Vehicle camera with modular construction

A camera assembly for a vehicular vision system includes a housing that accommodates a lens and a circuit board. An imager is disposed at the circuit board and optically aligned with the lens, and circuitry is disposed at the circuit board and electrically connected with the imager. The housing includes a rear housing portion that has an aperture therethrough, with the aperture aligned with an electrical connecting element of the circuit board. A bracket includes a mounting portion configured to attach at the vehicle and at the rear housing portion. With an electrical connector electrically connected to the electrical connecting element of the circuit board, the bracket is attached at the rear housing portion, and a structural element of the electrical connector is clamped between the bracket and the rear housing portion to maintain electrical connection of the electrical connector with the electrical connecting element of the circuit board.

FIELD OF THE INVENTION

BACKGROUND OF THE INVENTION

Use of imaging sensors in vehicle imaging systems is common and known. Examples of such known systems are described in U.S. Pat. Nos. 5,949,331; 5,670,935 and/or 5,550,677, which are hereby incorporated herein by reference in their entireties. Various cameras are known, such as described in U.S. Pat. Nos. 7,965,336 and/or 8,542,451, which are hereby incorporated herein by reference in their entireties.

SUMMARY OF THE INVENTION

The present invention provides a camera assembly configured for mounting at a vehicle. The camera assembly comprises a camera module or unit (having a lens assembly, imager and circuit element or circuit board and associated circuitry) and a bracket for receiving or attaching to the camera unit and for mounting the camera at the vehicle. An electrical connector is received at a rear portion of the bracket and electrically connects with the circuitry of the circuit element for electrically connecting the circuitry to a wiring harness of a vehicle or the like.

According to an aspect of the present invention, a camera assembly for a vision system of a vehicle includes a camera, a bracket and an electrical connector. The camera includes a lens assembly, an imager disposed on a circuit element, and an outer camera housing portion. The circuit element has a connector disposed at a surface thereof generally opposite the imager. The bracket comprises an outer bracket housing portion, an attachment plate and a mounting portion. The mounting portion is configured to attach at a vehicle. The electrical connector has a connector plate and a connecting end at the connector plate. The outer camera housing portion mates with the outer bracket housing portion and, when so mated or attached, the connector of the circuit element is generally aligned with an aperture of the attachment plate and the connecting end of the electrical connector protrudes through the aperture to electrically connect with the connector of the circuit element. The connector plate is clamped or sandwiched between the housing portion and the attachment plate of the bracket to seal the connector at the bracket.

Thus, the present invention provides a modular camera design and camera assembly method or process that allows for easy adaptation into multiple applications, and reduced part count in the assembly. Automotive cameras require a method of absorbing the tolerances associated with alignment of the image sensor relative to the lens. Typically, this is done by allowing the housing to vary in position relative to the lens or by implementing flexible printed circuits, both of which increase the size of the camera. The present invention provides a method of absorbing these tolerances using a new connector-plate concept, which provides a much smaller size and the least impact to the packaging of the camera in the vehicle. In addition, the camera housing is integrated as part of the camera bracket to reduce the part count, cost, and complexity of the assembly. Various bracket-housings and connector-plates can then be interchanged to adapt the camera to multiple applications.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

A vehicle vision system and/or driver assist system and/or object detection system and/or alert system operates to capture images exterior of the vehicle and may process the captured image data to display images and to detect objects at or near the vehicle and in the predicted path of the vehicle, such as to assist a driver of the vehicle in maneuvering the vehicle in a rearward direction. The vision system includes an image processor or image processing system that is operable to receive image data from one or more cameras and provide an output to a display device for displaying images representative of the captured image data. Optionally, the vision system may provide display, such as a rearview display or a top down or bird's eye or surround view display or the like.

