Patent Description:
Camera systems play an important role in autonomous vehicles and in various driver assist applications to aid vehicle drivers. Among various sensors used in autonomous vehicles, cameras are the main sensor technology that can capture color and contrast information at a level of detail that enables object classification. Vision cameras enable driver assist system applications such as adaptive cruise control, automatic emergency braking, forward collision warning, automatic high beam control, traffic sign recognition, lane keep systems, parking assist, cross-traffic alert, and rear-view mirror. Vision cameras may also be included inside the vehicle cabin for such features as gaze tracking, presence detection and gesture recognition. Although cameras may be mounted on a vehicle roof, they are increasingly being arranged at other sections of a vehicle such as along the side or even front of a vehicle. Vision cameras arranged in low areas of a vehicle including the side or front sections are especially susceptible to weather conditions and variations in lighting. It is known from <CIT> to use a camera assembly comprising an image sensor, infrared illuminators, a single-piece cover element positioned in front of the image sensor and the infrared illuminators. The cover element includes a first portion corresponding to the image sensor and a second portion corresponding to the infrared illuminators. It is known from <CIT> to use a vision system of a vehicle that comprises a camera and an illumination source with a wavelength of between about <NUM> and about <NUM> that is activated during nighttime lighting conditions and the camera captures images of the area illuminated by the illumination source. It is known from <CIT> to use a camera integrated in the exterior mirror with infrared ray illumination.

For purposes of general illustration, a typical sensor arrangement for an autonomous vehicle is shown in <FIG>. The arrangement of <FIG> may include several vision cameras, such as forward stereo cameras, surround cameras, rear and side cameras. Vision cameras <NUM>, <NUM>, <NUM> may facilitate features including traffic sign recognition, lane departure warning, digital side mirror, park assist, and rear view. Vision cameras may be mounted at various positions of a vehicle. It is desirable to mount some vision cameras in lower sections of a vehicle, which may include locations near a vehicle wheel well. However, cameras located in these low positions are vulnerable to road debris and other objects that may come in contact with a camera and possibly cause damage to a camera lens.

A compact digital vehicle camera and IR illuminator apparatus according to the invention is defined in claim <NUM>. Preferred embodiments of the invention are set-out in the dependent claims.

A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:.

As used herein any reference to "one embodiment" or "some embodiments" or "an embodiment" means that a particular element, feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Conditional language used herein, such as, among others, "can," "could," "might," "may," "e.g.," and the like, unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements and/or steps. In addition, the articles "a" and "an" as used in this application and the appended claims are to be construed to mean "one or more" or "at least one" unless specified otherwise.

Furthermore, the terms "approximately," "proximate," "minor," and similar terms generally refer to ranges that include the identified value within a margin of <NUM>%, <NUM>% or preferably <NUM>% in certain embodiments, and any values therebetween.

In order to obtain video information for detecting objects in the field of view of the vision camera for a vehicle, the vision camera needs to capture video information under all types of lighting conditions. Vision cameras are able to operate at normal lighting conditions where there is sufficient daylight. However, vehicles must also operate in conditions where lighting is low, due to shading, and of course during early morning or early evening hours. Vehicles must operate during nighttime. During nighttime hours, lighting may be provided by street lights or other sources including the vehicle's own headlights and backup lights, but those sources may not sufficiently provide lighting for specific objects that the camera may be focused on. There is a need to provide light that covers the field of view of the vision camera under all lighting conditions, especially during conditions of low light and darkness. Although conditions of low light and darkness relate to conditions where visible light is low to non-existent, other wavelengths of electromagnetic radiation may be used. Lighting conditions may be enhanced using a source of visible light, such as a camera flash or other camera lighting source. However, camera flash or other camera lighting needs to be bright and is not practical for use on vehicles, as vehicles generally have specific lighting constraints, for purposes of safety and other reasons. Also vehicles are generally equipped with headlights, high beam lights, fog lights, and backup lights, which may obscure a camera light. In terms of safety, camera flash and camera lighting will blind pedestrians and other drivers.

One approach to providing lighting for low light and dark conditions has been to use infrared radiation. Infrared radiation generally is a range of the electromagnetic spectrum that is not visible to humans but is in a range than can be captured by cameras. Infrared radiation used as a source of camera lighting includes wavelengths that are near the visible range, referred to as near-infrared. Near-infrared is defined as electromagnetic radiation over the range of <NUM> to <NUM> micro meters.

Infrared radiation, similar to visible light, may be reflected off of objects, even including some black objects. Vision cameras may be provided with infrared radiation in order to enhance image capture during low light and nighttime conditions. Subsequently, infrared radiation may be used to augment the available ambient light.

There are various devices that may be used as a source for infrared radiation. Light emitting diodes (LEDs) are increasingly being used to transmit infrared radiation as they are energy efficient and can be implemented in a small space. When infrared (IR) LEDs are used for transmitting infrared (IR) radiation, they are typically enclosed by a cover that protects the LED from the environment and from being damaged. The IR LED, cover and associated mounting structure are referred to herein as an IR illuminator. The cover for the IR LED may be made IR Black using black pigments that have low infrared reflectivity. The dark lens allows IR radiation to pass, and is commonly referred to as transparent black. The transparent black cover prevents transmission of visible light.

