VEHICULAR CAMERA AND LENS ASSEMBLY

• US 20160255257A1
• Filed: 05/09/2016
• Published: 09/01/2016
• 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: Lu, Yuesheng, Byrne, Steven V., Sesti, Matthew C., Gibson, Joel S., Devota, Robert A.
• Granted Patent: US 10,270,949 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• 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 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.

Claims

1. A process for providing a vehicular camera suitable for vehicular use, said process comprising:

providing a front camera housing having a lens assembly disposed thereat;

said lens assembly including lens optics;

providing an imager disposed on a printed circuit board;

disposing an adhesive in its uncured state between 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 optical center-alignment and focusing of said lens optics relative to said imager is achieved via a multi-axis positioning device;

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; and

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.

2. The process of claim 1, wherein the secondary curing process comprises at least one of (i) thermal cure, (ii) moisture cure and (iii) radiation cure.

3. The process of claim 1, wherein said first time period is seven seconds or less.

4. The process of claim 3, wherein said second time period is greater than seven seconds.

5. The process of claim 4, wherein said second time period is greater than twenty five seconds.

6. The process of claim 1, comprising joining a rear camera housing to said front camera housing to substantially encase said printed circuit board, and wherein said rear camera housing comprises an electrical connector for electrically connecting circuitry associated with operation of said vehicular camera to electrical wiring of a vehicle.

7. The process of claim 6, 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.

8. The process of claim 1, 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.

9. The process of claim 8, 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.

10. The process of claim 1, wherein said lens assembly comprises a lens barrel, said lens barrel including said lens optics, and wherein said lens assembly secures to said front camera housing by at least one of (i) mechanical attachment, (ii) threaded connection and (iii) a cured adhesive.

11. The process of claim 1, wherein at least one of (a) a lens resolution of said lens optics is selected to meet but not substantially exceed a resolution determined from at least one of (i) the size of a display associated with said vehicular camera when said vehicular camera is mounted on a vehicle equipped with said vision system, (ii) a distance between an observer and a display associated with said vehicular camera when said vehicular camera is mounted on a vehicle equipped with said vision system, (iii) a selected point on a contrast sensitivity function and (iv) the size of the imager sensing surface, and (b) said lens optics omits achromatic lenses and employs digital chromatic correction based on a predetermined chromatic aberration measurement.

12. The process of claim 1, 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.

13. The process of claim 1, wherein 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.

14. The process of claim 1, wherein, when the adhesive is in the initially-cured state, a gap exists between the end of said lens optics and said imager.

15. The process of claim 14, wherein the gap is devoid of the adhesive.

16. The process of claim 1, wherein said lens assembly comprises a lens barrel, said lens barrel including said lens optics.

17. The process of claim 16, wherein said lens optics comprises a plurality of optical elements.

18. The process of claim 17, wherein said front camera housing comprises a cylindrical opening and wherein said lens barrel is at least partially received in said cylindrical opening of said front camera housing.

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

20. A vehicular camera provided in accordance with the process of claim 1.

21. A process for providing a vehicular camera suitable for vehicular use, said process comprising:

providing a front camera housing having a lens assembly disposed thereat;

said lens assembly including lens optics;

providing an imager disposed on a printed circuit board;

disposing an adhesive in its uncured state between 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 optical center-alignment and focusing of said lens optics relative to said imager is achieved via a multi-axis positioning device;

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; and

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, (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 (iii) when the adhesive is cured, a gap exists between the end of said lens optics and said imager.

22. The process of claim 21, wherein, when the adhesive is in the initially-cured state, a gap exists between the end of said lens optics and said imager, and wherein the gap is devoid of the adhesive.

23. The process of claim 22, wherein said lens assembly comprises a lens barrel, said lens barrel including said lens optics, and wherein said lens optics comprises a plurality of optical elements, and wherein said front camera housing comprises a cylindrical opening and wherein said lens barrel is at least partially received in said cylindrical opening of said front camera housing.

24. The process of claim 23, 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.

25. The process of claim 24, wherein said first time period is seven seconds or less.

26. The process of claim 25, wherein said vehicular camera is configured for use as a rearward viewing camera of a vehicle.

27. The process of claim 21, 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.

28. The process of claim 27, 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.

29. A vehicular camera provided in accordance with the process of claim 21.

30. A process for providing a vehicular camera suitable for vehicular use, said process comprising:

providing a front camera housing having a lens assembly disposed thereat;

said lens assembly including lens optics;

providing an imager disposed on a printed circuit board;

disposing an adhesive in its uncured state between 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 optical center-alignment and focusing of said lens optics relative to said imager is achieved via a multi-axis positioning device;

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 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, when the adhesive is in the initially-cured state, a gap exists between the end of said lens optics and said imager.

31. The process of claim 30, wherein the gap is devoid of the adhesive.

32. The process of claim 31, wherein 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.

33. The process of claim 31, wherein said vehicular camera is configured for use as a rearward viewing camera of a vehicle.

