U.S. patent application number 16/217145 was filed with the patent office on 2020-06-18 for common cover lens for camera and illuminators.
This patent application is currently assigned to VALEO NORTH AMERICA, INC.. The applicant listed for this patent is VALEO NORTH AMERICA, INC.. Invention is credited to Jon BEAUCHAMP, John ORISICH, Brant POTTER, Gregory STEIN.
Application Number | 20200195816 16/217145 |
Document ID | / |
Family ID | 69160366 |
Filed Date | 2020-06-18 |
![](/patent/app/20200195816/US20200195816A1-20200618-D00000.png)
![](/patent/app/20200195816/US20200195816A1-20200618-D00001.png)
![](/patent/app/20200195816/US20200195816A1-20200618-D00002.png)
![](/patent/app/20200195816/US20200195816A1-20200618-D00003.png)
![](/patent/app/20200195816/US20200195816A1-20200618-D00004.png)
![](/patent/app/20200195816/US20200195816A1-20200618-D00005.png)
United States Patent
Application |
20200195816 |
Kind Code |
A1 |
STEIN; Gregory ; et
al. |
June 18, 2020 |
COMMON COVER LENS FOR CAMERA AND ILLUMINATORS
Abstract
A compact digital camera and infrared (IR) illuminator
apparatus, including IR illuminators arranged adjacent to the
digital camera. The digital camera has a camera lens and each IR
illuminator includes IR LEDs. A single cover lens is positioned to
cover the at least one IR LED and the camera lens. A region of the
single cover lens that covers the IR LEDs blocks visible light and
a region of the single cover lens that covers the camera lens is a
neutral lens that transmits visible light. The single cover lens is
a two-shot molded lens or a three-shot molded lens.
Inventors: |
STEIN; Gregory; (Seymour,
IN) ; BEAUCHAMP; Jon; (Seymour, IN) ; ORISICH;
John; (Seymour, IN) ; POTTER; Brant; (Seymour,
IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
VALEO NORTH AMERICA, INC. |
Troy |
MI |
US |
|
|
Assignee: |
VALEO NORTH AMERICA, INC.
Troy
MI
|
Family ID: |
69160366 |
Appl. No.: |
16/217145 |
Filed: |
December 12, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B60R 2300/106 20130101;
G02B 3/0037 20130101; B60R 2300/802 20130101; H04N 5/2254 20130101;
H04N 5/2256 20130101; H04N 5/33 20130101; B60R 2300/105 20130101;
B60R 1/002 20130101; H04N 5/2252 20130101; B60R 2300/8093
20130101 |
International
Class: |
H04N 5/225 20060101
H04N005/225; B60R 1/00 20060101 B60R001/00; G02B 3/00 20060101
G02B003/00 |
Claims
1. A compact digital camera and infrared (IR) illuminator
apparatus, comprising: a plurality of IR illuminators arranged
adjacent to the digital camera, the digital camera having a camera
lens, each IR illuminator including at least one IR light emitting
diode (LED); and a single cover lens positioned to cover the at
least one IR LED and the camera lens, wherein a region of the
single cover lens that covers the at least one IR LED blocks
visible light and a region of the single cover lens that covers the
camera lens is a neutral lens that transmits visible light.
2. The compact digital camera and IR illuminator apparatus of claim
1, wherein the single cover lens is a two-shot molded lens.
3. The compact digital camera and IR illuminator apparatus of claim
2, wherein material of the region of the single cover lens that
covers the at least one IR LED and material of the region of the
single cover lens that covers the camera lens are the same.
4. The compact digital camera and IR illuminator apparatus of claim
2, wherein the region of the single cover lens that covers the at
least one IR LED is transparent black.
5. The compact digital camera and IR illuminator apparatus of claim
2, wherein the region of the single cover lens that covers the at
least one IR LED and the region of the single cover lens that
covers the camera lens are of different materials.
6. The compact digital camera and IR illuminator apparatus of claim
5, wherein material of the region of the single cover lens that
covers the at least one IR LED and material of the region of the
single cover lens that covers the camera lens are compatible
resins.
