Camera for motor vehicle and method for assembling camera

Abstract

The invention relates to a camera for a motor vehicle, comprising: a lens having at least one optical lens; the camera comprises a camera lens and a camera shell, and the camera lens is fixed on the camera shell; a printed circuit board having an image sensor arranged on the printed circuit board, in which the image sensor faces the lens and is optically oriented toward the lens; and a carrier element which is fastened on the printed circuit board on a side of the printed circuit board facing away from the image sensor. The camera further comprises at least one beam element which is fastened by means of a laser-welded connection at a contact point in contact with the carrier element and at a contact point in contact with the camera housing.

Description

TECHNICAL FIELD

[0001] The invention relates to a camera for a motor vehicle and to a method for assembling a camera. BACKGROUND

[0002] DE 10 2022 211 411 A1 discloses a camera for a motor vehicle, comprising: a lens having at least one optical lens; a camera housing, wherein the lens is fixed on the camera housing; a printed circuit board having an image sensor arranged on the printed circuit board, wherein the image sensor faces the lens and is optically oriented towards the lens. Herein, the camera additionally comprises: a carrier element fastened on the printed circuit board on a side of the printed circuit board facing away from the image sensor by means of at least one soldered connection, and wherein the carrier element is constructed such that a gap is configured between the camera housing and the carrier element; and at least one gap bridging element fastened at a contact point in contact with the carrier element and at a contact point in contact with the camera housing by means of a laser-welded connection. SUMMARY

[0003] The invention starts from a camera for a motor vehicle. The camera comprises: a lens having at least one optical lens; a camera housing, wherein the lens is fixed on the camera housing; and a printed circuit board having an image sensor arranged on the printed circuit board, wherein the image sensor faces the lens and is optically oriented towards the lens (in optical alignment with the lens).

[0004] In addition, the camera comprises a carrier element fastened on the printed circuit board on a side of the printed circuit board facing away from the image sensor.

[0005] According to the invention, the camera additionally comprises at least one crossbeam element fastened at a contact point in contact with the carrier element and at a contact point in contact with the camera housing by means of a laser-welded connection.

[0006] The lens can be screwed into the camera housing for fixation. Alternatively, the camera can have at least one soldered or soldered connection for fixing the lens on the camera housing.

[0007] The lens can have a plurality of optical lenses. The optical lenses can be configured as a lens stack. At least one optical lens can be arranged in a lens housing of the lens. Herein, the lens housing is fixed on the camera housing. Alternatively, the camera housing and the lens housing can be connected to one another as a one-piece component. In this case, at least one lens of the lens is arranged in a region provided for this purpose of the camera housing.

[0008] In addition, the camera can have a housing cover. The housing cover can be connected to the camera housing on the side of the camera housing facing away from the lens. The camera housing and the housing cover can be connected to one another in a material-locked or form-locked manner, such that the camera is protected against the ingress of media from the surroundings of the camera. The camera housing and the housing cover can be connected to one another in a material-locked or form-locked manner.

[0009] In particular, the printed circuit board is configured for receiving the image sensor and the carrier element. The printed circuit board can receive further components, such as a plug of the camera, and further electronic components. The image sensor is oriented toward the lens, which in particular means that, during the method for mounting the camera module, the image sensor has been arranged in the camera housing in such a way that the image projected onto the image sensor through the lens has the best possible quality. This is explained in more detail below when describing the method for mounting the camera according to the application.

[0010] The carrier element can be configured in such a way that at least a portion of the carrier element is arranged lying on the printed circuit board and is fastened thereon. Alternatively, the printed circuit board can have at least one through-opening and / or at least one recess into which at least a portion of the carrier element extends and is fastened thereon. The carrier element is fastened on the printed circuit board, in particular by means of a material-locked or form-locked connection. The carrier element is fastened on the printed circuit board, in particular by means of a soldered connection. The carrier element can be understood as an interface to the cross-member element.

[0011] The laser-welded connection can be configured in a point-like or line-like manner. The laser-welded connection allows a material-locked connection between the cross-member element and the carrier element and between the cross-member element and the camera housing.

[0012] An advantage of the application is that adhesive material connections in the camera can be avoided. Adhesive material connections have the disadvantage of unfavorable properties due to swelling upon temperature fluctuations, swelling due to moisture and / or aging of their properties over time. By avoiding this type of adhesive material connection in the camera presented here, it can be achieved that the optical orientation of the image sensor toward the lens can be kept constant. In this way, for example, a change in the distance between the image sensor and the lens and the accompanying defocusing can be avoided even in the case of temperature fluctuations, moisture or over time. The connection of the lens to the camera housing and the connection of the printed circuit board to the camera housing are designed to be very robust here.

