Vehicle camera assembly process

• US 10,237,456 B2
• Filed: 08/21/2017
• Issued: 03/19/2019
• Est. Priority Date: 08/22/2016
• Status: Active Grant

• Current Assignee: Magna Electronics Incorporated (Magna International Incorporated)
• Original Assignee: Magna Electronics Incorporated (Magna International Incorporated)
• Inventors: Kunze, Norbert
• Primary Examiner(s): Haliyur, Padma
• Application Number:
  US15/681,697
• Publication Number:
  US 20180054555A1
• Time in Patent Office: 575 Days
• CPC Class Codes: B60R 1/12 Mirror assemblies combined with other articles, e.g. clocks
• CPC Class Codes: B60R 11/04 Mounting of cameras operative during drive; Arrangement of controls thereof relative to the vehicle
• CPC Class Codes: B60R 2001/1253 with cameras, video cameras or video screens
• CPC Class Codes: B60R 2011/004 outside the vehicle
• CPC Class Codes: B60R 2300/105 using multiple cameras
• CPC Class Codes: B60R 2300/303 using joined images, e.g. multiple camera images
• CPC Class Codes: B60R 2300/607 from a bird's eye viewpoint
• CPC Class Codes: B60R 2300/8033 for pedestrian protection
• CPC Class Codes: B60R 2300/804 for lane monitoring
• CPC Class Codes: B60R 2300/8093 for obstacle warning
• CPC Class Codes: C09J 2301/416 use of irradiation
• CPC Class Codes: C09J 5/00 Adhesive processes in general; Adhesive processes not provided for elsewhere, e.g. relating to primers
• CPC Class Codes: G08G 1/16 Anti-collision systems road vehicle drive control systems for predicting or avoiding probable or impending collision otherwise than by control of a particular sub-unit B60W30/08
• CPC Class Codes: G08G 1/165 for passive traffic, e.g. including static obstacles, trees
• CPC Class Codes: G08G 1/166 for active traffic, e.g. moving vehicles, pedestrians, bikes
• CPC Class Codes: H04N 23/51 Housings
• CPC Class Codes: H04N 23/54 Mounting of pick-up tubes, electronic image sensors, deviation or focusing coils
• CPC Class Codes: H04N 23/55 Optical parts specially adapted for electronic image sensors; Mounting thereof

Abstract

A camera assembly process for assembling a camera for a vehicle vision system includes aligning and affixing an imager PCB at a lens holder so as to align an imager with a lens. A connector PCB is electrically connected to the imager PCB. The lens holder, the connector PCB and the imager PCB are inserted into a housing portion, and a cage retains the connector PCB at the housing portion. A connector assembly is disposed at a rear portion of the housing, and electrically conductive terminals of the connector assembly electrically conductively connect to electrically conductive terminals of the connector PCB at a rear opening at the rear portion of the housing. The lens holder and the connector assembly are movable along a longitudinal axis of the camera assembly relative to the housing portion and adhesively retained thereat.

Claims

1. A camera assembly process for assembling a camera for a vision system of a vehicle, said camera assembly process comprising:

providing a lens holder including a lens;

providing an imager PCB having a printed circuit board and an imager disposed at said printed circuit board;

aligning and affixing said imager PCB at said lens holder so as to align said imager with said lens;

providing a connector PCB having a printed circuit board and electrically conductive terminals;

electrically connecting said connector PCB to said imager PCB;

providing a housing portion having a rear opening at a rear portion of said housing;

inserting said lens holder and said connector PCB and said imager PCB into said housing portion, wherein a cage retains said connector PCB at said housing portion;

providing a connector assembly and disposing said connector assembly at said rear portion of said housing, wherein electrically conductive terminals of said connector assembly electrically conductively connect to said electrically conductive terminals of said connector PCB at said rear opening at said rear portion of said housing when said lens holder and said connector PCB and said imager PCB are inserted into said housing portion and when said connector assembly is disposed at said rear portion of said housing;

