Camera device and method for producing a camera device

Abstract

A camera device comprises a lens unit having a hermetically sealed housing and a plurality of optical lenses arranged in the housing. An optically adaptive unit with at least one optical lens is arranged outside the housing. An actuator unit can move at least one component of the optically adaptive unit relative to the lens unit. A sensor unit can detect light after passing through the lens unit and the optically adaptive unit.

Description

[0001] R.414585

[0002] - 1 -

[0003] Description

[0004] title

[0005] Camera device and method for manufacturing a camera device

[0006] The invention relates to a camera device and a method for manufacturing a camera device.

[0007] State of the art

[0008] Vehicle cameras can be used in environmental perception systems, as is known, for example, from DE 10 2017 218 722 A1. The demand for higher resolution in automotive cameras follows a trend also observed in other imaging applications such as mobile and drone cameras. However, the development of cameras for use in the automotive industry is subject to special requirements and limitations, particularly regarding size, power consumption, reliability, product lifecycle, environmental conditions during storage and operation, and cost. A key challenge is achieving high resolution across a wide temperature and humidity range throughout the entire lifespan of the vehicle camera, as well as maintaining resolution under the influence of motion caused by the interaction of vehicle dynamics and camera orientation during the integration process.

[0009] Disclosure of the invention

[0010] The invention provides a camera device and a method for manufacturing a camera device having the features of the independent claims. R.414585

[0011] - 2 -

[0012] Preferred embodiments are the subject of the respective dependent claims.

[0013] According to a first aspect, the invention relates to a camera device comprising a lens assembly with a hermetically sealed housing and a plurality of optical lenses arranged in the housing. An optically adaptive device, comprising at least one optical lens, is arranged outside the housing. An actuator can move at least one component of the optically adaptive device relative to the lens assembly. A sensor can detect light after it has passed through the lens assembly and the optically adaptive device.

[0014] According to a second aspect, the invention relates to a method for manufacturing a camera device. A lens assembly with a hermetically sealed housing and a plurality of optical lenses arranged in the housing is provided. An optically adaptive device with at least one optical lens is arranged outside the housing. An actuator device is provided which can move at least one component of the optically adaptive device relative to the lens assembly. A sensor device is provided which detects light after it has passed through the lens assembly and the optically adaptive device.

[0015] Advantages of the invention

[0016] The invention provides a suitable and cost-effective solution for correcting image quality during the life cycle of a camera device.

[0017] To simplify manufacturing, reduce adaptation costs, and improve image quality throughout the product's lifespan, an optically adaptive device is provided, which can be controlled so that image quality can be corrected in the event of disturbances such as those caused by environmental influences or aging. R.414585

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[0019] The optical lenses or other optical components of the optically adaptive device can have a long focal length and thus only slightly affect the light path. However, by moving the optically adaptive device, the focal length of the optical system as a whole can be adjusted, which allows for correction of the blurriness of the projected image on the image sensor of the sensor device.

[0020] At the same time, the requirements for the camera device's sealing and compactness can be met. This is achieved by using a lens assembly (i.e., a camera lens) with a hermetically sealed housing, thus protecting the optical lenses of the lens assembly from environmental influences. The optically adaptive unit is located outside the housing.

[0021] This allows the optically adaptive device to be controlled without affecting the lenses in the lens assembly.

[0022] The term "hermetically sealed" refers to the fact that the housing is designed to be gas- and liquid-tight. The hermetic seal ensures that the inner environment of the housing is isolated from the external environment.

[0023] Furthermore, it is advantageous that the lens assembly can be manufactured and assembled in a separate step, since no moving part is required within the lens assembly.

[0024] According to another embodiment of the camera device, the optically adaptive device is attached to the lens device.

[0025] According to another embodiment, the camera device comprises a camera housing, wherein the optically adaptive device is attached to the camera housing.

[0026] According to another embodiment of the camera device, the actuator assembly is designed to actuate at least one component of the optical R.414585

[0027] - 4 - to move the adaptive device along an optical axis of the camera device. Additionally or alternatively, other movements may be possible, such as displacements perpendicular to the optical axis or rotations relative to the optical axis.

