US Patent No. 10,367,984

METHOD OF FORMING CAMERA MODULE FOR VEHICULAR VISION SYSTEM


Patent No. 10,367,984
Issue Date July 30, 2019
Title Method Of Forming Camera Module For Vehicular Vision System
Inventorship Jamie A. Mleczko, Washington, MI (US)
Assignee MAGNA ELECTRONICS INC., Auburn Hills, MI (US)

Claim of US Patent No. 10,367,984

1. A method of forming a camera module for a vision system for a vehicle, said method comprising:providing a circuit board, wherein the circuit board has an imager and associated circuitry disposed thereat;
providing a lens holder for holding a lens assembly, the lens assembly including a plurality of optical elements;
disposing an adhesive in an uncured state at one or both of the lens holder and the circuit board;
positioning the lens holder at the circuit board with the uncured adhesive disposed between and contacting the lens holder and the circuit board;
optically aligning the plurality of optical elements with the imager at the circuit board;
with the plurality of optical elements optically aligned with the imager at the circuit board, and with the adhesive between and contacting the lens holder and the circuit board, forming a lens holder and circuit board construction by curing the adhesive to an at least partially cured state to secure the lens holder relative to the circuit board;
with the adhesive cured to the at least partially cured state, placing the lens holder and circuit board construction in a first mold, wherein, when placing the lens holder and circuit board construction in the first mold, the lens holder and circuit board construction is datumed in the first mold by a portion of the lens holder;
forming an inner molded construction by molding, using a first polymeric resin, an inner molding over and around the circuit board and over a portion of the lens holder;
placing the inner molded construction in a second mold, wherein, when placing the inner molded construction in the second mold, the inner molded construction is datumed in the second mold by the portion of the lens holder; and
forming an outer molded construction by molding, using a second polymeric resin, an outer molding over the inner molding and over another portion of the lens holder to encase the inner molding.