Vehicle vision system with fastenerless lens attachment

Abstract

A vehicle vision system includes a camera module including an image sensor array, a lens holder and a lens. The camera module is configured to mount at a receiving structure at an interior surface of a vehicle windshield of a vehicle. When the camera module is mounted at the receiving structure of the interior surface of the vehicle windshield, the image sensor array views forward of the vehicle and through the vehicle windshield. The image sensor array is established at a circuit element. The lens holder includes a lens holding portion and an attaching portion, with the lens holding portion accommodating the lens and the attaching portion configured to attach at the circuit element. The attaching portion of the lens holder includes a plurality of pins configured to be received at least partially through apertures of the circuit element so as to be soldered at the circuit element.

1 . A vehicle vision system comprising:
 a camera module comprising an image sensor array, a circuit element, a lens holder and a lens, wherein said camera module is configured to mount at a receiving structure at an interior surface of a vehicle windshield of a vehicle equipped with said vehicle vision system;   wherein, with said camera module mounted at the receiving structure at the interior surface of the vehicle windshield, said image sensor array views forward of the equipped vehicle and through the vehicle windshield;   wherein said circuit element has a first surface and a second surface opposite said first surface;   wherein said image sensor array is established at said first surface of said circuit element;   wherein said lens holder comprises a lens holding portion and an attaching portion;   wherein said lens holding portion of said lens holder accommodates said lens;   wherein said attaching portion of said lens holder comprises a mating surface that faces away from said lens holding portion of said lens holder, and wherein said mating surface is configured to mate with said first surface of said circuit element when said attaching portion is attached at said circuit element;   wherein said attaching portion comprises a plurality of pins extending longitudinally from said mating surface of said attaching portion;   wherein individual pins of said plurality of pins are configured to be received through respective apertures of said circuit element;   wherein, with said mating surface of said attaching portion of said lens holder mated with said first surface of said circuit element, said pins are received at least partially through said apertures; and   wherein, with said pins received at least partially through said apertures of said circuit element, said pins are soldered at said circuit element so as to fixedly attach said lens holder at said circuit element.   
     
     
         2 . The vehicle vision system of  claim 1 , wherein said lens holder comprises a plastic molded element. 
     
     
         3 . The vehicle vision system of  claim 2 , wherein said pins of said attaching portion of said lens holder are insert molded at said attaching portion of said lens holder and protrude from said attaching portion of said lens holder. 
     
     
         4 . The vehicle vision system of  claim 1 , wherein said lens holding portion comprises a generally cylindrical lens barrel that accommodates said lens. 
     
     
         5 . The vehicle vision system of  claim 4 , wherein said attaching portion of said lens holder comprises a generally rectangular portion having said plurality of pins disposed along and protruding from at least one side region of said attaching portion. 
     
     
         6 . The vehicle vision system of  claim 5 , wherein said plurality of pins are generally linearly disposed along and protruding from opposite side regions of said attaching portion, and wherein said pins are received through respective apertures at said circuit element. 
     
     
         7 . The vehicle vision system of  claim 1 , wherein said plurality of pins comprises at least two pins that are insert molded at said attaching portion of said lens holder, and wherein respective ends of said at least two pins protrude from said attaching portion of said lens holder and protrude at least partially into said apertures of said circuit element, and wherein said ends of said at least two pins are soldered at said circuit element to fixedly attach said lens holder at said circuit element. 
     
     
         8 . The vehicle vision system of  claim 1 , wherein, with said mating surface of said attaching portion of said lens holder mated with said first surface of said circuit element, said pins protrude through said circuit element and are soldered at said second surface of said circuit element. 
     
     
         9 . The vehicle vision system of  claim 1 , wherein, with said attaching portion attached at said circuit element, said image sensor array at said first surface of said circuit element is generally encased by said attaching portion and is generally optically aligned with said lens. 
     
     
         10 . The vehicle vision system of  claim 1 , wherein said circuit element comprises a printed circuit board with circuitry soldered thereat. 
     
     
         11 . The vehicle vision system of  claim 10 , wherein said circuitry is soldered at said first and second sides of said circuit element. 
     
     
         12 . The vehicle vision system of  claim 10 , wherein the solder that affixes said pins at said circuit element is applied and cured via a common process that applies and cures solder of said circuitry. 
     
