Camera Module Bonding Protrusion Groove Laser Welding
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Solution Overview
Problem
In the automobile manufacturing industry, camera modules face challenges in miniaturization and cost reduction while maintaining high functionality, often requiring larger lenses and more complex structures due to the integration of components like iris and heaters.
Innovation Solution
A camera module design that includes a lens barrel, upper and lower housings, and substrates with bonding protrusions and grooves for laser welding, reducing the need for additional sealing and fastening components, and allowing for increased substrate sizes and simplified assembly processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additional components (iris, heater) are integrated to enhance camera functionality, then camera functions become more advanced, but the lens size must be increased and structure becomes more complicated
Solution Approach 1:
The patent integrates multiple components (iris, heater, lens, substrates) into a unified camera module assembly where the housing provides a common structural framework. This merging approach allows advanced functionality while managing overall structure complexity through integrated design rather than separate assemblies.
Solution Approach 2:
The housing structure serves multiple functions: it provides mechanical support, integrates optical components, accommodates heating elements, and enables iris operation. This multi-functionality reduces the need for additional structural elements, addressing the complexity issue while maintaining enhanced camera functions.
2Adaptability or versatility
If additional components (iris, heater) are integrated to enhance camera functionality, then camera functions become more advanced, but the lens size must be increased
Solution Approach 1:
The patent arranges components in a compact three-dimensional configuration within the housing, utilizing vertical and radial spaces efficiently. The iris is positioned concentrically with the lens, and the heater is integrated into the housing structure, allowing advanced functionality without proportionally increasing lens size.
3Ease of manufacture
If traditional bonding methods with screws and sealing members are used, then assembly is straightforward, but component count increases and manufacturing efficiency decreases
Solution Approach 1:
The bonding protrusions and grooves integrate multiple functions into single structural features: they provide mechanical fastening, sealing, and alignment simultaneously. This eliminates the need for separate screws and sealing members, reducing component count while maintaining assembly simplicity and improving manufacturing efficiency.
Solution Approach 2:
The patent replaces traditional mechanical fastening systems (screws, clips) with an integrated bonding system using protrusions and grooves that can be joined through welding or adhesive bonding. This substitution reduces the number of discrete components and assembly steps, improving productivity while maintaining ease of manufacture.
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 design achieves miniaturization and cost reduction by eliminating the need for screws and separate sealing members, enhancing manufacturing efficiency and reducing component counts while maintaining camera functionality.
Implementation Method 1
The surface of the extension portion and the lens barrel may be bonded to each other by welding, and the other surface of the extension portion and the lower housing may be bonded to each other by welding.
Implementation Method 2
The upper housing may be formed of a laser-transmissive material.
Data Source
AI summary
A camera module includes a lens barrel comprising a lens; an upper housing, coupled to an end of the lens barrel, including an extension portion extending from an external surface of the lens barrel; a lower housing, coupled to the upper housing, configured to have an internal space; and a first substrate, disposed below the lens barrel, comprising an image sensor. A surface of the extension portion is bonded to the lens barrel, and another surface of the extension portion is bonded to the lower housing, and a shape of the first substrate corresponds to a shape of the internal space of the lower housing.