Vehicular camera and lens assembly
First Claim
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.
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Accused Products
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.
140 Citations
52 Claims
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1. A process for providing a vehicular camera suitable for vehicular use, said process comprising:
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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. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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17. A process for providing a vehicular camera suitable for vehicular use, said process comprising:
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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 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 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; wherein at least one of (i) said multi-axis positioning device comprises a multi-axis robot and said optical center-alignment and focusing of said lens optics relative to said imager is achieved robotically or (ii) 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; 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. - View Dependent Claims (18, 19, 20, 21, 22, 23, 24)
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25. A process for providing a vehicular camera suitable for vehicular use, said process comprising:
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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 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 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 first time period is seven seconds or less; 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; 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; 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. - View Dependent Claims (26, 27, 28, 29)
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30. A process for providing a vehicular camera suitable for vehicular use, said process comprising:
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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; said cylindrical receiving portion of said front camera housing comprising a cylindrical opening; inserting said cylindrical barrel portion of said lens assembly at least partially into the cylindrical opening of 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 printed circuit board and/or said front camera housing, 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 printed circuit board and/or said front camera housing, and with the adhesive in its uncured state between and contacting said printed circuit board and said front camera housing, adjusting said lens assembly relative to said front camera housing 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; 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; 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. - View Dependent Claims (31, 32, 33, 34, 35)
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36. A process for providing a vehicular camera suitable for vehicular use, said process comprising:
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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 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 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; joining a rear camera housing to said front camera housing to substantially encase said printed circuit board; 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; 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. - View Dependent Claims (37, 38, 39, 40, 41, 42, 43, 44)
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45. A process for providing a vehicular camera suitable for vehicular use, said process comprising:
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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; wherein said lens optics comprises a plurality of optical elements, and 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; 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; attaching said printed circuit board to said front camera housing; disposing an adhesive in its uncured state at said cylindrical receiving portion of said front camera housing and/or a portion of said cylindrical barrel portion of said lens assembly; after disposing the adhesive in its uncured state at said cylindrical receiving portion of said front camera housing and/or said portion of said cylindrical barrel portion of said lens assembly, and with the adhesive in its uncured state between and contacting said cylindrical receiving portion of said front camera housing and said portion of said cylindrical barrel portion of said lens assembly, adjusting said front camera housing and said lens assembly 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 cylindrical receiving portion of said front camera housing and said portion of said cylindrical barrel portion of said lens assembly; wherein, with the adhesive disposed in its uncured state between and contacting said cylindrical receiving portion of said front camera housing and said portion of said cylindrical barrel portion of said lens assembly, 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 lens assembly 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 lens assembly adhesively attached thereto, to the secondary curing process and 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; wherein, with said lens assembly 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; and joining a rear camera housing to said front camera housing to substantially encase said printed circuit board. - View Dependent Claims (46, 47, 48, 49, 50, 51, 52)
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Specification