7. The compact digital camera and IR illuminator apparatus of claim
1, wherein the single cover lens is a three-shot molded lens.
8. The compact digital camera and IR illuminator apparatus of claim
7, wherein the three-shot molded lens includes a light shielding
region that is between the region that covers the at least one IR
LED and the region that covers the camera lens, wherein the
shielding region has light absorption properties.
9. The compact digital camera and IR illuminator apparatus of claim
8, wherein the shielding region prevents transmission of both IR
radiation and visible light.
10. The compact digital camera and IR illuminator apparatus of
claim 1, wherein the region of the single cover lens that covers
the camera lens filters radiation in predetermined wavelengths.
11. The compact digital camera and IR illuminator apparatus of
claim 1, wherein the single cover lens includes a bezel for
securing the camera lens.
12. The compact digital camera and IR illuminator apparatus of
claim 1, wherein the single cover lens includes a bezel having a
portion that provides a liquid seal for the single cover lens and a
portion that provides an internal seal for the camera.
13. The compact digital camera and IR illuminator apparatus of
claim 1, wherein the digital camera has an optic axis in a
direction of focus, wherein a center axis of IR illuminator is
tilted by an angle greater than or equal to five degrees.
14. The compact digital camera and IR illuminator apparatus of
claim 1, wherein a top surface of the region of the single cover
lens that covers the at least one IR LED is positioned below a
field of view of the camera.
15. The compact digital camera and IR illuminator apparatus of
claim 13, wherein a field of view of an emission pattern of IR
radiation is substantially plus or minus 80 degrees or greater from
the optic axis.
16. The compact digital camera and IR illuminator apparatus of
claim 1, further including a mounting structure, wherein a pair of
mounting substrates are arranged adjacent to the digital camera and
the at least one IR LED is mounted to each of the mounting
substrates, wherein each of the pair of mounting substrates and IR
LED mounted thereon are identical.
17. The compact digital camera and IR illuminator apparatus of
claim 1, further including a single mounting structure that
supports the plurality of IR illuminators and camera.
18. The compact digital camera and IR illuminator apparatus of
claim 1, wherein the region of the single cover lens that covers
the at least one IR LED applies an optical property to IR
radiation.
19. The compact digital camera and IR illuminator apparatus of
claim 18, wherein the optical property applied is a diffraction
optic that increases or decreases a field of view of IR radiation
of the respective IR illuminator.
20. The compact digital camera and IR illuminator apparatus of
claim 17, wherein the single cover lens is attached to the mounting
structure by a snap latch, one end of which is an integral part of
the single cover lens.
Description
BACKGROUND OF THE INVENTION
Field of the Invention
[0001] The present disclosure relates generally to a cover lens for
a vehicle camera and illuminators, and in particular, two-shot or
three-shot lens for a camera and adjacent illuminators.
Description of the Related Art
[0002] 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.
[0003] For purposes of general illustration, a typical sensor
arrangement for an autonomous vehicle is shown in FIG. 1. The
arrangement of FIG. 1 may include several vision cameras, such as
forward stereo cameras, surround cameras, rear and side cameras.
Vision cameras 105, 107, 109 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.
SUMMARY OF THE INVENTION
[0004] An aspect is a compact digital camera and infrared (IR)
illuminator apparatus, including a plurality of IR illuminators
arranged adjacent to the digital camera, the digital camera having
a camera lens, each IR illuminator including at least one IR light
emitting diode (LED), and a single cover lens positioned to cover
the at least one IR LED and the camera lens. A region of the single
cover lens that covers the at least one IR LED blocks visible light
and a region of the single cover lens that covers the camera lens
is a neutral lens that transmits visible light.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] 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:
[0006] FIG. 1 illustrates a typical sensor arrangement for an
autonomous vehicle;
[0007] FIG. 2 illustrates a cross-section of a compact camera and
illuminator structure in accordance with an exemplary aspect of the
disclosure;
[0008] FIG. 3 illustrates a perspective view of a compact camera
and illuminator structure having an outer lens;
[0009] FIG. 4 illustrates a perspective view of a compact camera
and illuminator structure with two-shot molded outer lens; and
[0010] FIG. 5 illustrates a perspective view of a mount for an
outer lens of the compact camera and illuminator structure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0011] 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. The
appearances of the phrase "in one embodiment" in various places in
the specification are not necessarily all referring to the same
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.