Referring now to the drawings and the illustrative embodiments depicted therein, a vehicle10includes an imaging system or vision system12that includes at least one exterior facing imaging sensor or camera, such as a rearward facing imaging sensor or camera14a(and the system may optionally include multiple exterior facing imaging sensors or cameras, such as a forward facing camera14bat the front (or at the windshield) of the vehicle, and a sideward/rearward facing camera14c,14dat respective sides of the vehicle), which captures images exterior of the vehicle, with the camera having a lens for focusing images at or onto an imaging array or imaging plane or imager of the camera (FIG. 1). Optionally, a forward viewing camera may be disposed at the windshield of the vehicle and view through the windshield and forward of the vehicle, such as for a machine vision system (such as for traffic sign recognition, headlamp control, pedestrian detection, collision avoidance, lane marker detection and/or the like). The vision system12includes a control or electronic control unit (ECU) or processor18that is operable to process image data captured by the camera or cameras and may detect objects or the like and/or provide displayed images at a display device16for viewing by the driver of the vehicle (although shown inFIG. 1as being part of or incorporated in or at an interior rearview mirror assembly20of the vehicle, the control and/or the display device may be disposed elsewhere at or in the vehicle). The data transfer or signal communication from the camera to the ECU may comprise any suitable data or communication link, such as a vehicle network bus or the like of the equipped vehicle.

The camera assembly of the present invention comprises a mounting bracket and a camera portion and housing that reduces the total part count and provides a more flexible method for assembly. In this construction, the housing and bracket are one item which provides the advantages of reduced cost, reduced processes in assembly, and more accurate positioning of the imager relative to the mounting features in the vehicle. In addition, it is known that from camera to camera that the PCB will vary in position to optimize the focus and alignment of the image. Typical methods to absorb this tolerance have been a flexible printed circuit, a floating housing, or spring contacts or the like. The flexible printed circuit and spring contacts can be expensive, complicated, and may raise issues with electromagnetic interference. The floating housing method causes one half of the camera to purposely be offset in position relative to the other, raising cosmetic concerns and mounting issues for some vehicle manufacturers. The camera module or assembly may utilize aspects of the camera assemblies described in U.S. patent application Ser. No. 15/341,047, filed Nov. 2, 2016 and published May 11, 2017 as U.S. Publication No. US-2017-0129419, which is hereby incorporated herein by reference in its entirety.

The construction of the present invention provides a unique method to absorb this tolerance using a connector plate external to the camera module. The variation in position of the connector plate would not affect the mounting, cosmetics, or imager position. In addition, this construction is very cost efficient because the connector engages directly with the printed circuit board using a common surface mount header. The construction of the present invention offers a modular structure where a common lens and PCB assembly could accept a variety of bracket-housings and connector plates to build unique applications for each vehicle manufacturer.

For example, and such as shown inFIGS. 2-6, a camera assembly30includes a mounting bracket32and a camera34. The camera includes an imager36disposed at a circuit element or printed circuit board (PCB)38and includes a lens assembly40aligned with the imager36(seeFIGS. 5 and 6). As shown inFIGS. 5 and 6, the camera34has an outer or front camera housing portion41that accommodates the lens assembly and that is configured to mate with or attach to the bracket housing portion or rear housing portion42of the bracket32. The PCB38includes a connector or connecting circuitry or connecting element44(such as a SMT header or other connecting element or circuitry) at the side of the PCB opposite the imager. When the front camera housing portion41is mated with the rear housing portion42, the connecting circuitry or element is generally aligned with an aperture48athrough the attachment plate48of the rear camera housing portion42.