wherein said cage comprises structure to retain said connector PCB relative to said imager PCB;

wherein said connector PCB and said imager PCB engage said cage and are retained thereat before inserting said lens holder and said connector PCB and said imager PCB into said housing portion;

wherein said cage limits insertion of said lens holder into said housing;

wherein, with said lens holder inserted relative to said housing portion and said connector assembly disposed at said rear portion of said housing portion, said lens holder and said connector assembly are movable along a longitudinal axis of said camera assembly relative to said housing portion;

after said lens holder is inserted relative to said housing portion and after said connector assembly is disposed at said rear portion of said housing, applying adhesive at an interface of said connector assembly and said rear portion of said housing portion and applying adhesive at an interface of said lens holder and said housing portion; and

after applying adhesive, curing the adhesive at the interfaces to retain said connector assembly at said rear portion of said housing portion and to retain said lens holder at said housing portion.

2. The camera assembly process of claim 1, wherein curing the adhesive at the interfaces is done via a single curing process.

3. The camera assembly process of claim 1, wherein curing the adhesive at the interfaces is done via a UV curing process.

4. The camera assembly process of claim 1, wherein said cage is configured to support said connector PCB relative to said lens holder.

5. The camera assembly process of claim 1, wherein, with said lens holder and said connector assembly movable along the longitudinal axis of said camera assembly relative to said housing portion, said lens holder and connector assembly are not movable relative to said housing portion in a direction normal to the longitudinal axis.

6. The camera assembly process of claim 1, wherein the longitudinal axis is parallel to an optical axis of said lens.

7. The camera assembly process of claim 1, wherein electrically connecting said connector PCB to said imager PCB comprises electrically connecting circuitry of said connector PCB to circuitry of said imager PCB via a flexible connector.

8. The camera assembly process of claim 1, wherein said cage comprises a spring element that engages said connector PCB, said imager PCB, said housing and said lens holder to position said connector PCB, said imager PCB and said lens holder relative to said housing, while allowing for adjustment of said connector PCB, said imager PCB, and said lens holder relative to said housing and along the longitudinal axis of said housing.

9. The camera assembly process of claim 1, wherein said connector PCB and said imager PCB engage said cage and are retained thereat as said connector PCB and said imager PCB are inserted into said housing portion.

10. The camera assembly process of claim 1, wherein said electrically conductive terminals of said connector assembly are received at and electrically conductively connect to said electrically conductive terminals of said connector PCB when said lens holder and said connector PCB and said imager PCB are inserted into said housing portion and when said connector assembly is disposed at said rear portion of said housing.

11. The camera assembly process of claim 1, wherein, after said lens holder and said connector PCB and said imager PCB are inserted into said housing portion, said connector assembly is disposed at said rear portion of said housing to said electrically conductively connect electrically conductive terminals of said connector assembly to said electrically conductive terminals of said connector PCB.

12. A camera assembly process for assembling a camera for a vision system of a vehicle, said camera assembly process comprising:

providing a lens holder including a lens;

providing an imager PCB having a printed circuit board and an imager disposed at said printed circuit board;

aligning and affixing said imager PCB at said lens holder so as to align said imager with said lens;

providing a connector PCB having a printed circuit board and electrically conductive terminals;

electrically connecting said connector PCB to said imager PCB;

providing a housing portion having a rear opening at a rear portion of said housing;

inserting said lens holder and said connector PCB and said imager PCB into said housing portion, wherein a cage retains said connector PCB at said housing portion;

providing a connector assembly and disposing said connector assembly at said rear portion of said housing, wherein electrically conductive terminals of said connector assembly electrically conductively connect to said electrically conductive terminals of said connector PCB at said rear opening at said rear portion of said housing when said lens holder and said connector PCB and said imager PCB are inserted into said housing portion and when said connector assembly is disposed at said rear portion of said housing;

