DE102024206077A1 - Camera for a motor vehicle and a method for mounting a camera - Google Patents

Abstract

A camera (100) for a motor vehicle comprising: a lens (101) with at least one optical lens (102); a camera front housing (104) and a camera rear housing (110), wherein the lens (101) is fixed to the camera front housing (104); a printed circuit board (105) with an image sensor (106) arranged on the printed circuit board (105), wherein the image sensor (106) faces the lens (101) and is optically aligned with it; and at least two retaining elements (109-2) which are configured to hold the printed circuit board (105) at a distance from the camera front housing (104); and wherein the printed circuit board (105) has through-openings (111) corresponding to the at least two retaining elements (109-2), wherein one of the retaining elements (100-2) is guided at least partially through one of the through-openings (111). In this case, the at least two retaining elements (109-2) are part of a one-piece alignment element (109), and wherein the alignment element (109) further comprises a flat support frame (109-1) which is connected to the camera front housing (104), and wherein the at least two retaining elements (109-2) are arranged projecting away from a side of the support frame (109-1) opposite the camera housing in the direction of the circuit board (105).

Description

The present invention relates to a camera for a motor vehicle and a method for mounting a camera according to the independent claims.

State of the art

The DE 10 2017 124 550 A1 The disclosure relates to a camera for a motor vehicle, comprising a housing made of an electrically conductive material, a first circuit board on which an image sensor of the camera is arranged, and at least two retaining elements connected to the first circuit board and to the housing, wherein the first circuit board is held spaced apart from the housing by means of the at least two retaining elements and is electrically connected to the housing, wherein the housing comprises a front housing part and a rear housing part, wherein the front housing part and the rear housing part are electrically connected to each other and wherein the front housing part and the rear housing part are connected to each other by means of a welded connection.

Disclosure of the invention

The present invention relates to a camera for a motor vehicle. The camera comprises a lens with at least one optical lens; a camera front housing and a camera rear housing, wherein the lens is fixed to the camera front housing; a printed circuit board with an image sensor arranged on the printed circuit board, wherein the image sensor faces the lens and is optically aligned with it; and at least two retaining elements, which are configured to hold the printed circuit board at a distance from the camera front housing; and wherein the printed circuit board has through-holes corresponding to the at least two retaining elements, wherein one of the retaining elements is guided at least partially through one of the through-holes.

According to the invention, the at least two retaining elements are part of a one-piece alignment element, wherein the alignment element further comprises a flat support frame which is connected to the camera front housing, and wherein the at least two retaining elements are arranged projecting away from a side of the support frame opposite the camera housing in the direction of the circuit board.

The lens can be screwed into the camera front housing for fixation. Alternatively, the camera can have at least one welded or soldered connection to fix the lens to the camera front housing. The optical lenses can be designed as a lens stack. The at least one optical lens can be arranged in a lens housing of the lens. In this case, the lens housing is fixed to the camera front housing. Alternatively, the camera front housing and the lens housing can be designed as a single component. In this case, the at least one lens of the lens is arranged in a designated area of the camera front housing.

The flat support frame has, in particular, a recess through which at least part of the lens protrudes.

The circuit board is specifically designed to accommodate the image sensor and at least two mounting elements. The circuit board can also accommodate other components, such as a camera connector, as well as other electronic components. The fact that the image sensor is optically aligned with the lens means, in particular, that during a camera assembly process, the image sensor was positioned such that images projected onto the image sensor through the lens exhibit the best possible quality. This will be explained in more detail in the subsequent description of the inventive method for assembling a camera.

The at least two retaining elements and the circuit board are each connected to each other by means of a soldered connection.

The camera's front housing and rear housing can be connected in such a way as to protect the camera from the ingress of materials from its surroundings. The front and rear housings can be connected by a material-fit or form-fit connection. The camera may also have a housing cover. The housing cover can be located on the side of the rear housing facing away from the lens.

The advantage of the invention lies in the fact that adhesive bonds in the camera can be avoided. Adhesive bonds have the disadvantage of undesirable behavior due to expansion during temperature fluctuations, swelling due to moisture, and/or the deterioration of their properties over time. By avoiding such adhesive bonds in the camera presented here, it is possible to maintain a constant optical alignment of the image sensor to the lens. For example, a change in the distance between the image sensor and the lens and This prevents the associated defocusing, even with temperature fluctuations, humidity, or over time. The connections between the lens and the camera front housing, as well as between the circuit board and the mounting elements, are designed to be very robust. The one-piece alignment element is advantageously an extremely robust component. The flat support frame of the mounting element rests completely against the camera front housing. The connection of the flat support frame to the camera front housing, and the direct and robust connection of the flat support frame to the at least two mounting elements, allows for significantly fewer rejects during camera assembly and, in particular, optical alignment. The connection between the circuit board and the camera front housing via the one-piece alignment element remains extremely stable, even when the camera is used in a motor vehicle.

