Vehicular Camera Lens Assembly With Two-Stage UV Adhesive Alignment
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Solution Overview
Problem
Existing vehicular camera systems face challenges in achieving precise lens positioning relative to the image sensor, which affects video quality and system performance, especially in compact designs where small variations in position can lead to significant angular offsets.
Innovation Solution
The use of a UV-curable adhesive that undergoes a two-stage curing process, initially cured quickly by UV light to support the lens position, and then fully cured by heat to achieve a strong bond, allowing for precise alignment and assembly of the lens and imager using a multi-axis robot system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single-stage curing adhesive is used, then the manufacturing process is simpler, but the lens positioning precision and assembly efficiency deteriorate due to long curing time
Solution Approach 1:
The curing process is segmented into two distinct stages: an initial fast-cure stage using UV light that provides immediate positioning stability, and a subsequent slow-cure stage using heat that achieves full bond strength. This segmentation allows the lens to be precisely positioned and quickly fixed in place, while the complete curing continues in the background, resolving the conflict between positioning precision and assembly efficiency
Solution Approach 2:
The fast-cure adhesive component is activated first to immediately secure the lens in its precise position before the slower complete curing process begins. This preliminary action ensures that the lens positioning precision is achieved and maintained while the productivity benefit of continued curing occurs without requiring the lens to remain in delicate positioning
2Productivity
If a fast-curing adhesive is used, then the assembly efficiency is improved, but the final bond strength and reliability deteriorate
Solution Approach 1:
The adhesive system uses a composite formulation containing both fast-curing and slow-curing components. The fast-curing component (such as cyanoacrylate or UV-curable resin) provides immediate bond strength for assembly efficiency, while the slow-curing component (such as epoxy or polyurethane) continues to cure over time to achieve maximum bond strength and long-term reliability, combining the benefits of both curing speeds
3Manufacturing precision
If complex mechanical positioning mechanisms are used, then the lens positioning precision is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
Complex mechanical positioning mechanisms are replaced with a chemically-based positioning system using fast-cure adhesive. The adhesive chemically bonds the lens to its mounting structure, providing precise and stable positioning without requiring complex mechanical adjustment mechanisms, thereby reducing device complexity and manufacturing cost while maintaining positioning precision
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 approach enables the production of a more integrated and cost-effective camera assembly with improved precision and accuracy in lens positioning, maintaining performance over a useful operating life while optimizing manufacturing efficiency.
Implementation Method 1
The adhesive is capable of being initially cured relatively quickly by exposure to UV light for supporting the lens relative to the lens holder
Implementation Method 2
The adhesive is further capable of being cured by exposure to a secondary curing condition, such as by exposure to heat, to achieve a fully cured strength
Data Source
AI summary
A vehicular camera includes a camera housing having a front housing portion and a rear housing portion. The front housing portion includes a plurality of optical elements, a CMOS imager, and an imager printed circuit board. The CMOS imager is at a first side of the imager printed circuit board. The plurality of optical elements is held in position relative to the CMOS imager by an adhesive, whereby the imaging array at the outer side of the CMOS imager is devoid of the adhesive. The adhesive is formed by curing an adhesive material that is curable via exposure of the adhesive material to ultraviolet (UV) light. The adhesive maintains the position of the plurality of optical elements with respect to the CMOS imager during use of the vehicular camera assembly on a vehicle equipped with the vehicular camera assembly. The back housing portion is joined at the front housing portion.