Method for manufacturing a camera for a vehicle and camera for a vehicle

Abstract

Method for manufacturing a camera (200, 300) for a vehicle, wherein the camera (200, 300) comprises a printed circuit board (107) with an image sensor (108) arranged thereon, a lens holder (105), and a lens (101) with a lens housing (102) and at least one optical lens (103); and wherein the method comprises the steps: inserting (111) the lens (101) into the lens holder (105) to such an extent that the lens housing (102) and the lens holder (105) are at least partially arranged against each other within a contact area (112); and mechanically deforming (211, 311) a region (110) of the lens holder (105) within the contact area (112) such that the lens (101) is tightly clamped in place.

Description

[0001] The present invention relates to a method for manufacturing a camera for a vehicle and a camera for a vehicle according to the independent claims. State of the art

[0002] Cameras for driver assistance systems are usually made up of several parts that are joined together in such a way that the camera is watertight and airtight.

[0003] DE 10 2023 204 760 discloses a method for producing a camera, comprising an image sensor and a multi-part housing for accommodating the image sensor, wherein the housing has a metallic first housing part and a metallic second housing part, and wherein the two housing parts are joined by means of a circumferential flanging.

[0004] A lens can be attached to a camera's front housing using adhesive or a screw thread against a screw stop in the housing or lens mount. If the resulting interface between the lens and the housing or lens mount is to be sealed against external influences such as water, dust, or similar, this can be achieved, for example, by selecting a suitable adhesive or by inserting a sealing element into the interface.

[0005] The present invention is concerned with the task of providing a camera with the simplest possible, but also the tightest possible connection of the lens to a front housing or a lens holder. Disclosure of the invention

[0006] The present invention is based on a method for producing a camera for a vehicle, wherein the camera comprises a circuit board with an image sensor arranged thereon, a lens holder, and a lens with a lens housing and at least one optical lens. The method comprises the following steps: inserting the lens into the lens holder to such an extent that the lens housing and the lens holder are at least partially arranged against one another within a contact area; and mechanically deforming a region of the lens holder within the contact area such that the lens is tightly caulked and fixed.

[0007] The lens holder can be formed as part of a camera front housing. In addition to the image sensor, other electronic components can also be arranged on the circuit board. The image sensor is, in particular, arranged on the circuit board so that it faces the lens. The camera can also have a rear housing. The camera can also have a housing cover. The camera can also have a connector for electronic connection. The mechanical deformation is primarily cold-mechanical. The mechanical deformation of the lens holder occurs primarily around the lens. The mechanical deformation of the lens holder occurs primarily around the lens. A closed structure can form.

[0008] The advantage of the invention is that no thermal stresses occur during mechanical deformation, as occurs, for example, in a welding process. Furthermore, neither the lens housing nor the lens mount requires a costly thread. Furthermore, the mechanical deformation can be carried out in a tight manner. An additional sealing element can be avoided. Due to the manufacturing process, the interior of the camera can be designed to be so tight that no water, air, dust, or similar substances can penetrate.

[0009] In an advantageous embodiment, the method may comprise the further step of optically aligning the lens to the image sensor after the step of inserting the lens into the lens holder and before the step of mechanical deformation.

[0010] In an advantageous embodiment, it is provided that the lens housing has a radially outwardly projecting flange, and wherein the lens holder has a recess on a side facing away from the image sensor, and wherein when the lens is inserted into the lens holder, the flange comes to lie in the recess of the lens holder. The flange can also be referred to as a lens collar. The recess of the lens holder is formed in particular in an interior of the lens holder. The recess of the lens holder faces in particular the lens. The recess of the lens holder is in particular L-shaped. In this case, the longer leg of the L is aligned in particular parallel to the lens housing and the shorter leg of the L is aligned in particular parallel to the circuit board.The area of ​​the lens holder that is mechanically deformed is located in particular in the immediate vicinity of the recess. In this embodiment, the contact area includes the flange, the recess, and the area of ​​the lens holder that is mechanically deformed.