In order to provide unobstructed radiation toward an object, a cover for an IR illuminator may be provided without a secondary optic, such as a neutral cover. In this disclosure, a neutral cover is a cover that allows visible light and infrared radiation to pass without applying optics. The cover for an IR illuminator may be clear, or may include black pigments to make a transparent black lens.

Vehicle mounted vision cameras and IR illuminators are preferably provided as an assembly, or at least the IR illuminators associated with a vision camera are positioned in close proximity to the camera in order to provide IR radiation that is within the field of view of the camera. Vehicle mounted vision cameras are becoming smaller in size, but are generally incorporated with a wide-angle lens and are limited by focal length.

Locating a camera in a low section of a vehicle, such as near the ground or near a vehicle's wheel well, can expose a camera to debris or objects that can potentially damage the camera lens or even the camera circuit itself. An IR illuminator for providing infrared light for a camera is provided with an outer cover lens mounted over the LED light source for protection as well as to filter out visible light. Some embodiments may be a compact camera assembly that has IR illuminators attached adjacent to opposing sides of a vision camera. In one embodiment, a compact vision camera and IR illuminator assembly may have a width that is <NUM> or smaller. Adding a cover over the camera in such a compact assembly has been found to be difficult. The inventors have determined that in order to accommodate a cover for the camera, in a compact assembly that includes IR illuminators, the cover for the camera may be integrated with the cover lens of the IR illuminators as a single outer cover. However, a cover for the vision camera may have different optical properties than the cover lens for the IR illuminators.

<FIG> illustrates a cross-section of a compact vision camera and illuminator assembly in accordance with an exemplary aspect of the disclosure. Specific wiring and electrical contacts are omitted in order to reduce complexity. A compact camera and illuminator assembly may include a single common mounting structure <NUM>. In some embodiments, the compact vision camera and illuminator assembly may be integrated by way of a bracket. The mounting structure <NUM> or bracket preferably is of a material having some flexibility, in order to avoid breakage or cracking during installation. A single outer lens <NUM> is used for both the vision camera <NUM> and IR illuminators with IR LEDs <NUM>. The vision camera <NUM> includes a camera lens <NUM>. In some embodiments, the single outer lens <NUM> may incorporate cover bezel portions 209a, 209b for securing the outer lens <NUM> and sealing the camera with the mounting structure <NUM>. In some embodiments, the IR illuminators may each include an array of two or more IR LEDs.

In some embodiments, the mounting structure <NUM> or bracket may position the IR illuminators at an angle directed away from the focus axis of the vision camera <NUM>. The single outer lens includes a neutral portion 205a that covers the vision camera <NUM> and a transparent black portion 205b that covers the IR LEDs <NUM> of the illuminators. The transparent black portion passes IR radiation and provides other optical properties such as diffraction that increases or decreases the field of view of the IR radiation. The neutral portion 205a that covers the vision camera <NUM> may not provide optical properties, but primarily will provide protection for the camera lens. It is preferred that the neutral portion 205a be of a material that allows the image to be un-obstructively viewed by the vision camera. Both the neutral portion and the transparent black portion may be made of polycarbonate (PC) or polymethyl methacrylate (PMMA). PC may be used to protect against environmental conditions. In some embodiments, the single outer lens may be made of a glass laminant.

<FIG> illustrates a perspective view of a compact camera and illuminator structure having an outer lens. The compact vision camera and IR illuminator assembly includes a single outer lens 205a, 205b for both the camera <NUM> and IR illuminators. The compact vision camera and IR illuminators may be mounted on a mounting structure <NUM>. The single outer lens 205a, 205b may include a bezel for securing the outer lens 205a, 205b and camera lens <NUM>. The bezel may include a portion 209a that provides a liquid seal for the single outer lens 205a, 205b and a portion 209b that provides an internal seal for the camera <NUM>. The bezel portions 209a, 209b may be made of a plastic material that has low enough stiffness to conform to the mating surfaces and sufficient creep resistance to maintain tight seals. An example material is nylon, silicone plastic, and other rubbery materials.

The IR illuminators include an IR LED. In some embodiments, the IR illuminators may each include an array of two or more IR LEDs. Further, although <FIG> illustrates a pair of IR LEDs on opposite sides of the camera <NUM>, other arrangements are possible. For example, the IR illuminator may be arranged on a ring that encircles the camera. The ring arrangement may have IR LED's spaced equidistant around the camera. Alternatively, the ring arrangement may be a balanced arrangement where an equal number of IR LEDs are arranged on one side of the camera as a semicircular and the same on the other side of the camera.