[0028] According to another embodiment of the camera device, the actuator assembly comprises at least one microelectromechanical (MEMS) element configured to move the at least one component of the optically adaptive device relative to the lens assembly. According to further embodiments, the actuator assembly includes voice coil motors, silent wave motors, ultrasonic micrometers, or stepper motors.

[0029] According to a further embodiment of the camera device, the optically adaptive device comprises a first lens and a second lens, wherein the first lens is arranged in the beam path between the lens assembly and the second lens, and wherein the second lens has a flat top surface on one side. This simplifies the attachment of the second lens to a component of the actuator assembly.

[0030] According to another embodiment of the camera device, the optically adaptive device comprises a first lens and a second lens. The actuator can change the distance between the first lens and the second lens. This allows the focal length to be adjusted.

[0031] According to another embodiment of the camera device, at least one lens of the optically adaptive device is designed as a diffractive optical element. This allows for a lightweight and compact optically adaptive device.

[0032] According to a further embodiment of the camera device, at least one lens of the optically adaptive device is at least partially made of a lightweight material, such as a polymer material, e.g. a cyclic olefin- R.414585

[0033] - 5 -

[0034] Copolymer. This allows the optically adaptive device to be made thin and lightweight, reducing the effort required for actuation.

[0035] According to another embodiment of the camera device, at least one lens of the optically adaptive device is at least partially made of an optical metamaterial. Optical metamaterials are artificially nanostructured materials in which the propagation properties of light are determined by the structure.

[0036] According to a further embodiment, the camera device includes a calibration device which can calibrate the camera device to correct for aging and / or temperature effects by controlling the actuator device to move the at least one component of the optically adaptive device relative to the lens device. This enables precise operation over the device's lifetime.

[0037] According to another embodiment of the camera device, athermalization and focus correction can be performed during operation. This aims to achieve a fixed focus and compensate for thermal and aging effects. The focus can be dynamically adjusted to obtain optimal image quality.

[0038] Furthermore, it may be possible to eliminate active alignment processes during the end-of-line assembly of the camera device. Manual alignment of the optical path between the sensor assembly and the lens assembly during the assembly process can become unnecessary. Precise alignment is possible without the need for additional alignment steps.

[0039] According to another embodiment of the camera device, optical image stabilization can be provided. The optically adaptive device R.414585

[0040] - 6 - can be moved to compensate for vibrations caused by the vehicle's movement. This stabilization ensures a precise image, even under difficult conditions.

[0041] According to another embodiment of the camera device, a higher equivalent resolution can be achieved with a lower-resolution imager by activating the optically adaptive mechanism of the camera device and reconstructing the image by superimposing shifted images. This enables improved image quality and detail accuracy, and higher resolution even with small sensors.

[0042] According to another embodiment of the camera device, autofocus can be provided. By activating the optically adaptive device, the camera can dynamically focus on specific objects or distances during operation. The camera device is therefore suitable, for example, for applications such as vehicle interior monitoring systems. This ensures that the camera device captures the desired areas in sharp focus.

[0043] According to another embodiment of the camera device, a focus scan can be provided, which allows an implicit distance estimation from focus fluctuations caused by movement in the direction of the optical axis.

[0044] According to another embodiment, the camera device has a hermetically sealed camera housing. The lens assembly, the optically adaptive assembly, and the sensor assembly are arranged within the camera housing.

[0045] Further advantages, features and details of the invention will become apparent from the following description, in which various embodiments are described in detail with reference to the drawings.

[0046] Brief description of the drawings R.414585

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[0048] They show:

[0049] Figure 1 shows a schematic cross-sectional view of a camera device according to an embodiment of the invention;

[0050] Figure 2 shows a schematic cross-sectional view of a camera device according to a further embodiment of the invention;

[0051] Figure 3 shows a schematic cross-sectional view of a camera device according to a further embodiment of the invention;

[0052] Figure 4 shows an optically adaptive device for use in a camera device according to an embodiment of the invention;

[0053] Figure 5 shows a further optically adaptive device for use in a camera device according to an embodiment of the invention; and

[0054] Figure 6 shows a flowchart of a method for manufacturing a camera device according to an embodiment of the invention.