In an advantageous embodiment, the support frame and the camera front housing are connected by means of a positive-locking or a material-locking connection. A positive-locking connection can, for example, be a riveted joint. A material-locking connection can, for example, be a welded joint. The advantage of this embodiment is that the support frame and the camera front housing are extremely stable. This significantly reduces the likelihood of a change in the optical alignment of the lens to the image sensor over time.

In a further advantageous embodiment, the camera front housing has a first area into which the lens is inserted and fixed, and a lens collar projecting outwards from the first area on a side facing the circuit board, with the support frame of the alignment element being arranged abutting the lens collar. The lens collar can advantageously form a bearing surface for the flat support frame. The support frame can be attached to this bearing surface with particular stability. The first area of the camera front housing is, in particular, designed as a hollow cylinder. In this case, the hollow cylindrical first area of the camera housing can accommodate a lens that is at least partially cylindrical.

In an advantageous embodiment, the lens collar and the support frame have a square base structure. The advantage of this embodiment is that the support frame can be adapted to a base structure of the printed circuit board, which can also be square, for example. At the same time, the support frame with its square base structure can rest against the lens collar, which also has a square base structure, as a contact surface and be attached there particularly securely.

In an advantageous embodiment, the retaining elements are pin-shaped and at least partially have a cavity. This advantageously reduces the weight of the alignment element.

The invention further relates to a method for mounting a camera. The method comprises the following steps: providing a pre-assembly consisting of a camera front housing and a lens fixed to the camera front housing; providing a one-piece alignment element, wherein the alignment element has a flat support frame, with at least two retaining elements projecting from one side of the support frame; arranging and attaching the support element of the alignment element to the camera front housing such that the at least two retaining elements project from a side of the support frame opposite the camera housing; providing a printed circuit board with an image sensor arranged on the printed circuit board, wherein the printed circuit board has through-holes corresponding to the at least two retaining elements; guiding the retaining elements at least partially through the respective through-holes of the printed circuit board, wherein the image sensor faces the lens and the printed circuit board is held at a distance from the camera front housing; optically aligning the image sensor with the lens; and connecting the retaining elements and the printed circuit board.

The circuit board may still have an electrical connector on a side opposite the image sensor. The procedure may include the further step of attaching a camera rear housing to the camera front housing.

In particular, the method can be used to build a camera as described above.

In the step of optically aligning the image sensor with the lens, the image sensor is aligned with the lens fixed in the camera's front housing. During assembly, the image sensor is advantageously operated, whereby the resulting image of the test image captured above the fixed lens is automatically evaluated for sharpness in various image sections and for different positions. The final positioning of the image sensor The positioning is based on the contrast profiles determined by image processing. The final positioning of the image sensor is then determined so that a predefined criterion for image quality is met across the entire image field.

1. a) Es ist eine Verschiebung des Bildsensors entlang der optischen Achse (z-Achse) möglich (Fokussierung).
2. b) Es ist eine Verschiebung des Bildsensors in der Bildebene entlang einer ersten Richtung (Bildvertikale, x-Achse) möglich.
3. c) Der Bildsensor kann in der Bildebene entlang einer zweiten Richtung im rechten Winkel zur Bildvertikalen (Bildhorizontale, y-Achse) verschoben werden.
4. d) Der Bildsensor kann um die optische Achse gedreht werden (R_z).
5. e) Es kann eine Drehung des Bildsensors um die Bildhorizontale erfolgen (R_y). und
6. f) Es kann eine Drehung des Bildsensors um die Bildvertikale vorgenommen werden (R_x).

Optical alignment is preferably achieved using a computer-controlled mechanical adjustment unit. Six degrees of freedom are available for optically aligning the image sensor to the lens, as listed below:

1. a) It is possible to shift the image sensor along the optical axis (z-axis) (focusing).
2. b) It is possible to shift the image sensor in the image plane along a first direction (image vertical, x-axis).
3. c) The image sensor can be moved in the image plane along a second direction at a right angle to the image vertical (image horizontal, y-axis).
4. d) The image sensor can be rotated around the optical axis (R _z ).
5. e) The image sensor can be rotated about the image horizontal (R _y ). and
6. f) The image sensor can be rotated about the image vertical (R _x ).

