Camera System Parallel Optical Axis Alignment

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Solution Overview

Problem

Existing camera systems face challenges in achieving precise and reproducible positioning of the lens and image sensor for high-quality image recording, particularly in industrial production, due to issues with adhesive bonding that can lead to defects under varying conditions such as temperature and mechanical loads, and the need for faster alignment in large quantity production.

Innovation Solution

The camera system is divided into two units with precise laser welding for direct thermal connection, using multi-axis positioning devices to align the sensor and lens units with parallel optical axes, ensuring accurate and permanent positioning without adhesive, and allowing for prefabrication and adaptation to different applications.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If adhesive bonding is used to fix the lens and image sensor, then the positioning can be adjusted during curing time, but the adhesive bond may crack under high temperatures, mechanical loads, and light effects, leading to scattered light and image quality reduction

Engineering Contradiction:

Improveadjustability during positioningVSAvoidbond stability under temperature and mechanical loads

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent removes the adhesive bonding step entirely from the manufacturing process. Instead of using adhesive to fix the lens and image sensor, the invention employs a mechanical positioning system with a positioning plate that has precisely machined positioning surfaces. The lens barrel and image sensor are directly mounted on these positioning surfaces, eliminating the adhesive layer that would crack under thermal and mechanical stress.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the chemical bonding mechanism (adhesive) with a purely mechanical positioning and fixing system. The positioning plate with precision-machined surfaces provides mechanical constraint, and the fixing means (screws or clips) provide mechanical fixation. This mechanical system is resistant to thermal expansion and contraction, and does not suffer from the cracking issues that plague adhesive bonds under high temperatures and mechanical loads.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If adhesive is used for lens positioning, then the connection can be made between different materials, but the adhesive application requires precise application and curing time, reducing productivity

Engineering Contradiction:

Improveconnection between different materialsVSAvoidproduction speed for large quantities

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent incorporates positioning surfaces directly into the housing structure during the housing manufacturing process. The positioning plate is pre-formed with precise positioning surfaces that match the lens barrel and image sensor mounting surfaces. This preliminary preparation of positioning features eliminates the need for separate adhesive application and curing steps, allowing for rapid assembly of multiple camera modules in high-volume production.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If laser welding is used to fix the lens, then the fixing process is faster, but laser-transparent and laser-absorbing housing materials are required, limiting material selection

Engineering Contradiction:

Improvefixing speedVSAvoidhousing material selection

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The patent removes the laser welding process entirely from the manufacturing sequence. Instead of using laser welding to attach the lens, the invention employs a mechanical fixing system where the lens barrel is mounted on the positioning plate and secured with fixing means. This eliminates the need for laser-transparent or laser-absorbing materials, allowing any suitable housing material (metals, plastics, composites) to be used without restriction.

Inventive Principle:

Principle #2Taking out (Extraction)

4Manufacturing precision

If multi-axis positioning devices are used to align lens and image sensor with parallel optical axes, then the positioning precision and repeatability are improved, but the device complexity increases

Engineering Contradiction:

Improvepositioning accuracy and repeatabilityVSAvoidpositioning system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent uses master positioning surfaces with precisely defined geometric relationships. The positioning plate contains reference surfaces that are machined to exact tolerances, and the lens barrel and image sensor mounting surfaces are designed to mate with these references. This master-copy approach allows for high positioning precision and repeatability across multiple units without requiring complex active positioning mechanisms, as the precision is built into the tooling and fixtures themselves.

Inventive Principle:

Principle #26Copying

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 ensures high precision and repeatability in positioning, reducing the risk of defects and improving image quality by eliminating adhesive-related issues, while enabling efficient production of camera systems for various applications.

Implementation Method 1

a laser device (27) for irradiating the joining surface (23) with laser radiation

Methodology Applied

Scientific EffectLaser radiation: Laser

Implementation Method 2

at least one of the two housing components (3, 15) has in the area of its joining surface (23) a laser-absorbing material, while a second housing component has in the area of the joining surface (23) a laser-transparent material

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Implementation Method 3

Methodology Applied

Scientific EffectLaser transparency: Absorption (EM radiation)

Data Source

PatentEP3516859B1Housed camera system, and method and device for producing same

Publication Date: 2021.08.18 FIRST SENSOR MOBILITY GMBH

Figure 1A~1C
Figure 2~3B
Figure 4A~5

AI summary

The invention relates to a camera system and to a method and a device for producing same. The camera system comprises two camera units, a sensor unit (1) with an image sensor (5), a printed circuit board (7), and a housing main part (3) and a lens unit (10) with a lens (12), a lens holder (14), and a housing cover (15). The lens (12) is arranged in front of the image sensor (5) at a distance a therefrom so that the image sensor (5) and the lens (10) have parallel optical axes (20, 21). Both housing components are directly connected at a joint surface (23) mechanically or thermally such that the housing components encase the image sensor (5) and the lens (12) and light is only incident on the image sensor (5) through the lens (12). For production purposes, the relative camera unit positions in which the optical axes (20, 21) of the lens (12) and the image sensor (5) are parallel are ascertained relative to each other, and the lens and the image sensor are positioned relative to each other accordingly by means of a multi-axis positioning device. After the lens unit (10) and the sensor unit (1) are positioned relative to each other, the lens unit and the sensor unit are joined at the joint surface (23).