Dual-Sided Spacer Camera Carrier for Precise Optical Alignment
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Solution Overview
Problem
Existing methods for manufacturing automotive cameras fail to achieve the required accuracy of alignment with respect to pitch, yaw, and roll angles, while maintaining high cleanliness and precision, leading to increased process risks, costs, and extended assembly times, especially for augmented reality applications.
Innovation Solution
A method involving the mounting of a camera objective on a carrier with a contamination-proof space formed by the carrier, objective housing, and optical components, allowing precise alignment and reduced contamination risk, followed by assembly into a camera housing, using techniques like gluing and alignment based on reference markers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing methods are used to mount camera sensor and objective separately, then alignment accuracy can be achieved, but process time and costs increase significantly
Solution Approach 1:
The patent combines the camera sensor and camera objective into a single integrated camera module. The sensor is mounted directly on the carrier board, and the objective is mounted on the same carrier board with integrated alignment features, eliminating the need for separate mounting and alignment processes. This merging of components reduces process time while maintaining alignment accuracy through the integrated design.
Solution Approach 2:
The patent incorporates preliminary alignment features directly into the carrier board design, including alignment pins and reference marks that are pre-positioned during carrier manufacturing. This preliminary action ensures that when the sensor and objective are mounted, alignment is achieved more quickly and accurately without requiring extensive post-mounting adjustment processes.
2Reliability
If high cleanliness standards are maintained throughout the manufacturing process, then optical performance is improved, but process complexity and costs increase
Solution Approach 1:
The patent extracts the contamination risk from the manufacturing process by designing a sealed camera module housing that encloses the sensor and objective. This housing prevents contamination during assembly and protects the optical components from environmental factors, maintaining high cleanliness standards without requiring complex contamination control measures throughout the entire manufacturing process.
Solution Approach 2:
The patent segments the camera module into distinct functional areas with controlled access. The sensor mounting area and objective mounting area are separated with defined boundaries, allowing for targeted cleaning and assembly procedures. This segmentation simplifies the overall cleanliness management by focusing contamination control efforts on specific critical areas rather than the entire assembly process.
3Manufacturing precision
If alignment accuracy below ±1 degree is achieved for pitch, yaw, and roll angles, then optical performance improves, but manufacturing complexity increases
Solution Approach 1:
The patent replaces complex mechanical alignment adjustment mechanisms with a simplified mounting system that uses precision-machined alignment pins and reference features on the carrier board. This mechanical substitution eliminates the need for manual adjustment and complex alignment equipment, achieving high alignment accuracy through precise manufacturing of the carrier board itself rather than through complex assembly processes.
Data Source
AI summary
A camera includes an objective carrier assembly including a carrier where a camera sensor and a camera objective are mounted. The camera includes a camera housing configured to at least partially enclose the objective carrier assembly. The camera housing includes a first housing part where the objective carrier assembly is mounted. The camera housing includes a second housing part that is mounted on the first housing part.