34. The process of claim 33, 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.

35. The process of claim 34, 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.

36. The process of claim 35, 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.

37. A vehicular camera provided in accordance with the process of claim 30.

38. A process for providing a vehicular camera suitable for vehicular use, said process comprising:

providing a front camera housing having a lens assembly disposed thereat;

said lens assembly including lens optics;

said front camera housing comprising a cylindrical opening;

wherein said lens barrel is at least partially received in said cylindrical opening of said front camera housing;

providing a printed circuit board;

wherein an imager is disposed on said printed circuit board;

disposing an adhesive in its uncured state between 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 optical center-alignment and focusing of said lens optics relative to said imager is achieved via a multi-axis positioning device;

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, 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, when the adhesive is in the initially-cured state, a gap exists between the end of said lens optics and said imager and wherein the gap is devoid of the adhesive.

39. The process of claim 38, wherein the secondary curing process comprises at least one of (i) thermal cure, (ii) moisture cure and (iii) radiation cure.

40. The process of claim 39, comprising joining a rear camera housing to said front camera housing to substantially encase said printed circuit board, and wherein said rear camera housing comprises an electrical connector for electrically connecting circuitry associated with operation of said vehicular camera to electrical wiring of a vehicle.

41. The process of claim 39, wherein said lens assembly comprises a lens barrel, said lens barrel including said lens optics, and wherein said lens optics comprises a plurality of optical elements, and wherein said front camera housing comprises a cylindrical opening and wherein said lens barrel is at least partially received in said cylindrical opening of said front camera housing.

42. The process of claim 41, 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.

43. A vehicular camera provided in accordance with the process of claim 38.

44. A process for providing a vehicular camera suitable for vehicular use, said process comprising:

providing a front camera housing having a lens assembly disposed thereat;

said lens assembly including lens optics;

providing an imager disposed on a printed circuit board;

disposing an adhesive in its uncured state between 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 optical center-alignment and focusing of said lens optics relative to said imager is achieved via a multi-axis positioning device;

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, when the adhesive is in the initially-cured state, a gap exists between the end of said lens optics and said imager and wherein the gap is devoid of the adhesive; and

joining a rear camera housing to said front camera housing to substantially encase said printed circuit board.

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

46. The process of claim 45, wherein said rear camera housing comprises an electrical connector for electrically connecting circuitry associated with operation of said vehicular camera to electrical wiring of a vehicle.

47. The process of claim 45, wherein said lens assembly comprises a lens barrel, said lens barrel including said lens optics, and wherein said lens assembly secures to said front camera housing by at least one of (i) mechanical attachment, (ii) threaded connection and (iii) a cured adhesive.

48. The process of claim 47, wherein the secondary curing process comprises at least one of (i) thermal cure, (ii) moisture cure and (iii) radiation cure.

49. The process of claim 48, wherein said lens assembly comprises a lens barrel, said lens barrel including said lens optics, and wherein said lens optics comprises a plurality of optical elements, and wherein said front camera housing comprises a cylindrical opening and wherein said lens barrel is at least partially received in said cylindrical opening of said front camera housing.

50. The process of claim 44, 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.

51. The process of claim 50, 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.

52. The process of claim 51, 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.

53. A vehicular camera provided in accordance with the process of claim 44.

54. A process for providing a vehicular camera suitable for vehicular use, said process comprising:

providing a front camera housing;

providing a lens assembly including lens optics;

providing an imager disposed on a printed circuit board;

attaching said printed circuit board to said front camera housing;

disposing an adhesive in its uncured state between said front camera housing and a 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 optical center-alignment and focusing of said lens optics relative to said imager is achieved via a multi-axis positioning device;

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; and

wherein, when the adhesive is in the initially-cured state, a gap exists between the end of said lens optics and said imager, and wherein the gap is devoid of the adhesive.

55. The process of claim 54, wherein said lens assembly comprises a lens barrel, said lens barrel including said lens optics, and wherein said lens optics comprises a plurality of optical elements, and wherein said front camera housing comprises a cylindrical opening and wherein said lens barrel is at least partially received in said cylindrical opening of said front camera housing.

56. The process of claim 54, 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.

57. The process of claim 56, wherein said first time period is seven seconds or less.

58. The process of claim 57, 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.

59. The process of claim 57, 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.

60. The process of claim 54, comprising joining a rear camera housing to said front camera housing to substantially encase said printed circuit board.

61. The process of claim 60, wherein said vehicular camera is configured for use as a rearward viewing camera of a vehicle.

62. The process of claim 61, wherein said rear camera housing comprises an electrical connector for electrically connecting circuitry associated with operation of said vehicular camera to electrical wiring of a vehicle.

63. The process of claim 54, wherein the adhesive, as disposed in its uncured state between said lens assembly and said front camera housing, has a thickness of up to approximately 0.75 mm.

64. A vehicular camera provided in accordance with the process of claim 54.