[0011] The advantage of this design is that only the area of ​​the lens holder located in the contact area is mechanically deformed. Sufficient lens holder material is available in the contact area to provide mechanical deformation to secure and seal the camera. The design of the lens housing ensures that the optical properties of the lens are not, or only very slightly, affected by the mechanical deformation.

[0012] In a further advantageous embodiment, the area of ​​the lens holder is mechanically deformed to form a caulking contour. The caulking contour is particularly designed to extend circumferentially around the lens. The caulking contour is particularly designed to ensure that mechanical customer interfaces, such as contact surfaces of the housing in the consumer compartment, are not disrupted.

[0013] The advantage of this design is that with the help of the proposed caulking contour, a tight, in particular water-, air- and dust-tight connection can be created between the lens holder and the lens housing.

[0014] In a further advantageous embodiment, the lens has a groove, and during the mechanical deformation step, the region of the lens holder is deformed into the groove. This ensures, in particular, that the material deformation into the groove of the lens does not impair the optical behavior of the lens.

[0015] The advantage of this design is that the lens can be manufactured cost-effectively. For example, the lens can be manufactured more cost-effectively than without a flange. Furthermore, the space required on the lens holder can be reduced.

[0016] In a further advantageous embodiment, the mechanical deformation is performed by means of a caulking tool having at least one wedge-shaped caulking mandrel. This advantageously allows the lens to be effectively caulked in place.

[0017] In a further advantageous embodiment, the mechanical deformation is performed using an annular caulking tool, which is placed around the lens and moved along an optical axis of the lens toward the image sensor. In other words, the mechanical deformation occurs in a linear process. This advantageously allows the lens to be caulked tightly and very simply.

[0018] Depending on the location of an interface for optically aligning the lens to the image sensor, the image sensor may already be attached to the lens holder or may only be attached to the lens holder after the lens has been attached.

[0019] In a further advantageous embodiment, the mechanical deformation is carried out by means of a caulking tool comprising at least three units that rest at specific points on the area of ​​the lens holder, and wherein the deformation is carried out by means of a rolling process. In other words, the mechanical loading is applied at specific points, thus advantageously significantly reducing the force. The process is carried out in a rotating manner until the desired, tight caulking contour in the form of a rolling contour is produced.

[0020] The invention further relates to a camera for a vehicle, comprising a circuit board with an image sensor arranged thereon; a lens holder; and a lens with a lens housing and at least one optical lens. The lens housing and the lens holder are arranged at least partially adjacent to one another within a contact area. A region of the lens holder within the contact area is mechanically deformed such that the lens is tightly caulked and fixed.

[0021] Thanks to its tightly caulked mounting, the camera is designed to be so sealed that no water, air, dust, or similar contaminants can penetrate. An additional sealing element is not required, and a costly thread is also avoided.

[0022] In an advantageous embodiment, it is provided that the lens housing has a radially outwardly projecting flange, and wherein the lens holder has a recess on a side facing away from the image sensor, and wherein the flange is arranged lying in the recess of the lens holder.

[0023] In a further advantageous embodiment, it is provided that the region of the lens holder is mechanically deformed in such a way that a caulking contour is formed.

[0024] It is understood that the features mentioned above and those to be explained below can be used not only in the combination specified in each case, but also in other combinations or on their own, without departing from the scope of the present invention. Drawings

[0025] Embodiments of the present invention are explained in more detail below with reference to the accompanying drawings. Like reference numerals in the figures denote like or equivalent elements. They show: Fig. 1 shows an embodiment of a method for manufacturing a camera after inserting the lens into the lens holder; Fig. 2 shows a first embodiment of a mechanical deformation of a region of the lens holder and a camera manufactured in this way; Fig. 3 shows a second embodiment of a mechanical deformation of a region of the lens holder and a camera manufactured in this way; Fig. 4 shows another embodiment of a method for manufacturing a camera after inserting the lens into the lens holder; Fig. 5 shows a further embodiment of a mechanical deformation of a region of the lens holder and a camera manufactured in this way.

