Vehicular camera with adhesively bonded construction

• US 10,419,652 B2
• Filed: 04/15/2019
• Issued: 09/17/2019
• Est. Priority Date: 11/07/2013
• Status: Active Grant

• Current Assignee: Magna Electronics Incorporated (Magna International Incorporated)
• Original Assignee: Magna Electronics Incorporated (Magna International Incorporated)
• Inventors: Winden, Brian J., Devota, Robert A., Sesti, Matthew C., Stemmer, Joseph A., Byrne, Steven V., Garcia, John R., Olson, David F.
• Primary Examiner(s): Williams, Jeffery A
• Application Number:
  US16/384,034
• Publication Number:
  US 20190246020A1
• Time in Patent Office: 155 Days
• Field of Search: 348148
• CPC Class Codes: C09J 163/00 Adhesives based on epoxy resins; Adhesives based on derivatives of epoxy resins
• CPC Class Codes: C09J 2463/00 Presence of epoxy resin
• CPC Class Codes: C09J 5/00 Adhesive processes in general; Adhesive processes not provided for elsewhere, e.g. relating to primers
• 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 vehicular camera includes a lens accommodated in a lens barrel, a lens holder that accommodates at least part of the lens holder, and a printed circuit board with an imager disposed thereat. The lens barrel is attached at the lens holder by a cured adhesive with the printed circuit board attached at the lens holder, or the printed circuit board is attached at the lens holder by a cured adhesive with the lens barrel attached at the lens holder. With the lens in focus with the imager and optically center-aligned therewith, the adhesive is initially cured to an initially-cured state in an initial curing process that includes UV light exposure for a first period of time. The initially-cured adhesive is further cured to a further-cured state in a secondary curing process that is achieved within a second period of time that is longer than the first period of time.

Claims

1. A vehicular camera, said vehicular camera comprising:

a lens comprising a plurality of optical elements, wherein the lens is accommodated in a lens barrel, and wherein the lens barrel comprises a cylindrical portion;

a lens holder comprising a cylindrical passageway that accommodates at least a portion of the cylindrical portion of the lens barrel;

a printed circuit board;

a CMOS imager disposed at the printed circuit board;

a flexible electrical ribbon cable with one end electrically connecting at the printed circuit board and with another distal end electrically terminating at an electrical connector of the flexible electrical ribbon cable;

wherein said vehicular camera utilizes an adhesive to hold the lens optically center-aligned and in focus with the CMOS imager, and wherein one selected from the group consisting of (i) the lens barrel is attached at the lens holder by the adhesive and the printed circuit board is attached at the lens holder and (ii) the printed circuit board is attached at the lens holder by the adhesive and the lens barrel is attached at the lens holder;

wherein the adhesive is initially curable in an initial radiation curing process that comprises exposure to UV light for an initial-cure time period of less than 10 seconds, and wherein the initially-cured adhesive is further curable to a further-cured strength in a secondary curing process;

wherein the adhesive is initially cured via the initial radiation curing process after the lens is brought into focus with the CMOS imager and is optically center-aligned therewith;

wherein the initially-cured adhesive, as cured via the initial radiation curing process, holds the lens optically center-aligned and in focus with the CMOS imager;

wherein, as further cured via the secondary curing process for a further-cure time period that is longer than the initial-cure time period, the further-cured adhesive maintains focus and optical center-alignment of the lens with the CMOS imager for use of said vehicular camera in a vehicle;

wherein the adhesive, in its uncured state, comprises a one-part, filled adhesive;

wherein the further-cured adhesive maintains at least 70% strength of bond after being exposed to at least one operating condition for a period of time; and

wherein the at least one operating condition comprises a temperature of 85 degrees Celsius, and wherein the period of time is greater than 1000 hours.

2. The vehicular camera of claim 1, wherein the printed circuit board is attached at the lens holder by the adhesive and the lens barrel is threadedly attached at the lens holder.