The connector44of the PCB38electrically connects to terminals of a connecting end of a connector46, with the connecting end disposed at or protruding through the aperture of the attachment plate, and with the connector46including a connecting plate46athat is attached at the attachment plate or portion48of the mounting bracket32, whereby the camera34is sealed at the bracket32. The connector46may comprise any suitable connecting end (depending on the application) and the connector plate46ais configured for attaching at the attachment plate48of the bracket. For example, the electrical connector46may comprise a 90 degree connector or may comprise a wire harness46′ (FIG. 4), depending on the particular application of the camera assembly. The connector plate is ready for direct connection with a vehicle harness, such as via the 90 degree connector, or may exit at any angle and have any known connector configuration or geometry. The camera construction allows for various bracket-housings and connector plates to be interchanged for different camera applications. Optionally, the electrical connector may comprise an overmolded connector element with the connector plate molded at the connecting end of the connector, such as by utilizing aspects of the connectors described in U.S. patent application Ser. No. 15/341,048, filed on Nov. 2, 2016 and published May 11, 2017 as U.S. Publication No. US-2017-0133811, which is hereby incorporated herein by reference in its entirety.

In the illustrated embodiment ofFIGS. 2-8, the attachment plate48of the bracket32has an opening or aperture therethrough for receiving the connecting end or portion of the electrical connector46in order to make electrical connection to the connector or SMT header44of the PCB38when the camera is attached at the bracket and/or when the electrical connector46is attached at the bracket. The rear surface of the attachment plate48includes a sealing element50that seals against the connector plate or portion46aof the electrical connector when the electrical connector is attached at the bracket. The aperture of the attachment plate may be slightly oversized relative to the connecting end of the connector (in other words, a cross dimension of the aperture may be slightly greater than a corresponding cross dimension of the connecting end of the connector that is received in the aperture), such that the electrical connector46(and its connecting end) may be laterally adjusted relative to the attachment plate48and the connecting circuitry44to align the connecting end of the connector46with the connecting circuitry44, without need for other tolerance compensating connectors or flexible circuits. When the connecting end of the connector46is aligned with the connecting circuitry44, the connector may be pressed towards the camera housing to electrically connect the connecting end of the connector46with the connecting circuitry44and to engage the connector plate46awith the attachment plate48, whereby the connector plate46amay be secured relative to the attachment plate48, such as via welding or fasteners or the like.

Optionally, and such as shown inFIG. 5, the attachment plate48of the bracket may also include weld ribs52to facilitate fastening of the connector plate46aof the electrical connector46at the bracket. The welding may be via ultrasonic welding, laser welding, hot plate welding, friction welding, vibration welding, hot riveting, heat staking or the like. Optionally, and such as shown inFIG. 6, the connector plate46a′ of the electrical connector46may be attached at the attachment plate48′ of the bracket32′ via one or more fasteners52′ (if fasteners are used, the holes through the connector plate46afor the fasteners may be slightly oversized to allow for lateral adjustment of the connector relative to the threaded fastener holes at the attachment plate).

The bracket32thus provides a support structure for the camera34and for an electrical connector46, while providing a desired mounting structure or element54for mounting or attaching the camera assembly30at a vehicle. For example, the mounting element54may comprise a snap-in type construction (or a screw-in or fastener type of bracket construction may also or otherwise be implemented). Optionally, the mounting structure or element may comprise latch features to facilitate a simple injection mold shape. Optionally, the bracket may be configured with mounting flanges for attachment at a vehicle with fasteners or screws or the like.

Optionally, the electrical connector may connect or attach at the camera housing via clamping of its flange between the camera housing and bracket, such that the bracket attachment (such as via threaded fasteners or adhesive or the like) also attaches and secures the electrical connector at the camera module. For example, and such as shown inFIGS. 7-11, a camera module or assembly130includes a mounting bracket132and a camera134, with an electrical connector146secured or retained at the camera when the mounting bracket is attached at the camera housing, as discussed in detail below. The camera includes an imager136disposed at a circuit element or printed circuit board (PCB)138and includes a lens assembly140aligned with the imager136. The camera134has an outer or front camera housing portion141that accommodates the lens assembly and that is configured to mate with or attach to a rear housing portion142that attaches to the bracket132. The PCB138includes a connector or connecting circuitry or connecting element144(such as a SMT header or other connecting element or circuitry) at the side of the PCB opposite the imager. When the front camera housing portion141is mated with the rear housing portion142, the connecting circuitry or element is generally aligned with an aperture through the attachment plate148of the rear camera housing portion142.