The optical alignment of the image sensor with the lens minimizes the adverse effects of various tolerances in the optical and mechanical components of the camera module. Thanks to the six degrees of freedom, the lens and image sensor can be aligned very precisely. This enables the camera module to achieve the image quality required, for example, for automotive applications.

It is understood that the features mentioned above and those to be explained below can be used not only in the combinations specified, but also in other combinations or on their own, without leaving the scope of the present invention.

Drawings

• 1 dreidimensionale Schnittzeichnung eines Ausführungsbeispiels einer Kamera;
• 2 zweidimensionale Schnittzeichnung des Ausführungsbeispiels einer Kamera;
• 3 dreidimensionale Ansicht eines an einem Kamerafrontgehäuse einer Kamera befestigten Ausrichteelements in der Art eines ersten Ausführungsbeispiels;
• 4 Draufsicht auf ein an einem Kamerafrontgehäuse einer Kamera befestigten Ausrichteelements in der Art des ersten Ausführungsbeispiels;
• 5 Beispiel einer Verbindung zwischen einem Kamerafrontgehäuse und einem Ausrichtelement in der Art des ersten Ausführungsbeispiels;
• 6 dreidimensionale Ansicht eines an einem Kamerafrontgehäuse einer Kamera befestigten Ausrichteelements und einer daran befestigten Leiterplatte in der Art des ersten Ausführungsbeispiels;
• 7 zweidimensionale Schnittzeichnung einer Baugruppe aus einem Kamerafrontgehäuse einer Kamera, einem daran befestigten Ausrichteelement und einer daran befestigten Leiterplatte in der Art des ersten Ausführungsbeispiels;
• 8 dreidimensionale Ansicht eines an einem Kamerafrontgehäuse einer Kamera befestigten Ausrichteelements in der Art eines zweiten Ausführungsbeispiels;
• 9 Draufsicht auf ein an einem Kamerafrontgehäuse einer Kamera befestigten Ausrichteelements in der Art des zweiten Ausführungsbeispiels;
• 10 Beispiel einer Verbindung zwischen einem Kamerafrontgehäuse und einem Ausrichtelement in der Art des zweiten Ausführungsbeispiels;
• 11 dreidimensionale Ansicht eines an einem Kamerafrontgehäuse einer Kamera befestigten Ausrichteelements und einer daran befestigten Leiterplatte in der Art des zweiten Ausführungsbeispiels;
• 12 zweidimensionale Schnittzeichnung einer Baugruppe aus einem Kamerafrontgehäuse einer Kamera, einem daran befestigten Ausrichteelement und einer daran befestigten Leiterplatte in der Art des zweiten Ausführungsbeispiels;
• 13 Ausführungsbeispiel eines Verfahrens zur Montage einer Kamera.

Exemplary embodiments of the present invention are explained in more detail below with reference to the accompanying drawings. Identical reference numerals in the figures denote identical or equivalently acting elements. The figures show:

• 1 Three-dimensional sectional drawing of an exemplary embodiment of a camera;
• 2 two-dimensional sectional drawing of an exemplary embodiment of a camera;
• 3 three-dimensional view of an alignment element attached to a camera front housing of a camera in the manner of a first embodiment;
• 4 Top view of an alignment element attached to a camera front housing of a camera in the manner of the first embodiment;
• 5 Example of a connection between a camera front housing and an alignment element of the type of the first embodiment;
• 6 three-dimensional view of an alignment element attached to a camera front housing of a camera and a circuit board attached thereto in the manner of the first embodiment;
• 7 two-dimensional sectional drawing of an assembly consisting of a camera front housing of a camera, an alignment element attached to it and a circuit board attached to it in the manner of the first embodiment;
• 8 three-dimensional view of an alignment element attached to a camera front housing of a camera in the manner of a second embodiment;
• 9 Top view of an alignment element attached to the front housing of a camera in the manner of the second embodiment;
• 10 Example of a connection between a camera front housing and an alignment element of the type of the second embodiment;
• 11 Three-dimensional view of an alignment element attached to a camera front housing of a camera and a circuit board attached to it in the manner of the second embodiment;
• 12 two-dimensional sectional drawing of an assembly consisting of a camera front housing of a camera, an alignment element attached to it and a circuit board attached to it in the manner of the second embodiment;
• 13 Exemplary embodiment of a method for mounting a camera.