3. The vehicular camera of claim 1, wherein the printed circuit board is attached at the lens holder by the adhesive and the lens barrel is adhesively attached at the lens holder.

4. The vehicular camera of claim 1, wherein the printed circuit board is attached at the lens holder by the adhesive and the lens barrel is threadedly and adhesively attached at the lens holder.

5. The vehicular camera of claim 1, wherein the lens barrel is attached at the lens holder by the adhesive and the printed circuit board is attached at the lens holder.

6. The vehicular camera of claim 5, wherein the lens barrel is attached at the lens holder by the adhesive and the printed circuit board is mechanically attached at the lens holder.

7. The vehicular camera of claim 5, wherein the lens barrel is attached at the lens holder by the adhesive and the printed circuit board is mechanically attached at the lens holder via at least one fastener.

8. The vehicular camera of claim 5, wherein the lens barrel is attached at the lens holder by the adhesive and the printed circuit board is mechanically attached at the lens holder via two screw fasteners.

9. The vehicular camera of claim 1, wherein the at least one operating condition comprises a humidity of 85% RH.

10. The vehicular camera of claim 1, wherein the further-cure time period is at least 30 seconds.

11. The vehicular camera of claim 1, wherein the lens barrel comprises an annular flange that circumscribes and extends radially from the cylindrical portion of the lens holder.

12. The vehicular camera of claim 1, wherein the adhesive, in its uncured state, has a viscosity at 23 degrees Celsius from about 5,000 mPa to about 150,000 mPa.

13. The vehicular camera of claim 1, wherein the lens holder is adapted for attachment to a camera housing.

14. The vehicular camera of claim 1, wherein lens resolution of the lens meets but does not exceed a resolution determined by the size of a sensing surface of the CMOS imager.

15. The vehicular camera of claim 1, wherein the lens omits achromatic lenses.

16. The vehicular camera of claim 1, wherein the lens employs digital chromatic correction based on a predetermined chromatic aberration measurement.

17. The vehicular camera of claim 1, wherein optical center-alignment and focusing of the lens relative to the CMOS imager is achieved robotically.

18. The vehicular camera of claim 1, wherein the adhesive comprises one selected from the group consisting of (i) a Delo OB749 adhesive, (ii) a Delo AD VE 112203 adhesive and (iii) a Delo OB787 adhesive.

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

20. The vehicular camera of claim 1, wherein the secondary curing process comprises thermal curing.

21. The vehicular camera of claim 1, wherein the secondary curing process comprises moisture curing.

22. The vehicular camera of claim 1, wherein the secondary curing process comprises radiation curing.

23. The vehicular camera of claim 1, wherein said vehicular camera is configured for use as a forward viewing camera of a vehicle.

24. The vehicular camera of claim 1, wherein said vehicular camera is configured for use as a forward viewing camera for an automatic high-beam control of a vehicle.

25. The vehicular camera of claim 1, wherein the adhesive bonds to PBT/PC and PBT plastics.

26. The vehicular camera of claim 1, wherein the adhesive bonds to an FR4 PCB.

27. The vehicular camera of claim 1, wherein the adhesive bonds to zinc.

28. The vehicular camera of claim 1, wherein the adhesive bonds to aluminum.

29. The vehicular camera of claim 1, wherein the adhesive, in its further-cured state, has a bond shear strength greater than 1000 PSI.

30. The vehicular camera of claim 29, wherein bond shear strength of the adhesive, in its further-cured state, reduces less than 60% at 85 degrees Celsius.

31. The vehicular camera of claim 29, wherein the adhesive, in its further-cured state, has a glass transition temperature greater than 90 degrees Celsius.

32. The vehicular camera of claim 29, wherein the adhesive, in its further-cured state, has greater than 50 Shore D hardness.

33. The vehicular camera of claim 29, wherein the adhesive is halogen-free.

34. The vehicular camera of claim 1, wherein the initial radiation curing process comprises exposure to UV light for an initial-cure time period of less than 7 seconds.