wherein, with said lens holder inserted relative to said housing portion and said connector assembly disposed at said rear portion of said housing portion, said lens holder and said connector assembly are movable along a longitudinal axis of said camera assembly relative to said housing portion;

wherein said cage comprises structure to retain said connector PCB relative to said imager PCB;

wherein said cage engages said connector PCB, said imager PCB, said housing and said lens holder to position said connector PCB, said imager PCB and said lens holder relative to said housing, while allowing for adjustment of said connector PCB, said imager PCB and said lens holder relative to said housing and along the longitudinal axis of said housing;

wherein said cage limits insertion of said lens holder relative to said housing;

after said lens holder is positioned relative to said housing portion and after said connector assembly is disposed at said rear portion of said housing, applying adhesive at an interface of said connector assembly and said rear portion of said housing portion and applying adhesive at an interface of said lens holder and said housing portion; and

after applying adhesive, curing the adhesive at the interfaces to retain said connector assembly at said rear portion of said housing portion and to retain said lens holder at said housing portion.

13. The camera assembly process of claim 12, wherein, with said lens holder and said connector assembly movable along the longitudinal axis of said camera assembly relative to said housing portion, said lens holder and connector assembly are not movable relative to said housing portion in a direction normal to the longitudinal axis.

14. The camera assembly process of claim 12, wherein, after said lens holder and said connector PCB and said imager PCB are inserted into said housing portion, said connector assembly is disposed at said rear portion of said housing to said electrically conductively connect electrically conductive terminals of said connector assembly to said electrically conductive terminals of said connector PCB.

15. A camera assembly process for assembling a camera for a vision system of a vehicle, said camera assembly process comprising:

providing a lens holder including a lens;

providing an imager PCB having a printed circuit board and an imager disposed at said printed circuit board;

aligning and affixing said imager PCB at said lens holder so as to align said imager with said lens;

providing a connector PCB having a printed circuit board and electrically conductive terminals;

electrically connecting said connector PCB to said imager PCB;

providing a housing portion having a rear opening at a rear portion of said housing;

providing a cage;

engaging said connector PCB and said imager PCB with said cage;

inserting said cage, with said connector PCB and said imager PCB engaged therewith, into said housing portion, wherein said cage retains said connector PCB at said housing portion;

inserting said lens holder relative to said housing, wherein said cage limits insertion of said lens holder relative to said housing portion;

providing a connector assembly and disposing said connector assembly at said rear portion of said housing, wherein electrically conductive terminals of said connector assembly electrically conductively connect to said electrically conductive terminals of said connector PCB at said rear opening at said rear portion of said housing when said lens holder and said connector PCB and said imager PCB are inserted into said housing portion and when said connector assembly is disposed at said rear portion of said housing;

wherein, with said lens holder inserted relative to said housing portion and said connector assembly disposed at said rear portion of said housing portion, said lens holder and said connector assembly are movable along the longitudinal axis of said camera assembly relative to said housing portion;

wherein said cage comprises a spring element that engages said connector PCB, said imager PCB, said housing and said lens holder to position said connector PCB, said imager PCB and said lens holder relative to said housing, while allowing for adjustment of said connector PCB, said imager PCB, and said lens holder relative to said housing and along the longitudinal axis of said housing;

wherein, with said cage movable along the longitudinal axis of said camera assembly relative to said housing portion, said lens holder and said connector assembly are not movable relative to said housing portion in a direction normal to the longitudinal axis;

after said lens holder is inserted relative to said housing portion and after said connector assembly is disposed at said rear portion of said housing, applying adhesive at an interface of said connector assembly and said rear portion of said housing portion and applying adhesive at an interface of said lens holder and said housing portion; and

after applying adhesive, curing the adhesive at the interfaces to retain said connector assembly at said rear portion of said housing portion and to retain said lens holder at said housing portion.

16. The camera assembly process of claim 15, wherein the longitudinal axis is parallel to an optical axis of said lens.