[0026] Fig. 1 shows an embodiment of a method for manufacturing a camera after inserting 111 a lens 101 into a lens holder 105. The camera to be manufactured comprises a circuit board 107 with an image sensor 108 arranged thereon, the lens holder 105, and the lens 101 with a lens housing 102, which in this example has two optical lenses 103. In the example, the lens 101 was inserted into the lens holder 105 to such an extent that the lens housing 102 and the lens holder 105 are at least partially arranged adjacent to one another within the contact area 112.

[0027] In this specific example, this arrangement is realized as follows: the lens housing 102 has a radially outwardly projecting flange 104. Furthermore, the lens holder 105 has a recess 106 on a side facing away from the image sensor. After the lens 101 is inserted 111 into the lens holder 105, the flange 104 comes to rest in the recess 106 of the lens holder 105.

[0028] In this example, the recess 106 of the lens holder 105 is formed in an interior of the lens holder 105 and faces the lens 101. The recess 106 is L-shaped here. The longer leg of the L is aligned parallel to the lens housing 102, and the shorter leg of the L is aligned parallel to the circuit board 107.

[0029] In this example, the contact area 112 comprises the flange 104, the recess 106 and a region 110 of the lens holder 105, which is mechanically deformed in a further step 211, 311 of the method for manufacturing the camera. This will be explained below in the Fig. 2 and Fig. 3 is explained in more detail.

[0030] In the Fig. 1 also shows a beam path 109 of light passing through the lens 101 onto the image sensor 108. The method for manufacturing a camera presented here can, after step 111 of inserting the lens 101 into the lens holder 105, comprise a further step of optically aligning the lens 101 with the image sensor 108. In such a step, in particular, the lens 101 and the image sensor 108 are aligned with one another such that a sharp image can be captured when light strikes the image sensor 108.

[0031] Fig. Figure 2 shows a first embodiment of a mechanical deformation 211 of a region 110 of the lens holder 105 and a camera 200 manufactured in this way. In step 211, the lens holder 105 is mechanically deformed within the contact region 112 such that the lens 101 is tightly caulked. In particular, a caulking contour 203 is formed.

[0032] The mechanical deformation 211 is carried out by means of the caulking tool 201, which has a wedge-shaped caulking mandrel. More precisely, the caulking tool 201 in the case shown here is an annular caulking tool, which has a wedge-shaped caulking mandrel on one side. The wedge-shaped caulking mandrel can be formed circumferentially around the annular caulking tool on this side. The caulking tool 201 is placed around the lens 101 and moved along an optical axis of the lens 101 toward the image sensor 108. The mechanical deformation step is carried out in a single movement, force-displacement monitored, in one process step. The movement is symbolized by the double arrow 202.

[0033] Fig. Figure 3 shows a second embodiment of a mechanical deformation 311 of a region 110 of the lens holder 105 and a camera 200 manufactured in this way. In step 311, the lens holder 105 is mechanically deformed within the contact region 112 such that the lens 101 is tightly caulked and fixed. In particular, a caulking contour 303 is formed.

[0034] The mechanical deformation 311 is carried out by means of a caulking tool 301, which has at least three units that rest pointwise on the area 110 of the lens holder. Fig. Two of these three units can be seen in Figure 3. The mechanical deformation 311 itself is carried out by means of a rolling process, which is symbolized by the arrow 302. In other words, the mechanical deformation 311 is carried out in a rotating manner. For this purpose, either the caulking tool 301 or the camera to be manufactured can be rotated.

[0035] Fig. 4 shows a further embodiment of a method for producing a camera after inserting 411 a lens 101 into a lens holder 105. Here, too, the camera to be produced comprises a circuit board 107 with an image sensor 108 arranged thereon, the lens holder 105, and the lens 101 with a lens housing 102, which, in this example, has two optical lenses 103. In the example, the lens 101 was inserted into the lens holder 105 to such an extent that the lens housing 102 and the lens holder 105 are at least partially arranged adjacent to one another within the contact area 112.

[0036] The lens 101 shown here has a groove 401. More precisely, in the example shown, the lens housing 102 has a groove 401. The contact area 112 in this example comprises the groove 401 and a region 110 of the lens holder 105, which is mechanically deformed in a further step 511 of the method for manufacturing the camera. This will be explained below in Fig. 5 is explained in more detail.