     
         13 . A vehicle vision system comprising:
 a camera module comprising an image sensor array, a circuit element, a lens holder and a lens, wherein said camera module is configured to mount at a receiving structure at an interior surface of a vehicle windshield of a vehicle equipped with said vehicle vision system;   wherein, with said camera module mounted at the receiving structure at the interior surface of the vehicle windshield, said image sensor array views forward of the equipped vehicle and through the vehicle windshield;   wherein said circuit element has a first surface and a second surface opposite said first surface;   wherein said image sensor array is established at said first surface of said circuit element;   wherein said lens holder comprises a lens holding portion and an attaching portion;   wherein said lens holding portion of said lens holder accommodates said lens;   wherein at least one attachment element is attached at said circuit element and is configured for attaching said circuit element at a housing of said camera module;   wherein said at least one attachment element comprises a plurality of pins extending therefrom;   wherein individual pins of said plurality of pins are configured to be received at least partially through respective apertures of said circuit element;   wherein, with said at least one attachment element in engagement with said circuit element, said pins are at least partially received through said apertures; and   wherein, with said pins at least partially received through said circuit element, said pins are soldered at said circuit element so as to fixedly attach said at least one attachment element at said circuit element.   
     
     
         14 . The vehicle vision system of  claim 13 , wherein said at least one attachment element has at least one tab that is at least one of (i) disposed through said circuit element and (ii) fixedly attached at a surface of said circuit element. 
     
     
         15 . The vehicle vision system of  claim 14 , wherein said at least one attachment element comprises two attachment elements disposed at opposite regions of said circuit element that are at opposite sides of said lens holder. 
     
     
         16 . A vehicle vision system comprising:
 a camera module comprising an image sensor array, a circuit element, a lens holder and a lens, wherein said camera module is configured to mount at a receiving structure at an interior surface of a vehicle windshield of a vehicle equipped with said vehicle vision system;   wherein, with said camera module mounted at the receiving structure at the interior surface of the vehicle windshield, said image sensor array views forward of the equipped vehicle and through the vehicle windshield;   wherein said circuit element has a first surface and a second surface opposite said first surface;   wherein said image sensor array is established at said first surface of said circuit element;   wherein said circuit element comprises a printed circuit board with circuitry soldered thereat and wherein said circuitry is soldered at said first and second sides of said circuit element;   wherein said lens holder comprises a plastic molded element having a lens holding portion and an attaching portion;   wherein said lens holding portion of said lens holder comprises a generally cylindrical portion that accommodates said lens;   wherein said attaching portion of said lens holder comprises a mating surface that faces away from said lens holding portion of said lens holder, and wherein said mating surface is configured to mate with said first surface of said circuit element when said attaching portion is attached at said circuit element;   wherein said attaching portion comprises a plurality of pins extending longitudinally from said mating surface of said attaching portion;   wherein individual pins of said plurality of pins are configured to be received through respective apertures of said circuit element;   wherein, with said mating surface of said attaching portion of said lens holder mated with said first surface of said circuit element, said pins are received at least partially through said apertures;   wherein, with said pins received at least partially through said apertures of said circuit element, said pins are soldered at said circuit element so as to fixedly attach said lens holder at said circuit element;   wherein, with said attaching portion attached at said circuit element, said image sensor array at said first surface of said circuit element is generally encased by said attaching portion and is generally optically aligned with said lens; and   wherein the solder that affixes said pins at said circuit element is applied and cured via a common process that applies and cures solder of said circuitry.   
     
     
         17 . The vehicle vision system of  claim 16 , wherein said pins of said attaching portion of said lens holder are insert molded at said attaching portion of said lens holder and protrude from said attaching portion of said lens holder. 
     
     
         18 . The vehicle vision system of  claim 17 , wherein said attaching portion of said lens holder comprises a generally rectangular portion having said plurality of pins disposed along and protruding from at least one side region of said attaching portion. 
     
     
         19 . The vehicle vision system of  claim 18 , wherein said plurality of pins are generally linearly disposed along and protruding from opposite side regions of said attaching portion, and wherein said pins are at least partially received through respective apertures at said circuit element. 
     
     
         20 . The vehicle vision system of  claim 16 , wherein, with said mating surface of said attaching portion of said lens holder mated with said first surface of said circuit element, said pins protrude through said circuit element and are soldered at said second surface of said circuit element.