35. A vehicular camera, said vehicular camera comprising:

a lens comprising a plurality of optical elements, wherein the lens is accommodated in a lens barrel, and wherein the lens barrel comprises a cylindrical portion;

a lens holder comprising a cylindrical passageway that accommodates at least a portion of the cylindrical portion of the lens barrel;

a printed circuit board;

a CMOS imager disposed at the printed circuit board;

a flexible electrical ribbon cable with one end electrically connecting at the printed circuit board and with another distal end electrically terminating at an electrical connector of the flexible electrical ribbon cable;

wherein the lens barrel is attached at the lens holder by an adhesive and the printed circuit board is attached at the lens holder;

wherein the adhesive is initially curable in an initial radiation curing process that comprises exposure to UV light for an initial-cure time period of less than 7 seconds, and wherein the initially-cured adhesive is further curable to a further-cured strength in a secondary curing process;

wherein the adhesive is initially cured via the initial radiation curing process after the lens is brought into focus with the CMOS imager and is optically center-aligned therewith;

wherein the initially-cured adhesive, as cured via the initial radiation curing process, holds the lens optically center-aligned and in focus with the CMOS imager;

wherein, as further cured via the secondary curing process for a further-cure time period that is longer than the initial-cure time period, the further-cured adhesive maintains focus and optical center-alignment of the lens with the CMOS imager for use of said vehicular camera in a vehicle;

wherein the adhesive, in its uncured state, comprises a one-part, filled adhesive;

wherein the further-cured adhesive maintains at least 70% strength of bond after being exposed to at least one operating condition for a period of time; and

wherein the at least one operating condition comprises a temperature of 85 degrees Celsius, and wherein the period of time is greater than 1000 hours.

36. The vehicular camera of claim 35, wherein the printed circuit board is mechanically attached at the lens holder via at least one fastener.

37. The vehicular camera of claim 35, wherein the printed circuit board is mechanically attached at the lens holder via two screw fasteners.

38. The vehicular camera of claim 35, wherein the at least one operating condition comprises a humidity of 85% RH.

39. The vehicular camera of claim 35, wherein the further-cure time period is at least 30 seconds.

40. The vehicular camera of claim 39, wherein the adhesive, in its uncured state, has a viscosity at 23 degrees Celsius from about 5,000 mPa to about 150,000 mPa.

41. The vehicular camera of claim 39, wherein the adhesive comprises one selected from the group consisting of (i) a Delo OB749 adhesive, (ii) a Delo AD VE 112203 adhesive and (iii) a Delo OB787 adhesive.

42. The vehicular camera of claim 41, wherein said vehicular camera is configured for use as a rearward viewing camera of a vehicle.

43. The vehicular camera of claim 35, wherein the secondary curing process comprises at least one selected from the group consisting of (i) thermal curing, (ii) moisture curing and (iii) radiation curing.

44. The vehicular camera of claim 35, wherein the lens holder is adapted for attachment to a camera housing.

45. The vehicular camera of claim 44, wherein said vehicular camera is configured for use as a forward viewing camera of a vehicle.

46. The vehicular camera of claim 44, wherein said vehicular camera is configured for use as a forward viewing camera for an automatic high-beam control of a vehicle.

47. The vehicular camera of claim 35, wherein the adhesive bonds to at least one metal selected from the group consisting of (i) zinc and (ii) aluminum.

48. The vehicular camera of claim 47, wherein the adhesive bonds to an FR4 PCB.

49. The vehicular camera of claim 35, wherein the adhesive, in its further-cured state, has a bond shear strength greater than 1000 PSI, and wherein the adhesive, in its further-cured state, has greater than 50 Shore D hardness.

50. The vehicular camera of claim 49, wherein bond shear strength of the adhesive, in its further-cured state, reduces less than 60% at 85 degrees Celsius.

51. The vehicular camera of claim 35, wherein the adhesive, in its further-cured state, has a glass transition temperature greater than 90 degrees Celsius, and wherein the adhesive is halogen-free.