[0055] In all figures, identical or functionally equivalent elements and devices are designated with the same reference numerals. The numbering of process steps serves for clarity and generally does not imply a specific chronological order. In particular, several process steps can be performed simultaneously.

[0056] Description of the exemplary implementations

[0057] Figure 1 shows a schematic cross-sectional view of a camera device 100 with a lens assembly 1. The lens assembly 1 comprises a hermetically sealed housing 2 and five optical lenses 31 to 35 arranged in the housing 2. The housing 2 has a light-transmitting area 36. R.414585

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[0059] Outside the housing 2, an optically adaptive device 4 is arranged, which has two optical lenses 41 and 42, wherein the first lens 41 is arranged in the beam path between the lens device 1 and the second lens 42. However, the invention is not limited to a specific number of optical lenses 31 to 35, 41, 42 of the lens device 1 or of the optically adaptive device 4.

[0060] The second lens 42 has a flat top surface on one side facing the lens assembly 1. However, in other embodiments, the top surface can also be convex or concave.

[0061] At least one lens 41, 42 of the optically adaptive device 4 can be configured as a diffractive optical element. At least one lens 41, 42 of the optically adaptive device 4 can also be configured, at least partially, from an optical metamaterial.

[0062] An actuator 5 can move at least one component of the optically adaptive device 4 relative to the lens device 1. For example, at least one of the lenses 41, 42 of the optically adaptive device 4 can be moved towards or away from the lens device 1. The actuator 5 can, for example, change the distance between the first lens 41 and the second lens 42.

[0063] The camera device 100 further comprises a sensor device 6, which can detect light after it has passed through the lens device 1 and the optically adaptive device 4. The sensor device 6 can be configured as a camera chip or imager, which can detect light in a specific wavelength range, for example in the visible range and / or in the infrared range.

[0064] The camera device 100 further comprises a calibration device 9, which is designed to correct for aging and / or temperature effects. R.414585

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[0066] Calibration device 9 can be operated by a user to calibrate camera device 100, or it can automatically calibrate camera device 100. Calibration device 9 controls actuator device 5 to move at least one component of optically adaptive device 4 relative to lens device 1.

[0067] Figure 2 shows a schematic cross-sectional view of a camera device 200. The components of the camera device 200 essentially correspond to the components of the camera device 100 of Figure 1 described above, so reference is made to the above descriptions to avoid repetition.

[0068] The sensor device 6 is arranged on a substrate 61. The camera device 200 comprises a hermetically sealed camera housing 8. The lens device 1, the optically adaptive device 4, and the sensor device 6 are arranged in the camera housing 8.

[0069] The optically adaptive device 4 comprises mounts 43, 44, which are attached to the lens device 1 via a mounting structure 7a. The lenses 41, 42 of the optically adaptive device 4 can be moved along an optical axis A of the camera device 200.

[0070] Figure 3 shows a schematic cross-sectional view of a camera device 300. In contrast to the embodiment shown in Figure 2, the optically adaptive device 4 is attached to the substrate 61 via a mounting structure 7b.

[0071] According to another embodiment, the optically adaptive device 4 can also be attached to the camera housing 8.

[0072] Figure 4 shows an optically adaptive device 4a for use in a camera device, for example one of the camera devices 100 to 300 illustrated above. The optically adaptive device 4a can be directed through the first lens 41 onto an R.414585

[0073] - 10 - large focal length is optimized, while the second lens 42 is a focusing element. The optically adaptive device 4a acts like a compact telescope, whereby a displacement of the second lens 42 can focus or defocus the exit beam.

[0074] In a radially outer area, the second lens 42 has a flat section 421 to simplify assembly.

[0075] Figure 5 shows another optically adaptive device 4b for use in a camera device, such as one of the camera devices 100 to 300 illustrated above. The lenses 41, 42 of the optically adaptive device 4 can be moved relative to the lens device 1 by changing the distance between the lenses 41, 42 via microelectromechanical elements 51, 52. For this purpose, the lenses 41, 42 of the optically adaptive device 4 can be mounted via spring elements, the deflection of which can be controlled by a piezoelectric actuator or the like.