[0013] Advantageously, the cross member element can bridge the tolerances between the oriented printed circuit board and the camera housing. In order to be able to achieve the desired orientation of the image sensor towards the lens, the printed circuit board is dimensioned in particular such that there is a spacing between the printed circuit board and the part of the camera housing which surrounds the printed circuit board. Thereby, the necessary movement of the image sensor within the camera housing when orienting the image sensor can be ensured. After the orientation of the image sensor towards the lens, the cross member element can be positioned on the carrier element such that bridging of such a spacing is possible. The laser-welded connections between the cross member element and the carrier element and between the cross member element and the camera housing can achieve a permanent fixing of these components and thus a permanent fixing of the optical properties of the camera.

[0014] In an advantageous configuration, the cross member element is arranged parallel to the printed circuit board and is arranged to extend obliquely from a first side of the printed circuit board to an opposite side of the printed circuit board. If the printed circuit board has a quadrangular basic structure, for example, the cross member element is arranged in particular to extend from one corner of the printed circuit board to an obliquely opposite corner of the printed circuit board. By means of this oblique extension, the stability of the mutually fastened components can be advantageously significantly improved. Thereby, the camera becomes even more robust.

[0015] In another advantageous configuration, the cross member element has a circular ring-shaped region, the contact points with the carrier element being located on the circular ring-shaped region, and wherein two extensions extend from the circular ring-shaped region, the contact points with the camera housing being located on the ends of the two extensions.

[0016] In particular, the opening of the circular ring-shaped region can be configured as a receptacle for a plug of the camera. In other words, the plug of the camera can pass through the opening of the circular ring-shaped region. Advantageously, the circular ring-shaped region can provide sufficient contact possibilities with the carrier element even with the plug in order to be able to achieve a stable connection between the cross member element and the carrier element as far as possible. Advantageously, the two extensions can in turn achieve a stable connection with the camera housing.

[0017] In another advantageous configuration, the contours of the ends of the two extensions are adapted to the geometry of the camera housing. If the two ends, for example, protrude into two corners of a quadrangularly configured camera housing, these ends can be correspondingly bevelled ​The end portions can be configured bevelled such that the end portions of the cross member element fit into the corners of the camera housing. In other words, only a very small spacing is formed as far as possible between the end portions of the cross member element and the camera housing. The laser-welded connection can be formed in a region of this spacing. Advantageously, a particularly robust connection between the cross member element and the camera housing can thus be achieved.

[0018] In an advantageous configuration of the application, it is provided that the carrier element has a flat plate which is configured parallel to the printed circuit board. The flat plate has a longitudinal extent which is smaller than, equal to or larger than the extent of the printed circuit board along an axis parallel to the longitudinal extent. Advantageously, the profile of the carrier element thus serves as an interface to the cross member element.

[0019] In particular, the longitudinal extent is smaller than the extent of the printed circuit board. This configuration has the advantage that the carrier element can be designed more sparingly in terms of material. In particular, the longitudinal extent of the flat plate is so large that the cross member element is at least partially lapped over the plate. Advantageously, the flat plate thus forms a support surface for at least a portion of the cross member element. It can thus be advantageously achieved that the cross member element is stably arranged on the carrier element. In particular, the longitudinal extent of the flat plate is so large that the laser-welded connection can be configured at a contact point with the carrier element. It can thus be advantageously achieved that the connection between the cross member element and the carrier element is stably configured.

[0020] In another advantageous configuration of the application, it is provided that the carrier element additionally comprises two legs which are configured to extend from the longitudinal sides of the flat plate towards the printed circuit board, respectively, and wherein at least two legs are fastened on the printed circuit board. Here, the fastening is achieved in particular by means of a solder connection.

[0021] For example, the at least two legs are configured such that they each have an arc-shaped section from the longitudinal side of the flat plate, respectively, and have a straight section from the arc-shaped section, which is configured perpendicular to the printed circuit board and extends towards the printed circuit board. Here, the carrier element can in particular have a leg on each longitudinal side, respectively. For example, the respective leg on each longitudinal side can be configured to extend over a large part of the longitudinal side of the flat plate to the right and to the left from the centre of the longitudinal side of the flat plate, respectively. Alternatively, the carrier element can have a plurality of legs on each longitudinal side, respectively.