52. A vehicular camera, said vehicular camera comprising:

a lens comprising a plurality of optical elements, wherein the lens is accommodated in a lens barrel, and wherein the lens barrel comprises a cylindrical portion;

a lens holder comprising a cylindrical passageway that accommodates at least a portion of the cylindrical portion of the lens barrel;

a printed circuit board;

a CMOS imager disposed at the printed circuit board;

a flexible electrical ribbon cable with one end electrically connecting at the printed circuit board and with another distal end electrically terminating at an electrical connector of the flexible electrical ribbon cable;

wherein the printed circuit board is attached at the lens holder by an adhesive and the lens barrel is attached at the lens holder;

wherein the adhesive is initially curable in an initial radiation curing process that comprises exposure to UV light for an initial-cure time period of less than 7 seconds, and wherein the initially-cured adhesive is further curable to a further-cured strength in a secondary curing process;

wherein the adhesive is initially cured via the initial radiation curing process after the lens is brought into focus with the CMOS imager and is optically center-aligned therewith;

wherein the initially-cured adhesive, as cured via the initial radiation curing process, holds the lens optically center-aligned and in focus with the CMOS imager;

wherein, as further cured via the secondary curing process for a further-cure time period that is longer than the initial-cure time period, the further-cured adhesive maintains focus and optical center-alignment of the lens with the CMOS imager for use of said vehicular camera in a vehicle;

wherein the adhesive, in its uncured state, comprises a one-part, filled adhesive;

wherein the further-cured adhesive maintains at least 70% strength of bond after being exposed to at least one operating condition for a period of time; and

wherein the at least one operating condition comprises a temperature of 85 degrees Celsius, and wherein the period of time is greater than 1000 hours.

53. The vehicular camera of claim 52, wherein at least one selected from the group consisting of (i) the lens barrel is threadedly attached at the lens holder, (ii) the lens barrel is adhesively attached at the lens holder and (iii) the lens barrel is threadedly and adhesively attached at the lens holder.

54. The vehicular camera of claim 52, wherein the at least one operating condition comprises a humidity of 85% RH.

55. The vehicular camera of claim 52, wherein the further-cure time period is at least 30 seconds.

56. The vehicular camera of claim 55, wherein the adhesive, in its uncured state, has a viscosity at 23 degrees Celsius from about 5,000 mPa to about 150,000 mPa.

57. The vehicular camera of claim 55, wherein the adhesive comprises one selected from the group consisting of (i) a Delo OB749 adhesive, (ii) a Delo AD VE 112203 adhesive and (iii) a Delo OB787 adhesive.

58. The vehicular camera of claim 52, wherein the lens holder is adapted for attachment to a camera housing.

59. The vehicular camera of claim 52, wherein said vehicular camera is configured for use as a rearward viewing camera of a vehicle.

60. The vehicular camera of claim 59, wherein the secondary curing process comprises at least one selected from the group consisting of (i) thermal curing, (ii) moisture curing and (iii) radiation curing.

61. The vehicular camera of claim 52, wherein said vehicular camera is configured for use as a forward viewing camera of a vehicle.

62. The vehicular camera of claim 52, wherein said vehicular camera is configured for use as a forward viewing camera for an automatic high-beam control of a vehicle.

63. The vehicular camera of claim 52, wherein the adhesive bonds to at least one metal selected from the group consisting of (i) zinc and (ii) aluminum.

64. The vehicular camera of claim 63, wherein the adhesive bonds to an FR4 PCB.

65. The vehicular camera of claim 52, wherein the adhesive, in its further-cured state, has a bond shear strength greater than 1000 PSI, and wherein the adhesive, in its further-cured state, has greater than 50 Shore D hardness.

66. The vehicular camera of claim 65, wherein bond shear strength of the adhesive, in its further-cured state, reduces less than 60% at 85 degrees Celsius.

67. The vehicular camera of claim 52, wherein the adhesive, in its further-cured state, has a glass transition temperature greater than 90 degrees Celsius, and wherein the adhesive is halogen-free.