Heated Camera Module Assembly for Adhesive Optical Alignment
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Solution Overview
Problem
Existing camera modules face inefficiencies in attachment methods, such as screwing and welding, which lead to buckling or bending of parts 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 flanges and adhesive attachment between the lens assembly, electronics carrier, and housing, with a heater element for defrosting, 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 are used to attach the electronics carrier to the housing, then the attachment is mechanically strong, but the assembling process becomes time-consuming and difficult to automate
Solution Approach 1:
The patent replaces the mechanical screw attachment system with an adhesive bonding system. The adhesive is applied to the housing and bonds the electronics carrier to the housing without requiring mechanical fasteners, thereby eliminating the time-consuming screwing process while maintaining attachment strength.
Solution Approach 2:
The patent introduces adhesive as an intermediary substance between the housing and the electronics carrier. This adhesive layer provides the bonding function that previously required mechanical screws, enabling both strong attachment and automated assembly processes.
2Strength
If welding is used to attach the lens and electronics carrier, then the attachment is strong and permanent, but temperature changes cause buckling or bending of parts
Solution Approach 1:
The patent replaces the welding process with adhesive bonding. Adhesive bonding is a cooler process that does not subject the parts to the high temperatures of welding, thereby preventing thermal deformation and buckling while still providing strong attachment.
Solution Approach 2:
The patent changes the attachment method from a high-temperature process (welding) to a low-temperature or room-temperature process (adhesive bonding). This parameter change in processing temperature prevents thermal stress and deformation of the parts while maintaining attachment strength.
3Adaptability or versatility
If the camera housing is redesigned for different lens lengths, then the camera can accommodate different applications, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent designs the housing with a universal attachment interface that can accommodate lens assemblies of different lengths. The electronics carrier and housing are designed with standardized mounting features that work with various lens configurations, eliminating the need for custom housing designs for each application.
Solution Approach 2:
The patent separates the housing design from the lens assembly design, allowing the lens assembly to be changed independently while maintaining the same housing. The housing provides a standardized interface that can accommodate different lens lengths without requiring redesign of the entire camera system.
4Ease of manufacture
If adhesive is used to attach the lens barrel to the housing, then the assembling is simplified, but the attachment strength and reliability are insufficient
Solution Approach 1:
The patent uses a composite attachment system combining adhesive bonding with mechanical features such as recesses and protrusions. The adhesive provides the bonding function while the mechanical features provide reinforcement and positioning, creating a hybrid attachment method that achieves both ease of manufacture and high reliability.
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
The design ensures consistent optical alignment and reduced bending of electronics carriers, supports different lens lengths with the same housing, and provides efficient heating, maintaining high image quality and meeting automotive safety requirements.
Implementation Method 1
CN208156394U shows a camera having a lens with a heater that is arranged perimetrically around the lens in order to heat the lens for automatic defrosting and defogging in cold or wet weather conditions or environments.
Data Source
AI summary
The camera module comprises 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 (O), an electronics carrier, an image sensor on the electronics carrier in optical communication with the lens assembly, a positioning element projecting longitudinally along the optical axis (O) towards the electronics carrier for attaching the lens assembly and the electronics carrier to each other. The camera module further comprises a heater element, and a flange projecting radially perpendicular to the optical axis (O). The heater element is for the purpose of resistive heating of the lens body, the heater element comprising a sheet material with electrical resistance arranged at least partially surrounding the lens body wrapping an outer side surface thereof for removing any water-based obstructions that may be attached to the lens body as an electric current flows there through.