1 shows a three-dimensional sectional drawing of a first embodiment of a camera 100. 2 shows a two-dimensional Sectional drawing of this first embodiment of a camera 100. The camera 100 comprises a lens 101 with at least one optical lens 102 and a lens housing 103. The camera 101 further comprises a camera front housing 104 and a camera front housing 110. The lens 101 is fixed to the camera front housing 104. The camera 100 also comprises a circuit board 105 with an image sensor 106 arranged on the circuit board 105. The image sensor 106 faces the lens 101 and is optically aligned with it. The camera 100 further comprises a one-piece alignment element 109, the design of which is described in particular in the description of the 3 and 4 will be discussed in more detail. 1 and 2 Furthermore, the circuit board 105 has through openings 111 through which at least a part of the one-piece alignment element 109 is guided.

In this embodiment, the camera 100 also includes an electrical connector 108, which is arranged on the side of the circuit board 105 facing away from the image sensor 106. A housing cover 107 closes the area between the connector 108 and the camera front housing 110 in this example.

3 shows a three-dimensional view of an alignment element 109 attached to a camera front housing 104 of a camera in the manner of a first embodiment. 4 Figure 1 shows a top view of an alignment element 109 attached to the camera front housing 104. In the example shown here, the camera front housing 104 has a first section 104-1 into which the lens, here identifiable as the lens housing 103, is inserted and fixed. Furthermore, the camera front housing 104 has a lens collar 104-2 projecting outwards from the first section 104-1. The lens collar 104-2 is located on one side of the first section 104-1, which faces a circuit board 105 that will be added later.

The alignment element 109 has a flat support frame 109-1, which is connected to the camera front housing 104. In the example shown here, the support frame 109-1 is arranged abutting the lens collar 104-2. Both the lens collar 104-2 and the flat support frame 109-1 have a rectangular base structure in this example. Furthermore, the flat support frame 109-1 has a recess 302 through which at least a part of the lens, in this case at least the optical lens 102, protrudes.

In the first embodiment shown here, the support frame 109-1 and the camera front housing 104 are connected by means of a positive-locking connection. This positive-locking connection is realized in this embodiment by three rivet connections 301. This connection between the camera front housing 104 and the alignment element 109, as described in the first embodiment, is in 5 even more precisely illustrated.

In the 3 and 4 It is further evident that the alignment element 109 in the example shown here has the three retaining elements 109-2. The retaining elements 109-2 are arranged projecting from a side of the support element 109-1 opposite the camera front housing 104. The retaining elements 109-2 are pin-shaped.

The retaining elements 109-2 are designed to hold the camera's circuit board 105 at a distance from the camera's front housing 104. This can be easily achieved in the 6 and 7 recognize.

6 Figure 1 shows a three-dimensional view of an alignment element 109 attached to a camera front housing 104 of a camera and a circuit board 105 attached thereto in the manner of the first embodiment. 7 shows a two-dimensional sectional drawing of this assembly. As with the 1 and 2 As explained, the circuit board has 100 through-holes 111 through which at least part of the one-piece alignment element 109 is guided. In the 6 and 7 It is evident that the through-openings to the retaining elements 109-2 are designed to correspond and that each retaining element 109-2 is guided at least partially through one of the through-openings. In a method for mounting a camera, as exemplified in the 13 As shown, after guiding the retaining elements 109-2 into the through-holes, the image sensor 106 can be optically aligned to the lens 101.

Six degrees of freedom are available for the optical alignment of the image sensor 106 to the lens 101: a displacement of the image sensor 106 along the optical axis (z-axis; focusing); a displacement of the image sensor 106 in the image plane along a first direction (image vertical, x-axis); a displacement of the image sensor 106 in the image plane along a second direction at right angles to the image vertical (image horizontal, y-axis); a rotation of the image sensor 106 about the optical axis ( _Rz ); a rotation of the image sensor 106 about the image horizontal ( _Ry ); and a rotation of the image sensor 106 about the image vertical ( _Rx ).

After optical alignment, space is created between the retaining elements 109-2 and the ladder. The plate has 105 connections. In the example shown here, these are designed as solder connections 601.

The 8 , 9 , 10 , 11 until 12 Figure 1 shows a camera or parts thereof in the form of a second embodiment. This embodiment is largely similar to the first embodiment, so the following discussion will mainly focus on the differences compared to the first embodiment.

8 Figure 1 shows a three-dimensional view of an alignment element 109 attached to a camera front housing 104 of a camera in the manner of the second embodiment. 9 Figure 1 shows the corresponding top view. Compared to the first embodiment, it can be seen that the lens housing and the camera front housing 104-1 are formed in one piece. Furthermore, the retaining elements 109-2 in the second embodiment shown here are pin-shaped and each has a cavity 109-3. The support frame 109-1 and the camera front housing 104 are connected to each other by means of a material-fit connection, which is 9 and also in 10 are recognizable as weld joint 901.