[0022] This configuration has the advantage that the entire flat plate is not fastened on the printed circuit board in a planar manner. Here, the solder connection is configured on the at least two legs in a material-saving manner.

[0023] In another advantageous embodiment of the application, the camera is additionally provided with an electrical plug which is configured for electrical connection to the printed circuit board. Here, the carrier element and the cross member element each have an opening through which the plug passes.

[0024] In particular, the flat plate of the carrier element has an opening through which the plug passes. Here, the opening is preferably arranged in the center of the flat plate. In particular, the ring-shaped region of the cross member element forms an opening. Here, the plug can advantageously supply the printed circuit board with electrical energy. In addition, the plug can be configured such that data received by means of the image sensor can be transmitted. Here, advantageously, the openings of the carrier element and of the cross member element enable the connection between the printed circuit board and the plug. In addition, the openings can also serve as guide elements for the plug.

[0025] In another advantageous embodiment of the application, the carrier element and / or the cross member element is / are composed of sheet metal. In particular, the carrier element is composed of stable sheet metal. In particular, the cross member element is composed of stable sheet metal.

[0026] The advantage of this embodiment is that mechanical loads can be well received. Furthermore, the manufacture of the carrier element and / or of the cross member element can be easily realized. The carrier element and / or the cross member element can also be lightweight.

[0027] In addition, the application starts from a method for assembling a camera. The method has the following steps: providing a preassembly consisting of a camera housing and a lens which is fixed on the camera housing; providing a printed circuit board which has an image sensor arranged on the printed circuit board and a carrier element which is fastened on the printed circuit board on the side of the printed circuit board which faces away from the image sensor; positioning the printed circuit board in the camera housing such that the image sensor faces the lens; orienting the image sensor optically towards the lens; positioning at least one cross member element on the carrier element; and fastening the cross member element at a contact point on the carrier element and at a contact point on the camera housing by means of a laser-welded connection.

[0028] The cross member element comes into contact with the camera housing in particular by means of a translational movement and a rotational movement towards the camera housing when it is positioned on the carrier element.

[0029] Here, the carrier element is fastened on the printed circuit board in particular by means of at least one soldered connection.

[0030] In particular, the camera as described above can be installed by means of the method.

[0031] In the step of optically orienting the image sensor towards the lens, the image sensor is oriented towards the lens fixed in the camera housing. For this purpose, during assembly, the image sensor is advantageously actively operated, wherein the obtained imaging of test images taken via the fixed lens is automatically analyzed with regard to the sharpness in different image segments and for different positioning. Based on the contrast variation curve determined by the image processing, the final positioning of the image sensor is carried out. The final positioning of the image sensor is thus achieved in such a way that the predefined criteria for the image quality are met over the entire image area.

[0032] Preferably, the optical orientation is carried out by means of a computer-controlled mechanical calibration unit. Here, for the optical orientation of the image sensor towards the lens, six degrees of freedom are available, as follows:

[0033] a) The image sensor can be moved along the optical axis (z-axis) (focusing).

[0034] b) The image sensor can be moved in the image plane along a first direction (image vertical, x-axis).

[0035] c) The image sensor can be moved in the image plane along a second direction at right angles to the image vertical (image horizontal, y-axis).

[0036] d) The image sensor can be rotated about the optical axis (Z_rot).

[0037] e) A rotation of the image sensor about the image horizontal (Y_rot) can be implemented. and

[0038] f) A rotation of the image sensor about the image vertical (X_rot) can be carried out.

[0039] By optically orienting the image sensor towards the lens, the adverse effects of different tolerances of the optical and mechanical components of the camera module can be minimized. Due to the six degrees of freedom, the lens and the image sensor can be oriented very precisely towards each other. This enables the image quality of the camera module which is necessary, for example, for applications in the automotive sector.

