Flanged Lens Assembly for Stable Camera Module Alignment
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Solution Overview
Problem
Existing camera modules face inefficiencies in attachment methods, such as screwing or welding, which can lead to buckling or bending of components due to temperature changes, and require redesigning the camera housing for different lens lengths, and prior solutions like adhesive attachment do not adequately address these issues.
Innovation Solution
A camera module design featuring a lens assembly with flanges for attachment to the housing and electronics carrier, using adhesives and a heater element for resistive heating, allowing for consistent optical alignment and modular use of housings with different lens lengths without screws or welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If screws or welding are used to attach the lens assembly and electronics carrier, then the attachment strength is improved, but the components are prone to buckling or bending due to temperature changes
Solution Approach 1:
The patent replaces mechanical attachment methods (screws, welding) with adhesive bonding. The adhesive layer bonds the lens assembly and electronics carrier without generating thermal stress or mechanical stress that causes buckling or bending during temperature changes, thus maintaining component stability while providing sufficient attachment strength.
2Adaptability or versatility
If the camera housing is redesigned for different lens lengths, then the adaptability to different applications is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent designs a universal camera housing with a standardized mounting interface that can accommodate lens assemblies of different lengths. The housing includes a mounting plate with threaded holes that accept various lens assemblies without requiring housing redesign, thus achieving adaptability while maintaining manufacturing simplicity.
Solution Approach 2:
The patent separates the housing into modular components: a standardized housing body and interchangeable lens assemblies. This segmentation allows the housing to remain unchanged while different lens assemblies are mounted, achieving versatility without increasing housing complexity.
3Stability of the object's composition
If adhesive is used to attach the lens assembly and electronics carrier, then the risk of buckling or bending is reduced, but the attachment strength and precision may be insufficient
Solution Approach 1:
The patent introduces a mounting plate as an intermediary component between the lens assembly and the housing. The mounting plate provides precise positioning features (threaded holes, alignment features) that ensure accurate alignment, while the adhesive applied to the mounting plate provides sufficient bonding strength without causing thermal stress, thus resolving both stability and strength requirements.
4Manufacturing precision
If positioning portions are used to attach the lens assembly and electronics carrier, then the alignment precision is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent combines multiple functions into the mounting plate: positioning, alignment, and attachment. The mounting plate integrates alignment features (such as recesses or protrusions) and threaded holes for secure attachment, providing precise optical alignment without requiring separate complex positioning mechanisms, thus achieving high precision while maintaining manufacturing simplicity.
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
Ensures consistent optical communication and reduced bending of components, enabling efficient heating and alignment, while allowing the same housing to accommodate lenses of varying lengths, thus meeting automotive safety requirements and reducing material usage.
Implementation Method 1
a heater element for resistive heating of the lens assembly
Data Source
AI summary
The camera module includes a housing having an interior space with an inner surface, a lens assembly comprising a lens body within the interior space defining an optical axis, an electronics carrier, an image sensor on the electronics carrier in optical communication with the lens assembly, at least one positioning element projecting longitudinally along the optical axis towards the electronics carrier for attaching the lens assembly and the electronics carrier to each other with a constant predetermined gap there between with the image sensor optically aligned with the lens assembly, and at least one flange projecting radially perpendicular to the optical axis that can be attached to the inner surface of the housing.