VEHICULAR CAMERA AND LENS ASSEMBLY AND METHOD OF MANUFACTURING SAME

• US 20140298642A1
• Filed: 10/24/2012
• Published: 10/09/2014
• Est. Priority Date: 03/25/2009
• Status: Active Grant

• Current Assignee: Magna Electronics Incorporated (Magna International Incorporated)
• Original Assignee: Magna Electronics Incorporated (Magna International Incorporated)
• Inventors: Sesti, Matthew C., Devota, Robert A., Lu, Yuesheng, Byrne, Steven V., Gibson, Joel S.
• Granted Patent: US 9,277,104 B2
• Time in Patent Office: Days
• US Class Current: 29/592.1
• CPC Class Codes: B60R 11/04 Mounting of cameras operative during drive; Arrangement of controls thereof relative to the vehicle
• CPC Class Codes: G02B 13/001 Miniaturised objectives for electronic devices, e.g. portable telephones, webcams, PDAs, small digital cameras G02B23/243 takes precedence
• CPC Class Codes: G02B 27/0025 for optical correction, e.g. distorsion, aberration
• CPC Class Codes: G02B 27/62 Optical apparatus specially adapted for adjusting optical elements during the assembly of optical systems
• CPC Class Codes: G02B 7/003 Alignment of optical elements G02B7/001, G02B7/002 take precedence; for mirrors G02B7/1822
• CPC Class Codes: G02B 7/02 for lenses supports for magnifying lenses G02B25/002
• CPC Class Codes: G02B 7/025 using glue
• CPC Class Codes: G02B 7/04 with mechanism for focusing or varying magnification
• CPC Class Codes: H01L 27/14618 Containers
• CPC Class Codes: H01L 27/14625 Optical elements or arrangements associated with the device
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/0002 Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
• 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
• CPC Class Codes: H04N 23/57 Mechanical or electrical details of cameras or camera modules specially adapted for being embedded in other devices
• CPC Class Codes: H04N 23/63 by using electronic viewfinders
• CPC Class Codes: Y10T 29/49002 Electrical device making

Abstract

A method of assembling a vehicular camera includes providing a lens assembly having a base portion, a lens barrel and a plurality of optical elements in the lens barrel, and providing a circuit element having a circuit board and an imaging array. An adhesive bead is dispensed at the base portion and/or circuit element. The circuit element is placed at the base portion with the adhesive bead therebetween and the optical elements are aligned with the imaging array via a six axis robotic device when the circuit element is at the base portion and in contact with the adhesive bead. The adhesive bead is cured to a first cure level via exposure of the adhesive bead to ultraviolet light. The assembly is moved to a second curing stage and the adhesive bead is cured to a second cure level via heating the adhesive bead.

Claims

1. A method of assembling a vehicular camera, said method comprising:

providing a lens assembly comprising a base portion, a lens barrel and a plurality of optical elements in said lens barrel;

providing a circuit element comprising a circuit board and an imaging array established at said circuit board;

dispensing at least one adhesive bead at one of (i) said base portion of said lens assembly and (ii) said circuit element;

placing said circuit element at said base portion of said lens assembly with said at least one adhesive bead between said circuit element and said base portion;

aligning said lens assembly with said imaging array when said circuit element is placed at said base portion and in contact with said at least one adhesive bead;

wherein aligning said lens assembly with said imaging array comprises aligning said lens assembly with said imaging array via a six axis robotic device;

curing said at least one adhesive bead to a first cure level via exposure of said at least one adhesive bead to ultraviolet light;

moving said lens assembly and said circuit element to a second curing stage and curing said at least one adhesive bead to a second cure level via heating said at least one adhesive bead to an elevated temperature for at least a selected period of time; and

attaching a housing portion to said base portion of said lens assembly to encase said circuit element and substantially sealing said housing portion and said base portion together.

2. The method of claim 1, wherein dispensing at least one adhesive bead at said base portion comprises dispensing at least four spaced apart adhesive dots at said base portion of said lens assembly.

3. The method of claim 1, wherein aligning said lens assembly with said imaging array comprises aligning said lens assembly with said imaging array via (i) translationally moving one of said imaging array and said lens assembly relative to the other of said imaging array and said lens assembly along x, y and z axes and (ii) rotationally moving one of said imaging array and said lens assembly relative to the other of said imaging array and said lens assembly about pitch, yaw and roll axes.

4. The method of claim 3, wherein providing a lens assembly comprises providing a lens assembly that is part of a camera body portion, and wherein aligning said lens assembly with said imaging array comprises positioning and aligning said circuit element at said camera body portion via said six axis robotic device.

5. The method of claim 1, wherein curing said at least one adhesive bead to a first cure level occurs after aligning said lens assembly with said imaging array to bring said optical elements of said lens assembly in focus and optically center-aligned with said imaging array.

6. The method of claim 1, wherein curing said at least one adhesive bead to a first cure level comprises curing said at least one adhesive bead to a first cure level via exposure of said at least one adhesive bead to ultraviolet light for less than about ten seconds.

7. The method of claim 6, further comprising further curing said at least one adhesive bead to a further cure level via a further exposure of said at least one adhesive bead to ultraviolet light.

8. The method of claim 7, wherein further curing said at least one adhesive bead to a further cure level comprises further curing said at least one adhesive bead to a further cure level via further exposure of said at least one adhesive bead to ultraviolet light for a period of time that is less than about twenty seconds and greater than about ten seconds.

9. The method of claim 6, wherein moving said lens assembly and said circuit element to a second curing stage comprises moving said lens assembly and said circuit element to an oven.

10. The method of claim 9, wherein curing said at least one adhesive bead to a second cure level comprises curing said at least one adhesive bead to a second cure level via heating said at least one adhesive bead in said oven to an elevated temperature of at least about 85 degrees C. for at least about five minutes.

