口絞り面
S2 第1樹脂レンズ非球面
S3 第1樹脂レンズ平面
S4 第1ガラス平行平板物体側面
S5 第1ガラス平行平板像側面
S6 第2樹脂レンズ平面
S7 第2樹脂レンズ非球面
S8 焦点面
Claims (6)
- ハイブリッドレンズの製造方法であって、以下の(a)~(c)のステップを含むことを特徴とするハイブリッドレンズの製造方法。
(a)貫通穴13を有するガイド部品1と光学ガラスで形成されたガラス平行平板Gを用意するステップ、
(b)前記ガイド部品1の少なくとも一方の面に、前記ガイド部品1の内側に収まるように前記ガラス平行平板Gを固定するステップ、
(c)前記ステップ(b)の後、前記ガラス平行平板Gの少なくとも一方の面に、エネルギー硬化型樹脂を塗布し、硬化させることによって、樹脂レンズLを形成するステップ、 - 前記ガイド部品1が、予め定められた波長での透過率が1%以下、かつ表面反射率が5%以下の遮光性をもつ弾性部材で形成されたことを特徴とする請求項1に記載のハイブリッドレンズの製造方法。
- 前記ガラス平行平板Gの少なくとも一方の面に、予め定められた波長における透過率が20%以下となるように、コーティング処理を施すことを特徴とする請求項1または2に記載のハイブリッドレンズの製造方法。
- 前記ガラス平行平板Gの少なくとも一方の面に、予め定められた波長における透過率が80%以上となるように、反射防止処理を施すことを特徴とする請求項1または2に記載のハイブリッドレンズの製造方法。
- 前記エネルギー硬化型樹脂で形成される樹脂レンズLの曲面が非球面形状であることを特徴とする請求項1または2に記載のハイブリッドレンズ製造方法。
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JP2012535494A JP5179680B1 (ja) | 2011-08-12 | 2012-08-06 | ハイブリッドレンズの製造方法 |
US13/641,828 US9193116B2 (en) | 2011-08-12 | 2012-08-06 | Method of manufacturing hybrid lens unit |
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Cited By (1)
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JP2017032967A (ja) * | 2015-07-28 | 2017-02-09 | エーエーシー テクノロジーズ ピーティーイー リミテッドAac Technologies Pte.Ltd. | レンズモジュールの製造方法及び当該レンズを応用した撮像モジュール |
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US9193116B2 (en) | 2015-11-24 |
US20140159260A1 (en) | 2014-06-12 |
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JPWO2013024733A1 (ja) | 2015-03-05 |
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JP5179680B1 (ja) | 2013-04-10 |
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