<FIG> illustrates a perspective view of a compact camera and IR illuminator structure with two-shot molded outer lens. For Two Shot Molding, a multi-shot mold may be used. There are several types of multi-shot molding techniques available, such as over-molds, core-back, and multi-station molds. The mold type generally depends on part geometry, volume, quality, and molder capacity/capability. Two-shot molding may be performed using two independent injection units that inject two resin materials into a single, multi-chambered mold.

The outer lens is molded as a transparent black cover 205b bonded to a neutral cover 205a for the camera lens. The transparent black cover 205b is an elliptical shape having an oval peripheral, and an inner surface that is of a different shape than the external surface such that the thickness of the elliptical cover lens varies. The variation in thickness of the cover lens provides IR light distribution that is wider than the distribution pattern of the IR LED. The neutral cover lens 205a for the camera lens may have a circular peripheral and dome shape. The material of the transparent black cover 205b and neutral cover 205a may be the same, except that black pigments may be added to the transparent black cover 205b. In some embodiments, the material of the transparent black cover 205b and neutral cover 205a may be different, but compatible resins.

In some embodiments, the compact camera and IR illuminator structure may include a three-shot molded outer lens. In addition to one region for the neutral cover lens 205a and another region 205b for the transparent black cover, a third molded section may be included as a shielded region having light absorption properties. The single outer lens having a third molded section may be produced using a three (<NUM>)-shot molding process. Three-shot molding may be performed using three independent injection units that inject three resin materials into a single, multi-chambered mold. The shielded region may be sections of the single cover lens that are between the camera lens portion 205a and each of the transparent black regions 205b. The shielded region may be of a material that absorbs light and does not provide other optical properties such as light diffraction. The shielded region may function to prevent visible light from entering into the IR LEDs or indirectly entering the camera lens. In some embodiments, the shielded region may be of a material that prevents transmission of both IR radiation and visible light to prevent IR light from entering the camera lens.

In some embodiments, the cover lens portion 205a may include optical properties that supplement the properties of the camera lens <NUM>. The cover lens 205a may filter light so that only light within a specific wavelength range is allowed to enter into the camera sensor. For example, the camera may be made to only capture images based on IR radiation in order to alleviate affects that may occur due to variations in lighting conditions due to sunlight as well as artificial light. The cover lens 205a may skew the image so that the image that enters the camera sensor is less curved that an image that is obtained by a wide-angle lens. The cover lens 205a may improve the camera view, such as by reducing glare from exceptionally bright conditions, and repelling water.

<FIG> illustrates a perspective view of a mount for an outer lens of the compact camera and illuminator structure. The outer lens may be attached to the camera and illuminator structure by an adhesive. However, an adhesive may not be reliable, as it may degrade over time. Also, some gaps in the adhesive may result. In each case, leakage may occur that allows moisture to enter the space under the outer lens. In some embodiments, an attachment mechanism may be used to secure the single outer lens <NUM> to the mount structure on which the camera and IR illuminator are mounted. In one embodiment, as shown in <FIG>, the single outer lens <NUM> may be attached by a flexible snap latch <NUM> that tightly fits over a protrusion <NUM> on the mount structure. In the embodiment, two flexible snap latches <NUM> may be provided on opposite sides of the single cover lens <NUM>. In some embodiments, more than two flexible snap latches <NUM> may be provided on opposing sides of the single cover lens. For example, a pair of flexible snap latches <NUM> may be provided on two opposing sides of the single cover lens <NUM>, and another pair of flexible snap latches <NUM> may be provided on the other set of opposing sides.

The snap latch <NUM> may be an integral part of the cover lens that is formed during double-shot molding. Alternatively, the snap latch may be a separate component that is secured over a protrusion extending from the cover lens. In the latter case, the separate snap latch may be made of metal or plastic, or even include an elastic material. The protrusion may be in the form of a hook to prevent the snap latch from coming loose and slipping off of the protrusion.

Claim 1:
A compact digital vehicle camera (<NUM>) and infrared (IR) illuminator (<NUM>) apparatus, comprising:
a plurality of IR illuminators (<NUM>) arranged adjacent to the digital
camera (<NUM>), the digital camera (<NUM>) having a camera lens (<NUM>),
each IR illuminator (<NUM>) including at least one IR light emitting diode (LED); and
a single cover lens (<NUM>) positioned to cover the IR LEDs and the camera lens (<NUM>), wherein a region of the single cover lens (<NUM>) that covers the IR LEDs comprises a transparent black cover (205b) and blocks visible light and a region of the single cover lens (<NUM>) that covers the camera lens (<NUM>) comprises a neutral cover (205a) and is a neutral lens that transmits visible light;
characterized in that the single cover lens (<NUM>) is molded as the transparent
black cover (205b) bonded to the neutral cover (205a) for the camera lens (<NUM>) and in that the transparent black cover (205b) has an elliptical shape having an oval peripheral and an inner surface that is of a different shape than the external surface
such that the thickness of the elliptical cover lens varies such that the variation in thickness of the cover lens provides IR light distribution that is wider than the distribution pattern of the IR LEDs.