[0076] Figure 6 shows a flowchart of a method for manufacturing a camera device, in particular one of the camera devices 100, 200, 300 described above.

[0077] In step S1, a lens assembly 1 is provided with a hermetically sealed housing 2 and a plurality of optical lenses 31-35 arranged in the housing 2.

[0078] In step S2, an optically adaptive device 4 arranged outside the housing 2 with at least one optical lens 41 , 42 is formed.

[0079] In step S3, an actuator assembly 5 is formed which can move at least one component of the optically adaptive assembly 4 relative to the lens assembly 1. R.414585

[0080] In step S4, a sensor device 6 is formed which detects light after it has passed through the lens device 1 and the optically adaptive device 4. Steps S1 to S4 can also be carried out in a different order or at least partially in parallel.

Claims

R.414585 - 12 - Claims 1. Camera device (100; 200; 300), comprising: a lens assembly (1) with a hermetically sealed housing (2) and a plurality of optical lenses (31-35) arranged in the housing (2); an optically adaptive device (4; 4a; 4b) arranged outside the housing (2) with at least one optical lens (41, 42); an actuator assembly (5) configured to move at least one component of the optically adaptive device (4; 4a; 4b) relative to the lens assembly (1); and a sensor assembly (6) configured to detect light after it has passed through the lens assembly (1) and the optically adaptive device (4; 4a; 4b).

2. Camera device (100; 200; 300) according to claim 1, wherein the optically adaptive device (4; 4a; 4b) is attached to the lens device (1).

3. Camera device (100; 200; 300) according to claim 1 or 2, further comprising a camera housing (8), wherein the optically adaptive device (4; 4a; 4b) is attached to the camera housing (8).

4. Camera device (100; 200; 300) according to one of the preceding claims, wherein the actuator device (5) is configured to move the at least one component of the optically adaptive device (4; 4a; 4b) along a R.414585 - 13 - optical axis (A) of the camera device (100; 200; 300) to be moved.

5. Camera device (100; 200; 300) according to one of the preceding claims, wherein the actuator device (5) has at least one microelectromechanical element configured to move the at least one component of the optically adaptive device (4; 4a; 4b) relative to the lens device (1).

6. Camera device (100; 200; 300) according to one of the preceding claims, wherein the optically adaptive device (4; 4a; 4b) has a first lens (41) and a second lens (42), wherein the first lens (41) is arranged in the beam path between the lens device (1) and the second lens (42), and wherein the second lens (42) has a flat top surface on one side.

7. Camera device (100; 200; 300) according to one of the preceding claims, wherein the optically adaptive device (4; 4a; 4b) has a first lens (41) and a second lens (42), and wherein the actuator device (5) is configured to change a distance between the first lens (41) and the second lens (42).

8. Camera device (100; 200; 300) according to one of the preceding claims, wherein at least one lens (41 , 42) of the optically adaptive device (4; 4a; 4b) is designed as a diffractive optical element.

9. Camera device (100; 200; 300) according to one of the preceding claims, with a calibration device (9) which is configured to calibrate the camera device (100; 200; 300) to correct aging and / or temperature effects by controlling the actuator device (5) to move the at least one component of the optically adaptive device (4; 4a; 4b) relative to the lens device (1). R.414585 - 14 - 10. Method for manufacturing a camera device (100; 200; 300), comprising the steps: Providing (S1) a lens assembly (1) with a hermetically sealed housing (2) and a plurality of optical lenses (31-35) arranged in the housing (2); Forming (S2) an optically adaptive device (4; 4a; 4b) arranged outside the housing (2) with at least one optical lens (41 , 42); Training (S3) an actuator device (5) which is configured to move at least one component of the optically adaptive device (4; 4a; 4b) relative to the lens device (1); and Forming (S4) a sensor device (6) which is designed to detect light after passing through the lens device (1) and the optically adaptive device (4; 4a; 4b).

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