Vehicular camera and lens assembly

Patent metadata

Field	Value
Publication number	US-10270949-B2
Application number	US-201615149337-A
Country	US
Kind code	B2
Filing date	May 9, 2016
Priority date	Mar 25, 2009
Publication date	Apr 23, 2019
Grant date	Apr 23, 2019

Abstract

A process for providing a vehicular camera suitable for vehicular use includes providing a front camera housing having a lens assembly disposed thereat and providing an imager disposed on a printed circuit board. An adhesive is disposed in its uncured state between the front camera housing and the printed circuit board. The front camera housing and said printed circuit board are adjusted relative to each other to achieve optical center-alignment and focusing of the lens optics relative to the imager. The adhesive is initially cured from its uncured state to an initially-cured state in an initial radiation curing process that includes exposure to UV light for a first time period. After optical center-alignment and focusing, the adhesive is further cured from the initially-cured state to a further more cured state in a secondary curing process undertaken for a second time period that is longer than the first time period.

First claim

The invention claimed is:

1. A process for providing a vehicular camera suitable for vehicular use, said process comprising:
providing a front camera housing having a cylindrical receiving portion;
providing a lens assembly comprising a cylindrical barrel portion;
said lens assembly including lens optics;
inserting said cylindrical barrel portion of said lens assembly at least partially into said cylindrical receiving portion of said front camera housing;
securing said cylindrical barrel portion of said lens assembly at said cylindrical receiving portion of said front camera housing;
providing a printed circuit board having a first side and a second side opposite the first side, wherein said printed circuit board comprises electronic circuitry at least on the first side of said printed circuit board, and wherein the electronic circuitry of said printed circuit board comprises an imager having an outer surface and an inner surface, and wherein the inner surface of said imager is mounted at the first side of said printed circuit board;
disposing an adhesive in its uncured state at said front camera housing and/or at said printed circuit board, wherein disposing the adhesive in its uncured state comprises disposing the adhesive in its uncured state at said front camera housing and/or said printed circuit board laterally outboard of said imager;
after disposing the adhesive in its uncured state at said front camera housing and/or at said printed circuit board, and with the adhesive in its uncured state between and contacting said front camera housing and said printed circuit board, adjusting said front camera housing and said printed circuit board relative to each other to achieve optical center-alignment and focusing of said lens optics relative to said imager;
wherein the lens optics comprise a lens having an inner surface that directly opposes the outer surface of said imager when the adhesive is disposed in its uncured state between and contacting said front camera housing and said printed circuit board;
wherein, with the adhesive disposed in its uncured state between and contacting said front camera housing and said printed circuit board, an air gap exists between the inner surface of the lens of said lens optics and the outer surface of said imager;
wherein optical center-alignment and focusing of said lens optics relative to said imager is achieved via a multi-axis positioning device that is operable to adjust said lens optics relative to said imager in x, y and z directions and in two orthogonal rotations;
initially curing the adhesive from its uncured state to an initially-cured state in an initial radiation curing process that comprises exposure to UV light for a first time period;
further curing the adhesive from the initially-cured state to a further more cured state in a secondary curing process undertaken for a second time period;
wherein said second time period is longer than said first time period;
wherein the adhesive is initially cured from its uncured state to the initially-cured state via the initial radiation curing process after said lens optics is brought into focus with said imager and is optically center-aligned therewith;
wherein the adhesive, as cured to the initially-cured state via the initial radiation curing process, (i) attaches said printed circuit board to said front camera housing and (ii) holds said lens optics optically center-aligned and in focus with said imager;
after the initial radiation curing process is completed, moving said front camera housing, with said printed circuit board adhesively attached thereto, to the secondary curing process and further curing the adhesive to the further more cured state;
wherein the air gap between the inner surface of the lens of said lens optics and the outer surface of said imager remains devoid of the adhesive in its further more cured state; and
wherein, with said printed circuit board attached to said front camera housing by the adhesive in the further cured state, at least a minimum strength of bond exists between said printed circuit board and said front camera housing after being exposed to a temperature of approximately 85 degrees Celsius and a humidity of approximately 85% for 1000 hours.

2. The process of claim 1 , wherein the secondary curing process comprises at least one of (i) thermal cure, (ii) moisture cure and (iii) radiation cure.

3. The process of claim 1 , wherein said first time period is seven seconds or less.

4. The process of claim 3 , wherein said second time period is greater than seven seconds.

5. The process of claim 4 , wherein said second time period is greater than twenty five seconds.

6. The process of claim 1 , comprising joining a rear camera housing to said front camera housing to substantially encase said printed circuit board, and wherein said rear camera housing comprises an electrical connector for electrically connecting circuitry associated with operation of said vehicular camera to electrical wiring of a vehicle.

7. The process of claim 6 , wherein said rear camera housing is joined to said front camera housing via at least one of (i) ultrasonic welding, (ii) adhesive and (iii) press fitting.

8. The process of claim 1 , wherein, when more cured via the secondary curing process, the adhesive, in the further more cured state, maintains focus and optical center-alignment of said lens optics with said imager for use of said vehicular camera on a vehicle.

9. The process of claim 1 , wherein said cylindrical barrel portion of said lens assembly secures at said cylindrical receiving portion of said front camera housing by at least one of (i) mechanical attachment, (ii) threaded connection and (iii) a cured adhesive.

10. The process of claim 1 , wherein at least one of (a) a lens resolution of said lens optics is selected to meet but not substantially exceed a resolution determined from at least one of (i) the size of a display associated with said vehicular camera when said vehicular camera is mounted on a vehicle, (ii) a distance between an observer and a display associated with said vehicular camera when said vehicular camera is mounted on a vehicle, (iii) a selected point on a contrast sensitivity function and (iv) the size of the imager sensing surface, and (b) said lens optics omits achromatic lenses and employs digital chromatic correction based on a predetermined chromatic aberration measurement.

11. The process of claim 1 , wherein said multi-axis positioning device comprises a multi-axis robot and wherein optical center-alignment and focusing of said lens optics relative to said imager is achieved robotically.

12. The process of claim 1 , wherein the adhesive, as disposed in its uncured state between said printed circuit board and said front camera housing, has a thickness of up to approximately 0.75 mm.

13. The process of claim 1 , wherein said lens optics comprises a plurality of optical elements.

14. The process of claim 13 , wherein said cylindrical receiving portion of said front camera housing comprises a cylindrical opening and wherein said cylindrical barrel portion is at least partially received in said cylindrical opening of said cylindrical receiving portion of said front camera housing.

15. The process of claim 1 , wherein said vehicular camera is configured for use as a rearward viewing camera of a vehicle.

16. A vehicular camera provided in accordance with the process of claim 1 .

17. A process for providing a vehicular camera suitable for vehicular use, said process comprising:
providing a front camera housing having a cylindrical recei

Assignees

• Magna Electronics Inc

Inventors

• Lu Yuesheng
• Byrne Steven V
• Sesti Matthew C
• Gibson Joel S
• Devota Robert A

Classifications

• H04N23/57

  Mechanical or electrical details of cameras or camera modules specially adapted for being embedded in other devices · CPC title

• G02B7/025 Primary

  using glue · CPC title

• H04N23/63

  by using electronic viewfinders · CPC title

• H04N23/55 Primary

  Optical parts specially adapted for electronic image sensors; Mounting thereof · CPC title

• H04N23/54

  Mounting of pick-up tubes, electronic image sensors, deviation or focusing coils · CPC title