11. The method of claim 10, wherein said at least one adhesive bead comprises an epoxy-amine adhesive.

12. The method of claim 1, wherein attaching a housing portion to said base portion of said lens assembly comprises laser welding a housing portion to said base portion of said lens assembly.

13. The method of claim 1, wherein said housing portion comprises an electrical connector configured to electrically connect to a wiring harness of a vehicle when said camera is mounted at the vehicle.

14. The method of claim 13, wherein said electrical connector is electrically connected to circuitry of said circuit element when said housing portion is attached to said base portion.

15. A method of assembling a vehicular camera, said method comprising:

providing a lens assembly comprising a base portion, a lens barrel and a plurality of optical elements in said lens barrel, wherein said base portion comprises part of a camera body portion of said vehicular camera;

providing a circuit element comprising a circuit board and an imaging array established at said circuit board;

dispensing at least one adhesive bead at one of (i) said base portion of said lens assembly and (ii) said circuit element;

providing a six axis robotic device that is operable to (i) translationally move a grasping portion of said robotic device along an x-axis, a y-axis and a z-axis and (ii) rotationally move said grasping portion about said x-axis, said y-axis and said z-axis;

placing said circuit element at said base portion of said lens assembly via said robotic device so that said at least one adhesive bead is between said circuit element and said base portion;

aligning said lens assembly with said imaging array and aligning said circuit element with said camera body portion via said robotic device when said circuit element is placed at said base portion and in contact with said at least one adhesive bead;

wherein aligning said lens assembly with said imaging array comprises aligning said lens assembly with said imaging array and aligning said circuit element with said camera body portion via (i) translationally moving one of said circuit element and said lens assembly relative to the other of said circuit element and said lens assembly along x, y and z axes and (ii) rotationally moving one of said circuit element and said lens assembly relative to the other of said circuit element and said lens assembly about pitch, yaw and roll axes;

when said imaging array and said lens assembly are aligned, at least partially curing said at least one adhesive bead; and

attaching a housing portion at said base portion of said lens assembly to encase said circuit element and substantially sealing said housing portion and said base portion together.

16. The method of claim 15, wherein at least partially curing said at least one adhesive bead occurs after aligning said lens assembly with said imaging array to bring said optical elements of said lens assembly in focus and optically center-aligned with said imaging array and after aligning said circuit element with said base portion of said lens assembly.

17. The method of claim 15, wherein aligning said lens assembly with said imaging array comprises aligning said lens assembly with said imaging array via (i) translationally moving said circuit element relative to said lens assembly along x, y and z axes and (ii) rotationally moving said circuit element relative to said lens assembly about pitch, yaw and roll axes.

18. The method of claim 15, wherein dispensing at least one adhesive bead at said base portion comprises dispensing at least four spaced apart adhesive dots at said base portion of said lens assembly.

19. The method of claim 15, wherein at least partially curing said at least one adhesive bead comprises curing said at least one adhesive bead to a first cure level via exposure of said at least one adhesive bead to ultraviolet light.

20. The method of claim 19, comprising, after curing said at least one adhesive bead to said first cure level, moving said lens assembly and said circuit element to a second curing stage and curing said at least one adhesive bead to a second cure level via heating said at least one adhesive bead to an elevated temperature for at least a selected period of time.

21. The method of claim 15, wherein attaching said housing portion to said base portion of said lens assembly comprises laser welding.

22. The method of claim 15, wherein said housing portion comprises an electrical connector configured to electrically connect to a wiring harness of a vehicle when said camera is mounted at the vehicle, and wherein said electrical connector is electrically connected to circuitry of said circuit element when said housing portion is attached to said base portion.

23. A method of assembling a vehicular camera, said method comprising:

providing a lens assembly comprising a base portion, a lens barrel and a plurality of optical elements in said lens barrel, wherein said base portion comprises part of a camera body portion of said vehicular camera;

providing a circuit element comprising a circuit board and an imaging array established at said circuit board;

dispensing at least one adhesive bead at one of (i) said base portion of said lens assembly and (ii) said circuit element; and

wherein dispensing at least one adhesive bead comprises dispensing at least four spaced apart adhesive dots at one of (i) said base portion of said lens assembly and (ii) said circuit element;

providing a six axis robotic device that is operable to (i) translationally move a grasping portion of said robotic device along an x-axis, a y-axis and a z-axis and (ii) rotationally move said grasping portion about said x-axis, said y-axis and said z-axis;

placing said circuit element at said base portion of said lens assembly via said robotic device so that said at least one adhesive bead is between said circuit element and said base portion;

aligning said lens assembly with said imaging array and aligning said circuit element with said camera body portion via said robotic device when said circuit element is placed at said base portion and in contact with said at least one adhesive bead;

wherein aligning said lens assembly with said imaging array comprises aligning said lens assembly with said imaging array and aligning said circuit element with said camera body portion via (i) translationally moving one of said circuit element and said lens assembly relative to the other of said circuit element and said lens assembly along x, y and z axes and (ii) rotationally moving one of said circuit element and said lens assembly relative to the other of said circuit element and said lens assembly about pitch, yaw and roll axes;

at least partially curing said at least one adhesive bead after aligning said lens assembly with said imaging array to bring said optical elements of said lens assembly in focus and optically center-aligned with said imaging array;

attaching a housing portion at said base portion of said lens assembly to encase said circuit element and substantially sealing said housing portion and said base portion together; and

wherein said housing portion comprises an electrical connector configured to electrically connect to a wiring harness of a vehicle when said camera is mounted at the vehicle, and wherein attaching said housing portion to said base portion includes electrically connecting said electrical connector to circuitry of said circuit element.