[0012] Furthermore, the terms "approximately," "proximate,"
"minor," and similar terms generally refer to ranges that include
the identified value within a margin of 20%, 10% or preferably 5%
in certain embodiments, and any values therebetween.
[0013] Referring now to the drawings, wherein like reference
numerals designate identical or corresponding parts throughout the
several views.
[0014] 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.
[0015] 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 0.75 to 1.4 micro meters.
[0016] 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.
[0017] 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.
[0018] 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.
[0019] 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.
[0020] 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 25 mm
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.
[0021] FIG. 2 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
211. In some embodiments, the compact vision camera and illuminator
assembly may be integrated by way of a bracket. The mounting
structure 211 or bracket preferably is of a material having some
flexibility, in order to avoid breakage or cracking during
installation. In some embodiments, a single outer lens 205 is used
for both the vision camera 201 and IR illuminators with IR LEDs
203. The vision camera 201 includes a camera lens 207. In some
embodiments, the single outer lens 205 may incorporate cover bezel
portions 209a, 209b for securing the outer lens 205 and sealing the
camera with the mounting structure 211. In some embodiments, the IR
illuminators may each include an array of two or more IR LEDs.
[0022] In some embodiments, the mounting structure 211 or bracket
may position the IR illuminators at an angle directed away from the
focus axis of the vision camera 201. The single outer lens may
include a neutral portion 205a that covers the vision camera 201
and a transparent black portion 205b that covers the IR LEDs 203 of
the illuminators. The transparent black portion passes IR radiation
and may provide 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 201 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.
[0023] FIG. 3 illustrates a perspective view of a compact camera
and illuminator structure having an outer lens. The compact vision
camera and IR illuminator assembly may include a single outer lens
205a, 205b for both the camera 201 and IR illuminators. The compact
vision camera and IR illuminators may be mounted on a mounting
structure 211. The single outer lens 205a, 205b may include a bezel
for securing the outer lens 205a, 205b and camera lens 207. 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 201. 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.
[0024] In some embodiments, the IR illuminators may each include an
IR LED. In some embodiments, the IR illuminators may each include
an array of two or more IR LEDs. Further, although FIG. 3
illustrates a pair of IR LEDs on opposite sides of the camera 201,
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.
[0025] FIG. 4 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.
[0026] In one embodiment, the outer lens may be molded as a
transparent black cover 205b bonded to a neutral cover 205a for the
camera lens. In some embodiments, 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.
[0027] 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 (3)-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.
[0028] In some embodiments, the cover lens portion 205a may include
optical properties that supplement the properties of the camera
lens 207. 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.
[0029] FIG. 5 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 205 to the
mount structure on which the camera and IR illuminator are mounted.
In one embodiment, as shown in FIG. 5, the single outer lens 205
may be attached by a flexible snap latch 501 that tightly fits over
a protrusion 503 on the mount structure. In the embodiment, two
flexible snap latches 501 may be provided on opposite sides of the
single cover lens 205. In some embodiments, more than two flexible
snap latches 501 may be provided on opposing sides of the single
cover lens. For example, a pair of flexible snap latches 501 may be
provided on two opposing sides of the single cover lens 205, and
another pair of flexible snap latches 501 may be provided on the
other set of opposing sides.
[0030] The snap latch 501 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.
[0031] Numerous modifications and variations of the present
invention are possible in light of the above teachings. It is
therefore to be understood that within the scope of the appended
claims, the invention may be practiced otherwise than as
specifically described herein.
* * * * *