11 Figure 1 shows a three-dimensional view of the alignment element 109 attached to the front housing 104-1 of a camera and a circuit board 105 attached thereto in the manner of the second embodiment. 12 The corresponding two-dimensional sectional drawing of this assembly. Reference is made to the details of the 6 and 7 referred.

13 Figure 1 shows an embodiment of a method 1300 for mounting a camera. This can be a camera 100, such as those wholly or partially integrated into the 1 , 2 , 3 , 4 , 5 , 6 , 7 , 8 , 9 , 10 , 11 until 12 is described.

Method 1300 starts in step 1301. In step 1302, a pre-assembly consisting of a camera front housing and a lens fixed to the camera front housing is provided. In step 1303, a one-piece alignment element is provided, wherein the alignment element has a flat support frame, with at least two retaining elements projecting from one side of the support frame. In step 1304, the support element of the alignment element is arranged and fastened to the camera front housing such that the at least two retaining elements project from a side of the support frame opposite the camera housing. In step 1305, a printed circuit board is provided with an image sensor arranged on the circuit board, wherein the circuit board has through-holes corresponding to the at least two retaining elements. In step 1306, the retaining elements are guided at least partially through the respective through-holes of the circuit board, wherein the image sensor faces the lens and the circuit board is held at a distance from the camera front housing. In step 1307, the optical image sensor is aligned with the lens. In step 1308, the mounting elements and the circuit board are connected. The process 1300 ends in step 1309.

QUOTES INCLUDED IN THE DESCRIPTION

This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions.

Cited patent literature

• DE 10 2017 124 550 A1 [0002]

Claims (6)

A camera (100) for a motor vehicle comprising: • a lens (101) with at least one optical lens (102); • a camera front housing (104) and a camera rear housing (110), wherein the lens (101) is fixed to the camera front housing (104); • a printed circuit board (105) with an image sensor (106) arranged on the printed circuit board (105), wherein the image sensor (106) faces the lens (101) and is optically aligned with it; and • at least two retaining elements (109-2) which are configured to hold the printed circuit board (105) at a distance from the camera front housing (104); and wherein the printed circuit board (105) has through-holes (111) corresponding to the at least two retaining elements (109-2), wherein one of the retaining elements (109-2) is guided at least partially through one of the through-holes (111); characterized in that • the at least two retaining elements (109-2) are part of a one-piece formed alignment element (109), and wherein the alignment element (109) further comprises a flat support frame (109-1) which is connected to the camera front housing (104), and wherein the at least two retaining elements (109-2) are arranged projecting away from a side of the support frame (109-1) opposite the camera front housing (104) in the direction of the circuit board (105). Camera (100) after Claim 1 , wherein the support frame (109-1) and the camera front housing (104) are connected by means of a positive or a material connection. Camera (100) after Claim 1 or 2 , wherein the camera front housing (104) has a first area (104-1) into which the lens (101) is inserted and fixed, and a lens collar (104-2) projecting outwards from the first area (104-1) on a side of the first area (104-1) facing the circuit board (105), and wherein the support frame (109-1) of the alignment element (109) is arranged adjacent to the lens collar (104-2). Camera (100) after Claim 3 , wherein the lens collar (104-2) and the support frame (109-1) have a square basic structure. Camera (100) according to one of the preceding claims, wherein the retaining elements (109-2) are pin-shaped and wherein the retaining elements (109-2) each have at least a partial cavity (109-3). A method (1300) for mounting a camera, comprising the steps of: • Providing (1302) a pre-assembly consisting of a camera front housing and a lens fixed to the camera front housing; • Providing (1303) a one-piece alignment element, wherein the alignment element has a flat support frame, with at least two retaining elements projecting from one side of the support frame; • Arranging and fastening (1304) the support element of the alignment element to the camera front housing such that the at least two retaining elements project from one side of the support frame opposite the camera housing; • Providing (1305) a printed circuit board with an image sensor arranged on the printed circuit board, wherein the printed circuit board has through-holes corresponding to the at least two retaining elements; • Guide (1306) the retaining elements at least partially through the respective through-holes of the circuit board, with the image sensor facing the lens and the circuit board held at a distance from the camera front housing; • Optically align (1307) the image sensor with the lens; and • Connect (1308) the retaining elements and the circuit board.