Reflow-Solderable Vehicle Lens Module Using Polyetherimide Optics
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Solution Overview
Problem
Existing vehicle-mounted lens modules fail to maintain stable imaging performance during high-temperature reflow soldering processes due to the use of plastic materials with low softening temperatures, which are not compatible with the high temperatures required for integration with vehicle electronics.
Innovation Solution
A reflow-solderable vehicle-mounted lens module utilizing polyetherimide lenses and a high-temperature-resistant lens barrel and holder, such as those made of polyphenylene sulfide or polyamide, to ensure stable performance through injection molding at elevated temperatures, allowing integration via reflow soldering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional plastic materials (PMMA, PC) are used for lenses and lens barrels, then manufacturing cost and ease of fabrication are improved, but the materials cannot withstand reflow soldering temperatures (softening temperature around 150°C or lower)
Solution Approach 1:
The patent changes the material parameter (softening temperature) by selecting polyetherimide and polyphenylene sulfide/polyamide instead of conventional PMMA or PC materials, enabling the lens system to withstand reflow soldering temperatures while maintaining manufacturability through injection molding
Solution Approach 2:
The patent employs composite material selection where the lens group uses polyetherimide (high temperature resistance) and the lens barrel/holder use polyphenylene sulfide or polyamide (high temperature resistance), creating a multi-material system that satisfies both thermal and manufacturing requirements
2Reliability
If the lens module is integrated with vehicle-mounted panel via reflow soldering, then integration reliability and stability are improved, but the high temperature (230°C to 260°C) causes deformation and performance degradation of conventional plastic lens components
Solution Approach 1:
The patent changes the thermal parameter (softening temperature) of the lens materials to exceed reflow soldering temperatures, ensuring that the lens module maintains its structural integrity and imaging performance stability during the high-temperature integration process
Solution Approach 2:
The patent eliminates the need for compensation mirrors and other temperature compensation mechanisms by selecting inherently high-temperature-resistant materials, simplifying the overall system design while maintaining reliability
3Manufacturing precision
If first-tier suppliers produce lenses and integrate modules with AA focusing capability, then manufacturing capability and quality control are improved, but production complexity and process difficulty increase significantly
Solution Approach 1:
The patent changes the material parameter (temperature resistance) to enable conventional injection molding processes to produce high-temperature-resistant lens components, allowing first-tier suppliers to manufacture complete lens modules without requiring specialized AA focusing capabilities or complex multi-step assembly processes
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 module maintains consistent imaging performance before and after reflow soldering, meeting the requirements for driver monitoring systems by ensuring the lens system's stability and integrity under extreme temperature conditions.
Implementation Method 1
the glass transition temperature Tg of the plastic material is higher than 260° C.
Implementation Method 2
the lens and the lens barrel are injection molded with the plastic material
Data Source
AI summary
The disclosure discloses a reflow-solderable vehicle-mounted lens module configured to be capable of performing imaging for near-infrared light, the vehicle-mounted lens module including: a lens barrel and a lens group disposed within the lens barrel, the lens group including a plurality of lenses, wherein at least one of the lenses is made of polyetherimide by means of injection molding, the lens made of polyetherimide being injection molded by setting a mold temperature controller at a temperature higher than 265° C.; wherein the near-infrared light has a wavelength ranging from 800 to 1,100 nm, and the highest ambient temperature for the reflow soldering is set at 230 to 260° C.; the vehicle-mounted lens module can ensure stable and consistent performance of a module system before and after undergoing a reflow soldering process. The disclosure overcomes the shortcomings of the existing technology and provides a reflow-solderable vehicle-mounted lens module, which can ensure stable and consistent performance of a module system before and after undergoing a reflow soldering process with the highest ambient temperature of 230 to 260° C., and can satisfy the process requirements for a camera system in DMS.