[0040] It is to be understood that the features mentioned above and those still to be explained below can be used not only in the combinations indicated, but also in other combinations or alone, without departing from the framework of the present application. BRIEF DESCRIPTION OF DRAWINGS

[0041] In the following, embodiments of the application are explained in more detail on the basis of the attached drawings. Identical reference signs in the drawings denote identical or identically acting elements. The drawings show:

[0042] Figure 1 perspective cut view of one embodiment of a camera;

[0043] Figure 2 longitudinal cut view of this embodiment;

[0044] Figure 3 view of the camera from a first perspective with the camera cover open;

[0045] Figure 4 view of the camera from a second perspective with the camera cover open;

[0046] Figure 5 one embodiment of a method for assembling a camera. DETAILED DESCRIPTION

[0047] Figure 1 perspective cut view of one embodiment of a camera 100. Figure 2 longitudinal cut view of the same embodiment. In this example, the camera 100 comprises a lens 111 which comprises at least one optical lens 102. Here, the lens 111 additionally comprises a lens housing 103. The camera 100 additionally comprises a camera housing 104, wherein the lens 111 is fixed on the camera housing 104. Furthermore, the camera 100 comprises a printed circuit board 105 which has an image sensor 106 arranged on the printed circuit board 105. The image sensor 106 faces the lens 111 and is optically oriented towards this lens.

[0048] Additionally, the camera 100 comprises a carrier element 109 which is fastened on the printed circuit board 105 on the side of the printed circuit board 105 which faces away from the image sensor 106. For example, the carrier element 109 can be fastened on the printed circuit board 105 by means of at least one soldered connection. Furthermore, the camera 100 has at least one crossbeam element 110 which is fastened by means of a laser-welded connection at contact points which are in contact with the carrier element 109 and at contact points which are in contact with the camera housing 104. Exemplary configurations of these contact points or laser-welded connections are shown in Figure 3 and Figure 4 which are described further below.

[0049] The camera housing 104 of the camera 100 shown here is constructed such that it has a neck 104-1 in which the lens housing 103 of the lens 111 is seated. Additionally, the camera 100 has a housing cover 107. In this example, the camera housing 104 and the housing cover 107 are connected to one another on the side of the camera housing 104 which faces away from the lens 111. Furthermore, the housing cover 107 has a neck 107-1 on the side which faces away from the lens 111. As Figure 1and Figure 2 As shown, the plug 108 can be guided through the neck 107-1 to the printed circuit board 105. The carrier element 109 and the crossbeam element 110 have openings, through which the plug 108 is guided.

[0050] The first crossbeam element 110 can be constructed from sheet metal. The carrier element 109 can be constructed from sheet metal. In the example shown here, the carrier element 109 has a flat plate 109-1, which is constructed parallel to the printed circuit board 105. Here, the flat plate 109-1 has a longitudinal extent, which is smaller than the extent of the printed circuit board 105 along an axis parallel to the longitudinal extent. Furthermore, in the example shown, the carrier element 109 has two legs 109-2, which are constructed to extend from the longitudinal sides of the flat plate 109-1 towards the printed circuit board 105, respectively. The two legs 109-2 are fastened on the printed circuit board 105.

[0051] Figure 3 A view from a first perspective of the camera 100 is shown with the camera cover open. Figure 4 A view from a second perspective of the camera 100 is shown with the camera cover open. In Figure 3 and Figure 4 The specific configuration of not only the carrier element 109, but also the crossbeam element 110 can be seen in Figure 1 and Figure 2 the components of the camera 100 already described in

[0052] In the embodiment shown here, in particular the carrier element 109, which can be clearly seen in Figure 4 has a flat plate 109-1, which is constructed approximately quadrangularly. The longitudinal extent of the flat plate is smaller than the extent of the printed circuit board 105 along an axis x parallel to the longitudinal extent. In the example shown here, the crossbeam element 110 is arranged parallel to the printed circuit board 105 and is arranged to extend obliquely from a first side of the printed circuit board 105 to an opposite side of the printed circuit board 105. Here, the printed circuit board 105 is constructed quadrangularly in terms of its basic shape. Thus, in other words, the crossbeam element 110 is arranged to extend from one corner of the printed circuit board 105 (the upper left corner in Figure 4 to an obliquely opposite corner of the printed circuit board 105 (the lower right corner in Figure 4 ).

[0053] The crossbeam element 110 has a circular ring-shaped area 303, on which contact points with the carrier element 109 are located. The circular ring-shaped area 303 rests on the flat plate 109-1 of the carrier element 109. At the contact points, the crossbeam element 110 is fastened on the carrier element 109 by means of the exemplarily shown laser-welded connections 302( Figure 3 ) or 302-1 and 302-2( Figure 4 ). Here, these are point-shaped laser-welded connections. However, other geometrical shapes of the laser-welded connections are possible.

