Method of forming camera module for vehicular vision system
First Claim
1. A method of forming a camera module for a vision system for a vehicle, said method comprising:
- providing a circuit board, wherein the circuit board has an imager and associated circuitry disposed thereat;
providing a lens holder for holding a lens assembly, the lens assembly including a plurality of optical elements;
disposing an adhesive in an uncured state at one or both of the lens holder and the circuit board;
positioning the lens holder at the circuit board with the uncured adhesive disposed between and contacting the lens holder and the circuit board;
optically aligning the plurality of optical elements with the imager at the circuit board;
with the plurality of optical elements optically aligned with the imager at the circuit board, and with the adhesive between and contacting the lens holder and the circuit board, forming a lens holder and circuit board construction by curing the adhesive to an at least partially cured state to secure the lens holder relative to the circuit board;
with the adhesive cured to the at least partially cured state, placing the lens holder and circuit board construction in a first mold, wherein, when placing the lens holder and circuit board construction in the first mold, the lens holder and circuit board construction is datumed in the first mold by a portion of the lens holder;
forming an inner molded construction by molding, using a first polymeric resin, an inner molding over and around the circuit board and over a portion of the lens holder;
placing the inner molded construction in a second mold, wherein, when placing the inner molded construction in the second mold, the inner molded construction is datumed in the second mold by the portion of the lens holder; and
forming an outer molded construction by molding, using a second polymeric resin, an outer molding over the inner molding and over another portion of the lens holder to encase the inner molding.
0 Assignments
0 Petitions
Accused Products
Abstract
A method of forming a camera module for a vehicular vision system includes providing a circuit board and providing a lens holder for holding a lens assembly. A lens holder and circuit board construction is placed in a first mold and datumed in the first mold by a portion of the lens holder. An inner molded construction is formed by molding an inner molding over the circuit board and a portion of the lens holder. The inner molded construction is placed in a second mold and datumed in the second mold by the portion of the lens holder. An outer molded construction is formed by molding an outer molding over the inner molding and over another portion of the lens holder. The outer molded construction may include a connector portion that is configured to connect to a connector end of a vehicular wire harness.
-
Citations
32 Claims
-
1. A method of forming a camera module for a vision system for a vehicle, said method comprising:
-
providing a circuit board, wherein the circuit board has an imager and associated circuitry disposed thereat; providing a lens holder for holding a lens assembly, the lens assembly including a plurality of optical elements; disposing an adhesive in an uncured state at one or both of the lens holder and the circuit board; positioning the lens holder at the circuit board with the uncured adhesive disposed between and contacting the lens holder and the circuit board; optically aligning the plurality of optical elements with the imager at the circuit board; with the plurality of optical elements optically aligned with the imager at the circuit board, and with the adhesive between and contacting the lens holder and the circuit board, forming a lens holder and circuit board construction by curing the adhesive to an at least partially cured state to secure the lens holder relative to the circuit board; with the adhesive cured to the at least partially cured state, placing the lens holder and circuit board construction in a first mold, wherein, when placing the lens holder and circuit board construction in the first mold, the lens holder and circuit board construction is datumed in the first mold by a portion of the lens holder; forming an inner molded construction by molding, using a first polymeric resin, an inner molding over and around the circuit board and over a portion of the lens holder; placing the inner molded construction in a second mold, wherein, when placing the inner molded construction in the second mold, the inner molded construction is datumed in the second mold by the portion of the lens holder; and forming an outer molded construction by molding, using a second polymeric resin, an outer molding over the inner molding and over another portion of the lens holder to encase the inner molding. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17)
-
-
18. A method of forming a camera module for a vision system for a vehicle, said method comprising:
-
providing a circuit board, wherein the circuit board has an imager and associated circuitry disposed thereat; providing a lens holder for holding a lens assembly, the lens assembly including a plurality of optical elements; disposing an adhesive in an uncured state at one or both of the lens holder and the circuit board; positioning the lens holder at the circuit board with the uncured adhesive disposed between and contacting the lens holder and the circuit board; optically aligning the plurality of optical elements with the imager at the circuit board; with the plurality of optical elements optically aligned with the imager at the circuit board, and with the adhesive between and contacting the lens holder and the circuit board, forming a lens holder and circuit board construction by curing the adhesive to an at least partially cured state to secure the lens holder relative to the circuit board; with the adhesive cured to the at least partially cured state, placing the lens holder and circuit board construction in a first mold, wherein, when placing the lens holder and circuit board construction in the first mold, the lens holder and circuit board construction is datumed in the first mold by a portion of the lens holder; forming an inner molded construction by molding, using a first polymeric resin, an inner molding over the circuit board and over a portion of the lens holder; wherein molding the inner molding comprises molding the inner molding at a first molding pressure in the first mold; wherein forming the inner molded construction comprises molding the first polymeric resin at a first molding temperature that is no more than 240 degrees Celsius; placing the inner molded construction in a second mold, wherein, when placing the inner molded construction in the second mold, the inner molded construction is datumed in the second mold by the portion of the lens holder; forming an outer molded construction by molding, using a second polymeric resin, an outer molding over the inner molding and over another portion of the lens holder to encase the inner molding; wherein molding the outer molding comprises molding the outer molding at a second molding pressure in the second mold; and wherein the first molding pressure is lower than the second molding pressure. - View Dependent Claims (19, 20, 21, 22, 23, 24)
-
-
25. A method of forming a camera module for a vision system for a vehicle, said method comprising:
-
providing a circuit board, wherein the circuit board has an imager and associated circuitry disposed thereat; providing a lens holder for holding a lens assembly, the lens assembly including a plurality of optical elements; disposing an adhesive in an uncured state at one or both of the lens holder and the circuit board; positioning the lens holder at the circuit board with the uncured adhesive disposed between and contacting the lens holder and the circuit board; optically aligning the plurality of optical elements with the imager at the circuit board; with the plurality of optical elements optically aligned with the imager at the circuit board, and with the adhesive between and contacting the lens holder and the circuit board, forming a lens holder and circuit board construction by curing the adhesive to an at least partially cured state to secure the lens holder relative to the circuit board; with the adhesive cured to the at least partially cured state, placing the lens holder and circuit board construction in a first mold, wherein, when placing the lens holder and circuit board construction in the first mold, the lens holder and circuit board construction is datumed in the first mold by a portion of the lens holder; forming an inner molded construction by molding, using a first polymeric resin, an inner molding over the circuit board and over a portion of the lens holder; wherein forming the inner molded construction comprises at least one selected from the group consisting of (i) molding the first polymeric resin at a first molding temperature that is no more than 240 degrees Celsius and (ii) molding the first polymeric resin at a first molding pressure that is less than 500 psi; wherein forming the inner molded construction includes providing a coaxial connector element that is, when provided, in electrical connection with electrical connecting elements at the circuit board; placing the inner molded construction in a second mold, wherein, when placing the inner molded construction in the second mold, the inner molded construction is datumed in the second mold by the portion of the lens holder; forming an outer molded construction by molding, using a second polymeric resin, an outer molding over the inner molding and over another portion of the lens holder to encase the inner molding; wherein forming the outer molded construction comprises molding a coaxial connector portion over at least part of the coaxial connector element; and wherein the molded coaxial connector portion is configured to connect to a coaxial connector end of a coaxial vehicular wire harness to electrically connect the coaxial connector end of the coaxial vehicular wire harness to the coaxial connector element to establish electrical connection between the coaxial vehicular wire harness and the electrical connecting elements at the circuit board. - View Dependent Claims (26, 27, 28, 29, 30, 31, 32)
-
Specification