Vehicular Camera Lens Barrel Welding for Micron-Level Alignment
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Solution Overview
Problem
Existing vehicular camera systems face challenges in achieving micron-level tolerances during lens alignment and focus due to environmental sensitivity of UV-cured glues and complications in weld joint processes, such as movement during welding and alloy compatibility, which increase manufacturing costs and cycle times.
Innovation Solution
A vehicular camera assembly that uses an alignment member, such as a lens bezel or wedge, adjustably secured via tack welding and further fixed via laser welding, to align and focus the lens relative to the imager, with post-weld processing to correct shifts, ensuring micron-level alignment and focus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If UV-cured glue is used to align and secure the lens barrel, then the lens alignment can be achieved, but the alignment becomes sensitive to environmental changes (temperature, humidity) and requires long curing times
Solution Approach 1:
The patent replaces the chemical bonding system (UV-cured glue) with a mechanical-welding system. The lens barrel is mechanically aligned using precision fixtures and then permanently secured through welding processes (tack welding followed by laser welding), eliminating the need for chemical adhesives and their associated environmental sensitivities and curing delays.
Solution Approach 2:
The patent changes the bonding mechanism from chemical (adhesive curing) to physical/thermal (welding). This parameter change transforms the alignment process from a time-dependent chemical reaction to an immediate physical bonding process, drastically reducing cycle time and eliminating environmental sensitivity to temperature and humidity.
2Reliability
If welding is used to secure the lens barrel, then the alignment stability is improved, but movement during welding and alloy compatibility issues increase manufacturing complexity
Solution Approach 1:
The patent applies preliminary alignment actions before welding. Precision fixtures and alignment tools are used to establish the correct lens-barrel position and orientation prior to any welding. This preliminary mechanical alignment ensures that once welding begins, no further adjustment is needed, simplifying the welding process itself and reducing its complexity.
Solution Approach 2:
The welding process is segmented into multiple stages: first tack welding at specific points to secure the alignment, then final laser welding to complete the bonding. This segmentation allows for controlled, step-by-step welding that manages thermal effects and reduces complexity compared to attempting a single-pass weld.
3Manufacturing precision
If micron-level alignment tolerances are achieved through traditional methods, then manufacturing precision is improved, but the process becomes sensitive to environmental factors and increases production costs
Solution Approach 1:
The patent replaces environmentally-sensitive chemical adhesive systems with a mechanical alignment and welding system. The alignment is achieved through precision mechanical fixtures that physically constrain the lens barrel to micron-level tolerances, then welding provides permanent fixation that is insensitive to temperature and humidity variations.
Solution Approach 2:
The patent introduces precision alignment fixtures and welding tooling as intermediary elements between the lens barrel and the camera housing. These intermediaries provide the mechanical constraints and bonding interface that achieve micron-level alignment without relying on environmentally-sensitive adhesives.
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 solution provides stable lens alignment with reduced sensitivity to environmental changes, minimizing manufacturing costs and cycle times while maintaining precise micron-level tolerances, thus enhancing the accuracy and reliability of vehicular camera systems.
Implementation Method 1
the alignment member is at least partially secured (such as tack welded) to the first portion of the camera housing and the lens barrel is at least partially secured (such as tack welded) to the alignment member
Implementation Method 2
the alignment member is further or finally secured (such as laser welded) to the first portion of the camera housing and the lens barrel is further or finally secured (such as laser welded) to the alignment member
Data Source
AI summary
A vehicular camera includes a lens barrel accommodating a lens, a housing, and an imager printed circuit board. During assembly of the camera, with the lens barrel received through an alignment element and a first portion of the housing, the lens barrel is adjusted relative to the first portion of the housing and alignment element to initially align the lens relative to the imager. With the lens initially aligned relative to the imager, the alignment element is initially attached to the first portion of the housing and the lens barrel is initially attached to the alignment element to initially retain the lens relative to the imager. With the lens initially retained relative to the imager, the lens barrel is adjusted to further align the lens relative to the imager and the alignment member is secured at the housing and the lens barrel is secured at the alignment member.