On-board Camera Laser Welding Seal Cavity
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Solution Overview
Problem
Traditional on-board camera manufacturing methods face challenges in ensuring waterproofness and accurate focal length due to issues with glue accuracy, deformation, integrated structures, and potential damage to electronic elements, leading to high defect rates and poor efficiency.
Innovation Solution
The camera employs laser welding to connect the rear and front housings, forming a seal cavity and allowing adjustable focal length by varying the welding height, eliminating the need for additional waterproof parts and preventing water ingress, while ensuring the lens and sensor are securely attached without damaging electronic components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If dispensing method is used to connect housing and lens, then assembly is simple, but waterproofness and optical accuracy cannot be guaranteed due to glue filling space and curing time requirements
Solution Approach 1:
The patent replaces the chemical bonding method (dispensing glue) with a mechanical connection method (threaded interface with sealing structure). The rear housing threads onto the front housing, creating a mechanical connection that provides both structural support and waterproof sealing through the integrated sealing ring, eliminating the need for separate adhesive materials.
Solution Approach 2:
The threaded connection structure serves multiple functions simultaneously: it provides mechanical attachment between housings, creates waterproof sealing through the integrated sealing ring, and maintains precise optical alignment by preventing housing deformation. This multi-functional design eliminates the need for separate components for each function.
2Reliability
If extrusion method with compression gasket is used, then waterproofness is achieved, but housing deformation occurs under stress causing focal length changes and blurry imagery
Solution Approach 1:
The patent replaces the compression gasket sealing mechanism with a threaded mechanical connection that incorporates an integrated sealing ring. Instead of relying on compressive force from a gasket, the threaded interface creates a rigid mechanical bond that prevents housing deformation while maintaining waterproof sealing through the sealing ring positioned at the thread interface.
Solution Approach 2:
The integrated sealing ring is positioned at the threaded interface to provide preemptive sealing before any potential stress or deformation can occur. The sealing ring prevents water ingress by creating a barrier at the connection point, eliminating the need for compression forces that would deform the housing.
3Productivity
If ultrasonic welding is used to integrate rear housing and front housing, then assembly is automated, but vibration damages electronic elements on the sensor
Solution Approach 1:
The patent replaces the ultrasonic welding process with a threaded mechanical assembly process. The rear housing threads onto the front housing in a controlled rotational motion that generates no harmful vibrations, yet achieves secure mechanical attachment and waterproof sealing. This eliminates the vibration damage risk to electronic elements while maintaining assembly automation capability.
4Device complexity
If integrated structure of sensor and front housing lens is used, then assembly is simplified, but focal length adjustment becomes impossible and defect rate increases due to part tolerance
Solution Approach 1:
The patent divides the camera assembly into separable modules: the front housing with lens assembly remains as one unit, while the rear housing with sensor can be independently positioned and adjusted. The threaded connection allows the rear housing to be precisely positioned relative to the front housing, enabling focal length adjustment while maintaining assembly simplicity. This modular approach eliminates the tolerance accumulation problem of fully integrated structures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enhances manufacturing efficiency, yield, and focal length accuracy, providing a reliable waterproof seal and preventing image blurriness, thus improving product quality and reducing defect rates compared to existing methods.
Implementation Method 1
the rear housing is connected with the front housing via laser welding so as to form a seal cavity between the rear housing and the front housing
Implementation Method 2
Since the the integrated ultrasonic welding of the rear housing 11 and the front housing lens 13 is achieved by welding two parts through mechanical vibration to heat and melt plastic parts
Data Source
AI summary
The present invention relates to an on-board camera, comprising a rear housing, a front housing, a lens mounted in the front housing and a sensor fixed on the rear housing; and its manufacturing method. The rear housing is welded to the front housing via a laser to form a seal cavity between the two housings to accommodate the lens and the sensor, and the focal length of the lens is adjusted by adjusting the distance between the sensor and the lens which is further adjusted by the welding height of the two housings.