The connector144of the PCB138electrically connects to terminals of a connecting end of an electrical connector146, with the connecting end disposed at or protruding through the aperture of the attachment plate. Optionally, a header guidance feature146bmay be provided (such as part of the connector end of the connector146) that guides the connector end of the connector146into engagement with the connector144. The header guidance feature (such as a sleeve portion configured to receive the header connector144therein) may comprise plastic, or may comprise an electrically conductive stamping to provide EMC shielding. The connector146includes a connecting plate or flange or structure146athat is disposed between and clamped or sandwiched between the attachment plate or portion148of the rear housing portion142and a flange or portion or structure132aof the bracket132, whereby the camera134is sealed at the bracket132. The connector146may comprise any suitable connecting end (depending on the application) and the connector plate146ais configured for being received in a space formed between the rear attachment plate148and the clamping portion132aof the bracket132. For example, the electrical connector146may comprise a 90 degree connector or may comprise a wire harness, depending on the particular application of the camera assembly.

As shown inFIG. 7, the gap or space formed between the clamping portion132aof the bracket132and the rear plate148of the rear housing portion142is sized to allow sufficient clearance for the flange or plate146aof the connector to move laterally to align the electrical pins or connectors of the connector146with the header connector144at the printed circuit board138of the camera. When so aligned and electrically connected (by pressing the connector toward and into engagement with the header connector144, the flange146ais at the rear attachment plate148of the rear housing portion and against the connector seal150of the camera housing. The connector may then be received through the bracket (such as can be seen with reference toFIGS. 7 and 10), whereby the clamping portions or tabs132aof the bracket132engage the connector plate or flange146aand clamp the connector in place when the fasteners152are tightened to attach the bracket132to the rear housing portion142of the camera. In the illustrated embodiment (and such as shown inFIGS. 9 and 11), the clamping portions132acomprise tabs or flanges that partially circumscribe the opening through the bracket, with the flanges132anot being present at the bosses132bthrough which the fasteners152are received for threadedly engaging threaded bores in the rear housing portion142of the camera (with the corner regions of the connector plate146abeing recessed at the fasteners and bosses to allow clearance for the fastener to be received through the bosses of the bracket and into the bores or passageways at the rear housing portion).

The construction of camera assembly130offers a simple cost-effective method of achieving a floating connector design without requiring additional fastening methods. Separating the bracket from the housing gives more flexibility for molded shapes, and it also allows the bracket and camera cover to comprise different materials (such as, for example, a plastic camera housing and a metal bracket or a metal camera housing and a plastic bracket). Also, such a configuration allows for a vehicle seal156to be placed between the camera housing and bracket (where the seal156may be part of the bracket), as some vehicle manufacturers use this camera seal to ensure water does not enter the cabin. This construction also has an advantage over current market cameras because the lens and camera housing can be aligned without requiring flexible circuits or springs inside the camera. This construction offers more flexibility to accommodate various vehicle applications and customer preferences.

Thus, the camera assembly for a vision system of a vehicle includes a camera and a bracket and an electrical connector. The camera or camera module comprises the lens assembly and has the imager disposed on the circuit element or PCB, with the outer camera housing portion supporting the lens assembly. The circuit element includes the connector (such as an SMT header or the like) disposed at a surface thereof generally opposite the imager. The bracket comprises the outer bracket housing portion, the attachment plate (having an aperture therethrough for the electrical connector to pass when the bracket is attached at the rear camera housing and connector assembly) and the mounting portion, with the mounting portion configured to attach at a vehicle.

