Vehicular Camera Lens Assembly With UV-Cured Focus Alignment
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Solution Overview
Problem
Vehicular cameras face challenges in maintaining lens position accuracy relative to the image sensor, especially in compact designs, due to tolerances in threaded connections, lens holders, and imager positions, which can result in blurry video and impaired collision detection systems.
Innovation Solution
The use of a UV-curable adhesive to quickly secure the lens to the lens holder, allowing for initial positioning by a robot and subsequent full curing, enabling precise alignment and focus without the need for continuous robotic grip, and integrating lens barrels with camera housings for simplified assembly and cost reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If threaded connections and lens holders are used to position the lens, then assembly is easier and components are replaceable, but positioning precision deteriorates due to tolerances
Solution Approach 1:
The positioning system is divided into two independent parts: mechanical support structures (lens holder, threaded connections) for ease of assembly and replacement, and a separate adhesive system for achieving precise positioning. This segmentation allows each subsystem to optimize for its specific function without compromise.
Solution Approach 2:
An adhesive is introduced as an intermediary substance between the lens and lens holder to eliminate positioning errors caused by mechanical tolerances. The adhesive fills gaps and compensates for dimensional variations in threaded connections and holder components, achieving precise lens positioning without requiring high-precision mechanical fixtures.
2Volume of moving object
If the camera size is reduced, then compactness is improved, but lens positioning stability deteriorates due to larger angular offset from small position variations
Solution Approach 1:
The adhesive is applied to the lens holder before the lens is installed, creating a pre-positioning layer that maintains lens alignment during assembly. This preliminary action ensures that even in compact cameras where small position variations cause large angular offsets, the lens remains stable and precisely positioned once the adhesive sets.
3Strength
If traditional adhesives requiring long curing time are used, then bond strength is improved, but production efficiency deteriorates
Solution Approach 1:
The adhesive chemistry is modified to enable dual-curing capability: initial rapid curing under UV light for quick production cycle completion, and secondary slow curing under heat or extended UV exposure for maximum bond strength. This parameter change in curing mechanism allows the adhesive to deliver both high strength and high productivity.
Solution Approach 2:
The curing process is divided into two periodic stages: a first curing phase using UV light for rapid initial bonding that enables quick production turnover, and a second curing phase using heat or extended UV for achieving full ultimate strength. This periodic action sequence allows the system to benefit from both fast initial setting and complete final curing.
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 solution ensures accurate lens positioning and focus, enhances manufacturing efficiency by allowing a single robot to handle multiple camera assemblies, and reduces production costs through simplified assembly processes and materials savings.
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 rear camera housing and a front camera housing. The front camera housing includes a lens, an imager and an imager printed circuit board. The lens is held in position relative to the imager by a UV-curable adhesive. With the lens held in position relative to the imager by the adhesive, the outer surface of the imager is devoid of the adhesive and an air gap exists between the lens and the outer surface of the imager. With the adhesive disposed in an uncured state on the imager printed circuit board and laterally outboard of the imager, and with the lens positioned relative to the imager, the adhesive is cured from its uncured state to an at least partially-cured state by exposure to UV light. The rear housing portion is joined at the front housing portion.