Vehicular Camera Lens Barrel Laser Brazing for Active Alignment

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Solution Overview

Problem

Current vehicle vision systems face challenges in efficiently and cost-effectively securing camera lenses to imager PCBs due to complex alignment and focus processes, which often require expensive adhesives and additional curing steps, increasing tolerance stacks and assembly complexity.

Innovation Solution

The system employs laser brazing of a filler material with a lower melting point than the lens barrel and camera housing to secure the lens barrel relative to the imager PCB after optical alignment, eliminating the need for quick cure adhesives and reducing assembly tolerances through non-contact heating and instant focus alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If expensive adhesives and curing steps are used to secure the lens to the imager PCB, then the lens can be securely attached, but the assembly complexity and manufacturing cost increase

Engineering Contradiction:

Improvelens attachment strengthVSAvoidassembly process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the adhesive curing step from the assembly process by using laser brazing instead. This removes the complexity associated with adhesive application, curing time, and quality control of adhesive bonds, while maintaining secure lens attachment through direct laser-induced brazing of the lens mounting structure to the imager PCB.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the chemical bonding mechanism (adhesive curing) with a thermal bonding mechanism (laser brazing). This substitution eliminates the need for curing steps and reduces assembly complexity while providing strong, reliable attachment of the lens to the imager PCB through controlled laser heating that melts and bonds the mounting structure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If adhesive curing steps are implemented to secure the lens, then reliable bonding is achieved, but the manufacturing cycle time increases

Engineering Contradiction:

Improvelens bonding reliabilityVSAvoidmanufacturing cycle time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent uses periodic or pulsed laser action to achieve rapid brazing of the lens mounting structure. Instead of continuous heating or prolonged curing, the laser delivers concentrated energy in controlled pulses or periods, rapidly melting and bonding the structure in seconds, thereby maintaining reliable attachment while dramatically reducing the time required compared to adhesive curing processes.

Inventive Principle:

Principle #19Periodic action

3Manufacturing precision

If traditional alignment and focus processes are used, then the lens can be aligned with the imager, but additional equipment and capital requirements increase

Engineering Contradiction:

Improvelens-to-imager alignment precisionVSAvoidalignment equipment complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent integrates multiple functions into the laser system itself. The laser serves both as a heating source for brazing and as part of the alignment system, eliminating the need for separate alignment equipment. The laser can be positioned and focused to provide both precise alignment of the lens with the imager and the necessary heating for brazing, thereby achieving high manufacturing precision while reducing device complexity and capital requirements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 simplifies the camera assembly process, reduces costs by eliminating expensive adhesives and curing steps, and enhances thermal transfer while decreasing cycle time and capital requirements, providing a more efficient and precise lens alignment.

Implementation Method 1

the brazing/filler material is heated, such as via a laser to melt or liquefy the material

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

heated, such as via a laser to melt or liquefy the material

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

whereby the material flows at least partially into and along the gap

Methodology Applied

Scientific EffectFlow:

Implementation Method 4

when cooled and re-solidified or hardened, retains or holds or secures the lens barrel relative to the lens holder and imager

Methodology Applied

Scientific EffectCooling and re-solidification: Freezing

Data Source

PatentUS11849204B2Vehicular camera assembly process using laser brazing during active focus and alignment to secure lens relative to imager

Publication Date: 2023.12.19 MAGNA ELECTRONICS INC

AI summary

A vehicular camera includes a lens barrel having a lens, a front camera housing having an aperture therethrough, and an imager printed circuit board (imager PCB) having an imager. The imager PCB is attached at the front camera housing with the imager aligned with the aperture. An attaching portion of the lens barrel is positioned at least partially in the aperture of the front camera housing with a gap between the attaching portion and the front camera housing that circumscribes the attaching portion. With the attaching portion positioned at least partially in the aperture, a filler material is disposed at least partially within the gap. After the lens is aligned relative to the imager, the filler material is heated to melt and flow into the gap, whereby the melted filler material hardens upon cooling to secure the lens barrel relative to the front camera housing and the imager PCB.