Camera module back-focal length adjustment method and ultra compact components packaging

A substrate apparatus for use in miniature camera applications comprising:

• a. a substrate assembly wherein electronic components are disposed on a top surface of the substrate assembly;
• b. a substrate cavity formed in a bottom surface of the substrate assembly;
• and
• c. an aperture passing from the top surface of the substrate assembly into the substrate cavity such that light is able to pass therethrough.

An ultra-compact camera comprising:

• a. a barrel housing comprising:
• i. a housing base with a top surface and a bottom surface;
• ii. a cylindrical barrel disposed on the top surface of the housing base, wherein an internal surface is composed of a portion of the top surface located within the cylindrical barrel;
• iii. at least one ramp disposed on the internal top surface, wherein the at least one ramp has a vertically increasing gradient;
• and
• iv. at least one locking key slot disposed on the internal top surface;
• b. a lens barrel assembly comprising:
• i. a cylinder section having a top cylinder, a bottom cylinder and a stand-off ridge positioned between the top cylinder and the bottom cylinder;
• ii. at least one locking key protrusion extending downward, away from the bottom cylinder;
• and
• iii. a first portion of a lens package included within the cylinder section;
• c. a ramp bridge comprising:
• i. a ring having a ring top and a ring bottom;
• and
• ii. at least one ramp foot on the bottom of the ring extending downward, away from the ring;
• and
• d. an actuator assembly, wherein the actuator assembly couples to the top cylinder, wherein the ramp bridge is positioned over the bottom cylinder, such that the ramp bridge is configured to exert a force on the stand-off ridge when a force is applied to the ring bottom, wherein the lens barrel is positioned within the cylindrical barrel such that the at least one locking key protrusion fits within the at least one locking key slot and the at least one ramp foot contacts the at least one ramp.

An ultra-compact camera comprising:

• a. a barrel housing comprising:
• i. a housing base with a top surface and a bottom surface;
• ii. a cylindrical barrel disposed on the top surface of the housing base, defining a cylindrical volume with a floor;
• iii. at least one ramp disposed on the floor, wherein the at least one ramp has a vertically increasing gradient;
• and
• b. a lens barrel assembly comprising:
• i. a cylinder section;
• ii. a first portion of a lens package included within the cylinder section;
• and
• iii. at least one lens barrel foot on the bottom of the cylinder section extending downward, away from the cylinder section, wherein the lens barrel assembly fits within the cylindrical volume such that at least one lens barrel foot makes contact with the at least one ramp, and wherein the at least one lens barrel foots moves up the at least one ramp when the lens barrel assembly rotates within the barrel housing;
• c. an actuator assembly, wherein the actuator assembly couples to the lens barrel assembly, wherein the lens barrel assembly is configured to exert a force on the actuator assembly when the at least one lens barrel foots moves up the at least one ramp, and wherein the force has a vertical component and a rotational component;
• and
• d. a fixture, comprising a chamber designed to contain the actuator assembly, such that when the lens barrel exerts the force on the actuator assembly, the fixture resists the rotational component and provides no resistance to the vertical component.

A method of manufacturing an ultra-compact camera module comprising:

• a. providing assembly pieces comprising:
• i. providing a barrel housing, wherein the barrel housing has a housing interface surface, wherein the barrel housing includes at least one ramp within the barrel housing, wherein the at least one ramp has a vertically increasing gradient, and wherein the barrel housing has at least one locking key slot on the housing interface surface;
• ii. providing a lens barrel, wherein the lens barrel has a barrel interface surface, wherein the lens barrel includes a lens package having a focal point, wherein the lens barrel has at least one locking key protrusion on the barrel interface surface;
• and
• iii. providing a ramp bridge, wherein the ramp bridge has at least one ramp foot;
• b. coupling the assembly pieces comprising:
• i. coupling the ramp bridge to the lens barrel such that a vertical force exerted on the ramp bridge exerts a vertical force on the lens barrel;
• ii. coupling the barrel interface surface to the housing interface surface, wherein the at least one locking key protrusion is positioned within the at least one locking key slot, and wherein the at least one ramp foot contacts the at least one ramp;
• c. rotating the ramp bridge about the lens barrel such that the at least one ramp foot moves vertically on the ramp such that the ramp bridge exerts a vertical force on the lens barrel and such that the at least one locking key protrusion inserted in the at least one locking key slot resists rotation of the lens barrel relative to the barrel housing, thus adjusting the focal point without rotating the lens barrel relative to the barrel housing.
• d. permanently coupling the lens barrel to the barrel housing.

An ultra-compact camera comprising:

• a. a barrel housing comprising:
• i. a housing base with a top surface and a bottom surface;
• ii. a cylindrical barrel disposed on the top surface of the housing base, defining a cylindrical volume with a floor
• iii. at least one ramp disposed on the floor, wherein the at least one ramp has a vertically increasing gradient;
• and
• iv. at least one locking key slot disposed on the floor;
• b. a lens barrel assembly comprising:
• i. a continuous cylinder section having a stand-off ridge positioned between a top portion of the cylinder and the bottom portion of the cylinder;
• ii. at least one locking key protrusion disposed on the bottom portion of the cylinder extending downward, away from the bottom portion of the cylinder;
• and
• iii. a first portion of a lens package contained within the cylinder section;
• c. a ramp bridge comprising:
• i. a ring having a ring top and a ring bottom;
• and
• ii. at least one ramp foot on the bottom of the ring extending downward, away from the ring, wherein the ramp bridge is positioned over the bottom portion of the cylinder, such that the ramp bridge exerts a force on the stand-off ridge when a vertical force is applied to the ring bottom, wherein the lens barrel is positioned within the cylindrical barrel such that the at least one locking key protrusions fits within the at least one locking key slot and the at least one ramp foot contacts the at least one ramp.