The PCB and imager and lens assembly may be part of a camera module or unit, and may be received at the outer bracket housing portion. A connecting end of the electrical connector is at the connector plate and protrudes from the connector plate for electrically connecting to the connector at the PCB. The connecting end of the electrical connector is received through an aperture in the rear attachment plate of the rear housing portion and is aligned with the connector at the PCB and electrically connected thereto (and the connector may be laterally adjusted relative to the connector of the circuit element and the attachment plate to align its connecting end with the connector of the circuit element). Thus, when the outer camera housing portion is mated with the outer bracket housing portion, the electrical connector is received through the bracket and the flange or plate of the connector is clamped or sandwiched between the bracket and rear housing portion of the camera.

The connector plate is thus secured at the attachment plate of the rear housing portion by the bracket, and after alignment and electrical connection is made between the connecting end of the electrical connector and the connector of the circuit element. The bracket may be attached at the attachment plate of the rear housing portion via welding or fasteners, and a sealing element may be disposed around the aperture to seal against the attachment plate and the connector plate when the bracket is attached at the attachment plate. The mounting portion of the bracket may be configured to attach at a vehicle via a snap attachment or via at least one fastener or the like, depending on the particular application of the camera assembly of the present invention.

The connector is ready for direct connection with a vehicle harness, such as via the 90 degree connector, or may exit at any angle and have any known connector configuration or geometry. The camera construction allows for various bracket-housings and connector plates to be interchanged for different camera applications. Optionally, the electrical connector may comprise an overmolded connector element with the connector plate molded at the connecting end of the connector, such as by utilizing aspects of the connectors described in U.S. patent application Ser. No. 15/341,048, filed on Nov. 2, 2016 and published May 11, 2017 as U.S. Publication No. US-2017-0133811, which is hereby incorporated herein by reference in its entirety.

Thus, a mounting bracket or bracket-housing piece of the present invention may be designed for a particular vehicle or application (so as to attach to the vehicle and provide a desired viewing angle of the camera when the bracket and camera are attached at the vehicle) and may allow for selection of a particular or desired camera (having a particular imager and lens assembly for a particular application) that may be readily attached at the bracket. Optionally, the camera (having the imager and lens assembly) may comprise a common or universal camera and may be readily attached at a particular bracket for a particular application or vehicle, thereby providing ease of manufacturing of the camera assembly and adapting of the camera assembly for a particular vehicle application. The electrical connection to the SMT header of the PCB of the camera is done via the connector end of the electrical connector that attaches at the rear of the bracket, and thus tolerances can be accommodated for during the connection of the electrical connector, without costly additional tolerance compensating connectors or the like. The connector plate of the connector may be movably or adjustably positioned at the rear of the attachment plate to electrically connect to the connector or SMT header of the PCB of the camera, and then the bracket may be welded or otherwise attached at the rear of the bracket attachment plate, thereby clamping the connector plate or flange between the bracket and camera housing and sealing the connector at the rear of the camera housing. Thus, the camera has a separate connector piece that follows the circuit board and that is plugged into the housing and the connecting circuitry and then is clamped or secured at the camera housing via the bracket being staked or welded or fastened to the housing. The lens housing of the camera may also be sealed at the outer end of the outer housing of the bracket to seal the camera at the bracket so as to provide a watertight camera and bracket assembly or module for attachment at a vehicle.

Therefore, the camera assembly and assembly process of the present invention provides for adaptation of a universal or common camera for a particular vehicle application. The front housing portion is provided with the lens and the circuit board and imager may be attached to the front housing portion with the imager optically centered and aligned with the lens. The rear housing portion is mated or joined with the front housing portion, with the rear housing portion being selected to have the desired or appropriate or selected mounting structure for mounting the camera at the vehicle. The electrical connector is selected (such as a straight socket connection or angled socket connection or wire or cable connection) for the particular electrical connection at that vehicle. The electrical connector is disposed at the rear attachment portion of the camera housing and the connecting end of the connector is inserted or received in the aperture of the rear attachment portion and aligned with (such as via lateral adjustment of the connecting end relative to the aperture and connecting element) and electrically connected with the connecting element of the circuit board. When the connecting end of the connector is electrically connected to (such as via being plugged into) the connecting element of the circuit board, the flange or structural element of the connector is sandwiched between the bracket and the rear attachment portion of the rear housing when the bracket is attached at the rear attachment portion of the rear housing (such as via fasteners or welding or the like). When the bracket is so attached, the flange or structural element of the connector engages the rear attachment portion and/or a seal disposed between the rear attachment portion and flange to seal the camera around the aperture of the rear attachment plate.

