Vehicular camera and lens assembly

• US 9,338,334 B2
• Filed: 09/23/2013
• Issued: 05/10/2016
• 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.
• Primary Examiner(s): Collins, Darryl J
• Assistant Examiner(s): Choudhury, Mustak
• Application Number:
  US14/033,964
• Publication Number:
  US 20140022657A1
• Time in Patent Office: 960 Days
• Field of Search: 359/708, 359/808, 359/599, 359/723, 359/811, 359/819, 359/830, 359/805, 359/796, 359/786, 359/787, 348/148, 348/E5.026, 348/E5.027, 348/E5.028, 385/88, 382/104
• 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 vehicular camera includes a lens disposed at a lens holder and an imager disposed at a printed circuit board. The lens holder is one of (i) attached at the printed circuit board by a cured adhesive and (ii) attached at a holding element by a cured adhesive with the printed circuit board held by the holding element. The adhesive is initially curable in an initial radiation curing process and initially-cured adhesive is further curable to a further cured strength in a secondary thermal curing process. The adhesive is initially cured via the initial radiation curing process after the lens is brought into focus with the imager and is optically center-aligned therewith. When further cured via the secondary thermal curing process, the further-cured adhesive maintains focus and optical center-alignment of the lens with the imager for use of the camera in a vehicle.

Claims

1. A vehicular camera suitable for use on a vehicle, said vehicular camera comprising:

a lens assembly comprising a lens barrel and an attaching portion, said lens barrel including lens optics comprising a plurality of optical elements;

a front camera housing having an imager disposed thereat;

said front camera housing comprising a cylindrical opening;

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

a printed circuit board attached at said front camera housing;

wherein said imager is disposed on said printed circuit board;

wherein, with an adhesive disposed in its uncured state between said attaching portion of said lens assembly and said front camera housing, said lens assembly is adjusted 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;

wherein the adhesive is initially curable 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, and wherein the adhesive is further curable 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;

wherein, after the initial radiation curing process is completed, said lens assembly, adhesively attached to said front camera housing, is moved to the secondary curing process to further cure the adhesive to the further more cured state; and

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.

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

3. The vehicular camera of claim 1, wherein further curing the adhesive to the further more cured state comprises further curing the adhesive for at least 25 seconds.

4. The vehicular camera of claim 1, wherein a rear camera housing is joined 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, and 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.

5. The vehicular camera of claim 1, 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 lens assembly and said front camera housing after being exposed to at least one operating condition for a period of time, and wherein the at least one operating condition includes a temperature of approximately 85 degrees Celsius, and wherein the at least one operating condition includes a humidity of approximately 85%, and wherein the period of time is greater than 1000 hours.

6. The vehicular camera of claim 1, wherein the adhesive is disposed between (i) an annular surface of said attaching portion of said lens assembly and (ii) an annular surface of said front camera housing.

7. The vehicular camera 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.

8. The vehicular camera of claim 1, wherein optical center-alignment and focusing of said lens optics relative to said imager is achieved robotically.

9. The vehicular camera of claim 1, wherein the adhesive, as disposed in its uncured state between said attaching portion of said lens assembly and said front camera housing, has a thickness of up to approximately 0.75 mm.

10. The vehicular camera 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.

11. The vehicular camera of claim 10, wherein the gap is devoid of the adhesive.

12. The vehicular camera of claim 1, wherein an annular surface of said attaching portion of said lens assembly opposes an annular surface of said front camera housing, and wherein the adhesive is disposed between said (i) said annular surface of said attaching portion of said lens assembly and (ii) said annular surface of said front camera housing.

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

14. A vehicular camera suitable for use on a vehicle, said vehicular camera comprising:

a lens assembly comprising a lens barrel and an attaching portion, said lens barrel including lens optics comprising a plurality of optical elements;

a front camera housing having an imager disposed thereat;

said front camera housing comprising a cylindrical opening;

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

a printed circuit board attached at said front camera housing;

wherein said imager is disposed on said printed circuit board;

wherein, with an adhesive disposed in its uncured state between said attaching portion of said lens assembly and said front camera housing, said lens assembly is adjusted 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;

wherein the adhesive is initially curable 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, and wherein the adhesive is further curable 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;

wherein, after the initial radiation curing process is completed, said lens assembly that is adhesively attached to said front camera housing is moved to the secondary curing process to further cure 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 at least one of (i) 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 attaching portion of said lens assembly 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.

15. The vehicular camera of claim 14, 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.

16. The vehicular camera of claim 14, wherein an annular surface of said attaching portion of said lens assembly opposes an annular surface of said front camera housing when said lens barrel is partially received in said cylindrical opening of said front camera housing, and wherein the adhesive is disposed between (i) said annular surface of said attaching portion of said lens assembly and (ii) said annular surface of said front camera housing.

17. A vehicular camera suitable for use on a vehicle, said vehicular camera comprising:

a lens assembly comprising a lens barrel and an attaching portion, said lens barrel including lens optics comprising a plurality of optical elements;

a front camera housing having an imager disposed thereat;

said front camera housing comprising a cylindrical opening;

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

a printed circuit board attached at said front camera housing;

wherein said imager is disposed on said printed circuit board;

wherein, with an adhesive disposed in its uncured state between said attaching portion of said lens assembly and said front camera housing, said lens assembly is adjusted 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;

wherein the adhesive is initially curable 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, and wherein the adhesive is further curable 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;

wherein, after the initial radiation curing process is completed, said lens assembly that is adhesively attached to said front camera housing is moved to the secondary curing process to further cure 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;

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.

18. The vehicular camera of claim 17, wherein the gap is devoid of the adhesive.

19. The vehicular camera of claim 18, wherein the adhesive, as disposed in its uncured state between said attaching portion of said lens assembly and said front camera housing, has a thickness of up to approximately 0.75 mm.

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

21. A vehicular camera suitable for use on a vehicle, said vehicular camera comprising:

a lens assembly comprising a lens barrel and an attaching portion, said lens barrel including lens optics comprising a plurality of optical elements;

a front camera housing having an imager disposed thereat;

said front camera housing comprising a cylindrical opening;

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

a printed circuit board attached at said front camera housing;

wherein said imager is disposed on said printed circuit board;

wherein, with an adhesive disposed in its uncured state between said attaching portion of said lens assembly and said front camera housing, said lens assembly is adjusted 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;

wherein the adhesive is initially curable 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, and wherein the adhesive is further curable 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;

wherein, after the initial radiation curing process is completed, said lens assembly that is adhesively attached to said front camera housing is moved to the secondary curing process to further cure 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;

wherein an annular surface of said attaching portion of said lens assembly opposes an annular surface of said front camera housing when said lens barrel is partially received in said cylindrical opening of said front camera housing, and wherein the adhesive is disposed between (i) said annular surface of said attaching portion of said lens assembly and (ii) said annular surface of said front camera housing; 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.

22. The vehicular camera of claim 21, wherein the secondary curing process comprises at least one of (i) thermal cure and (ii) moisture cure.

23. The vehicular camera of claim 22, wherein a rear camera housing is joined 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.