[0037] In the Fig. 4 also shows a beam path 109 of light passing through the lens 101 onto the image sensor 108. The method for manufacturing a camera presented here may, after step 311 of inserting the lens 101 into the lens holder 105, include a further step of optically aligning the lens 101 with the image sensor 108.

[0038] Fig. 5 shows the embodiment from Fig. 4, now with the step of mechanically deforming a region 110 of the lens holder 105 and a camera 500 manufactured in this way. In step 511, the lens holder 105 is thus mechanically deformed within the contact region 112 such that the lens 101 is tightly caulked. In particular, a caulking contour 503 is formed. The mechanical deformation 211 is performed by means of the caulking tool 501, which is shown schematically here. The caulking tool 501 can be an annular caulking tool. The caulking tool 501 can have a wedge-shaped caulking mandrel. The caulking tool 501 is placed around the lens 101 and moved radially toward the lens holder 105. The movement is symbolized by the arrow 502.

[0039] It should be noted that the components of the cameras to be manufactured shown here are purely schematic. Their geometric design may differ from that shown in the Fig. 1 to 5. Furthermore, the cameras manufactured may contain additional components such as a single- or multi-part housing, additional electronic components on the circuit board, a housing cover, a connector, and the like. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] DE 10 2023 204 760

[0003]

Claims

[1] A method for manufacturing a camera (200, 300) for a vehicle, wherein the camera (200, 300) comprises a circuit board (107) with an image sensor (108) arranged thereon, a lens holder (105), and a lens (101) with a lens housing (102) and at least one optical lens (103); and wherein the method comprises the steps: • Inserting (111, 411) the lens (101) into the lens holder (105) to such an extent that the lens housing (102) and the lens holder (105) are at least partially arranged against one another within a contact area (112); and • Mechanical deformation (211, 311, 511) of a region (110) of the lens holder (105) within the contact region (112) such that the lens (101) is fixed in a tightly caulked manner. [2] Method according to claim 1, wherein the lens housing (102) has a radially outwardly projecting flange (104), and wherein the lens holder (105) has a recess (106) on a side facing away from the image sensor (108), and wherein upon insertion (111) of the lens (101) into the lens holder (105), the flange (104) comes to lie in the recess (106) of the lens holder (105). [3] Method according to claim 1 or 2, wherein the region (110) of the lens holder (105) is mechanically deformed such that a caulking contour (203, 303, 503) is formed. [4] Method according to one of the preceding claims, wherein the lens (101) has a groove (401), and wherein in the step of mechanical deformation (511) the region (110) of the lens holder (105) is deformed into the groove (401). [5] Method according to one of the preceding claims, in which the mechanical deformation (211) is carried out by means of a caulking tool (201, 301, 501) which has at least one wedge-shaped caulking mandrel. [6] Method according to claim 4 or 5, wherein the mechanical deformation (211) is carried out by means of an annular caulking tool (201) which is placed around the lens (101) and is moved along an optical axis of the lens (101) in the direction of the image sensor (108). [7] Method according to claim 4 or 5, wherein the mechanical deformation (211) is carried out by means of a caulking tool (301) which has at least three units which rest pointwise on the region (110) of the lens holder and wherein the deformation is carried out by means of a rolling process. [8] Camera (200, 300, 500) for a vehicle comprising: • a circuit board (107) with an image sensor (108) arranged thereon; • a lens holder (105); and • a lens (101) with a lens housing (102) and at least one optical lens (103); • wherein the lens housing (102) and the lens holder (105) are arranged at least partially against each other within a contact area (112); and • wherein a region (110) of the lens holder (105) within the contact region (112) is mechanically deformed in such a way that the lens (101) is fixed in a tightly caulked manner. [9] Camera (200, 300) according to claim 8, wherein the lens housing (102) has a radially outwardly projecting flange (106), and wherein the lens holder (105) has a recess (106) on a side facing away from the image sensor (108), and wherein the flange (106) is arranged lying in the recess (106) of the lens holder (105). [10] Camera (200, 300, 500) according to claim 8 or 9, wherein the region (110) of the lens holder (105) is mechanically deformed such that a caulking contour (203, 303, 503) is formed.

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