[0054] From the circular ring-shaped area 303 of the crossbeam element 110, two elongations 304 and 305 extend, on the end of which elongations contact points with the camera housing 104 are located. At the contact points, the crossbeam element 110 is fastened on the camera housing 104 by means of the exemplarily shown laser-welded connections 301( Figure 3 ) or 301-1 and 301-2( Figure 4 ). Here, these are point-shaped laser-welded connections. However, other geometrical shapes of the laser-welded connections are possible. In the example shown here, the contour of the ends of the two elongations 304 and 305 is adapted to the geometry of the camera housing 104.

[0055] Here, the arrows 401 and 402 shown in Figure 4 indicate how the crossbeam element 110 is moved into contact with the camera housing 104 by means of a translational movement (401) and a rotational movement (402) when positioned on the carrier element 109.

[0056] Figure 5 An embodiment of a method 500 for assembling a camera is shown. This can involve the camera 100 described in Figures 1 to 4 .

[0057] The method 500 starts in step 501. In step 502, a pre-assembly structure group is provided, which consists of a camera housing and a lens fixed on the camera housing. In step 503, a printed circuit board is provided, which has an image sensor arranged on the printed circuit board and a carrier element fastened on the printed circuit board on the side of the printed circuit board facing away from the image sensor. In step 504, the printed circuit board is positioned in the camera housing in such a way that the image sensor faces the lens. In step 505, the image sensor is optically oriented towards the lens. In step 506, at least one crossbeam element is positioned on the carrier element. In step 507, the crossbeam element is fastened by means of laser-welded connections at contact points on the carrier element and at contact points on the camera housing. The method 500 ends in step 508.

Claims

1. A camera (100) for a motor vehicle, the camera comprising: • Lens (111), said lens having at least one optical lens (102); • Camera housing (104), wherein the lens (111) is fixed to the camera housing (104); • A printed circuit board (105) having an image sensor (106) disposed on the printed circuit board (105), wherein the image sensor (106) faces the lens (111) and is optically oriented toward the lens; • Carrier element (109), which is fastened to the printed circuit board (105) on the side of the printed circuit board (105) opposite to the image sensor (106); The camera (100) is characterized in that it further includes: • At least one beam element (110) is fastened by laser-welded joints (301, 302) at a contact point that contacts the carrier element (109) and at a contact point that contacts the camera housing (104).

2. The camera (100) according to claim 1, wherein, The beam element (110) is arranged parallel to the printed circuit board (105) and is arranged to extend obliquely from a first side of the printed circuit board (105) to an opposite side of the printed circuit board (105).

3. The camera (100) according to claim 1 or 2, wherein, The beam element (110) has an annular region (303) where the contact point with the carrier element (109) is located on the annular region, and wherein two extensions (304, 305) extend from the annular region (303) and the contact points with the camera housing (104) are located at the ends of the two extensions.

4. The camera according to claim 3, wherein, The contours of the ends of the two extensions (304, 305) are adapted to the geometry of the camera housing (104).

5. The camera (100) according to any one of the preceding claims, wherein, The carrier element (109) has a flat plate (109-1) constructed parallel to the printed circuit board (105), wherein the flat plate (109-1) has a longitudinal extension dimension that is less than, equal to or greater than the extension dimension of the printed circuit board (105) along an axis (x) parallel to the longitudinal extension dimension.

6. The camera (100) according to claim 5, wherein, The carrier element (109) further includes two legs (109-2) configured to extend from the longitudinal side of the flat plate (109-1) toward the printed circuit board (105), and wherein the at least two legs (109-2) are fastened to the printed circuit board (105).

7. The camera (100) according to any one of the preceding claims, wherein, The camera (100) also has an electrical plug (108) configured for electrical connection to the printed circuit board (105), wherein the carrier element (109) and the beam element (110) each have an opening through which the plug (108) passes.

8. The camera (100) according to any one of the preceding claims, wherein, The carrier element (109) and / or the beam element (110) are made of sheet metal.

9. A method (500) for assembling a camera, the method comprising the following steps: • Provide (502) a pre-assembled structure assembly, which consists of a camera housing and a lens fixed to the camera housing; • Provides (503) a printed circuit board having an image sensor and a carrier element disposed on the printed circuit board, the carrier element being fastened to the printed circuit board on the side of the printed circuit board opposite to the image sensor; • Position the printed circuit board (504) in the camera housing such that the image sensor faces the lens; • Orient the image sensor optically toward the lens (505); • Position at least one beam element (506) on the carrier element; and • The beam element is fastened (507) at the contact point on the carrier element and at the contact point on the camera housing by means of laser welding connection.

Images