The camera or sensor may comprise any suitable camera or sensor. Optionally, the camera may comprise a “smart camera” that includes the imaging sensor array and associated circuitry and image processing circuitry and electrical connectors and the like as part of a camera module, such as by utilizing aspects of the vision systems described in International Publication Nos. WO 2013/081984 and/or WO 2013/081985, which are hereby incorporated herein by reference in their entireties.

For example, the vision system and/or processing and/or camera and/or circuitry may utilize aspects described in U.S. Pat. Nos. 8,694,224; 7,005,974; 5,760,962; 5,877,897; 5,796,094; 5,949,331; 6,302,545; 6,396,397; 6,498,620; 6,523,964; 6,611,202; 6,201,642; 6,690,268; 6,717,610; 6,757,109; 6,802,617; 6,806,452; 6,822,563; 6,891,563; 6,946,978; 7,859,565; 5,550,677; 5,670,935; 7,881,496; 7,720,580; 7,038,577; 6,882,287; 5,929,786 and/or 5,786,772, which are all hereby incorporated herein by reference in their entireties. The system may communicate with other communication systems via any suitable means, such as by utilizing aspects of the systems described in International Publication Nos. WO/2010/144900; WO 2013/043661 and/or WO 2013/081985, and/or U.S. Publication No. US-2012-0062743, which are hereby incorporated herein by reference in their entireties.

The imaging device and control and image processor and any associated illumination source, if applicable, may comprise any suitable components, and may utilize aspects of the cameras (such as various imaging sensors or imaging array sensors or cameras or the like, such as a CMOS imaging array sensor, a CCD sensor or other sensors or the like) and vision systems described in U.S. Pat. Nos. 5,760,962; 5,715,093; 6,922,292; 6,757,109; 6,717,610; 6,590,719; 6,201,642; 5,796,094; 6,559,435; 6,831,261; 6,822,563; 6,946,978; 7,720,580; 8,542,451; 7,965,336; 7,480,149; 5,550,677; 5,877,897; 6,498,620; 5,670,935; 5,796,094; 6,396,397; 6,806,452; 6,690,268; 7,005,974; 7,937,667; 7,123,168; 7,004,606; 6,946,978; 7,038,577; 6,353,392; 6,320,176; 6,313,454 and/or 6,824,281, and/or International Publication Nos. WO 2009/036176; WO 2009/046268; WO 2010/099416; WO 2011/028686 and/or WO 2013/016409, and/or U.S. Pat. Publication Nos. US 2010-0020170 and/or US-2009-0244361, which are all hereby incorporated herein by reference in their entireties.

Optionally, the vision system may include a display for displaying images captured by one or more of the imaging sensors for viewing by the driver of the vehicle while the driver is normally operating the vehicle. Optionally, the vision system (utilizing the forward facing camera and a rearward facing camera and other cameras disposed at the vehicle with exterior fields of view) may be part of or may provide a display of a top-down view or birds-eye view system of the vehicle or a surround view at the vehicle, such as by utilizing aspects of the vision systems described in International Publication Nos. WO 2010/099416; WO 2011/028686; WO 2012/075250; WO 2013/019795; WO 2012/075250; WO 2012/145822; WO 2013/081985; WO 2013/086249 and/or WO 2013/109869, and/or U.S. Publication No. US-2012-0162427, which are hereby incorporated herein by reference in their entireties.