Optical Imager Assembly With Clamp Alignment to Prevent Rotational Variance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional optical device assembly methods are costly and prone to positional inaccuracies, particularly rotational variance, which are challenging to address in high-resolution automotive cameras required for autonomous driving and safety assistance systems.
Innovation Solution
A method involving precise alignment of a circuit board with an imager using manipulators and a housing assembly that secures the board with clamping formations, eliminating the need for screws or adhesives, and utilizing projected images for accurate positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional assembly methods with screws and adhesives are used, then the circuit board can be secured to the lens holder, but positional inaccuracies and rotational variance occur
Solution Approach 1:
The patent replaces the conventional mechanical fastening system (screws and adhesives) with a clamping formation system. The clamping formation mechanically secures the circuit board to the lens holder through a clamping action that maintains precise alignment without the rotational variance caused by overtightened screws or adhesive curing shifts.
Solution Approach 2:
The patent changes the mechanical parameters of the fastening system by using a clamping formation that applies controlled clamping force. This allows the circuit board to be secured with precise positional and rotational alignment maintained, overcoming the inaccuracies of conventional screw and adhesive methods.
2Manufacturing precision
If multiple assembly steps including active alignment are performed, then lens focal plane can be aligned with imager sensitivity plane, but manufacturing cost and process complexity increase
Solution Approach 1:
The patent incorporates alignment features directly into the lens holder and circuit board mounting structure during manufacturing. The clamping formation is designed with built-in alignment capabilities that automatically position the circuit board correctly when clamped, eliminating the need for separate active alignment steps during assembly.
Solution Approach 2:
The patent combines the fastening function and alignment function into a single integrated clamping formation system. The clamping formation simultaneously secures the circuit board and maintains precise alignment, merging what were previously separate functions performed by different components and steps.
3Ease of manufacture
If conventional fastening methods are used, then the circuit board can be secured, but positional shifts occur due to overtightened screws
Solution Approach 1:
The patent replaces the screw fastening system with a clamping formation system that provides securing capability without the risk of overtightening. The clamping action applies controlled force to hold the circuit board in position without causing positional shifts that occur with excessive screw tightening.
Data Source
AI summary
Method of assembling an optical device including providing a circuit board having an imager mounted thereto, wherein the imager has an active region. A housing is provided having a support for supporting the circuit board and an opening for an optical path to form an image at a known image position relative to the opening. The circuit board is placed on the support and its position is adjusted using one or more manipulators to align the active region with the image position. The circuit board may then be secured in an aligned position.