CROSS-REFERENCE TO RELATED APPLICATIONS

This application is related to co-pending U.S. design application No. 29/728,372, filed Mar. 18, 2020 the entire disclosure of which is incorporated by reference herein.

BACKGROUND

Vehicles, such as manually operated and autonomous vehicles, may employ in-vehicle cameras as part of a driver assistance system. Such cameras may be able to provide high quality images in certain lighting conditions. Optical or infrared illumination may be used to enhance image quality in low-light conditions. However, if the illumination device is not properly positioned with respect to the camera, this can adversely affect the camera's image quality.

BRIEF SUMMARY

The technology relates to a camera module cover that prevents infrared (IR) light from leaking into the lens of an adjacent camera. The camera module cover can be used in vehicles that operate in manual and autonomous driving modes, indoor locations and other places where infrared illumination is provided with a camera system.

According to one aspect, a camera module cover for an infrared-illuminated camera module is provided. The camera module cover includes an infrared-transparent surface having an opening therein, in which the opening is configured to receive a lens of a camera module. The infrared-transparent surface is configured to pass infrared light from an infrared emitter of a base unit therethrough to illuminate an external environment. The camera module cover also includes an exterior sidewall extending around the infrared-transparent surface, and an infrared-blocking member disposed within the opening and directly coupled to the infrared-transparent surface. The infrared blocking member includes an interior sidewall configured to block the infrared light from the infrared emitter from entering the lens of the camera module.

In one example, the infrared-blocking member further includes a beveled edge adjoining the infrared-transparent surface. The beveled edge angles away from the infrared transparent surface, so that the lens of the camera module, when the camera module is covered by the camera module cover, is disposed below a plane of the infrared-transparent surface. The infrared-blocking member may further include a lip that adjoins the beveled edge and is adjacent to the interior sidewall. The interior sidewall, beveled edge and lip may all be formed from a single piece of infrared-blocking material.

In any of the examples, the exterior sidewall may be formed of a same material as the infrared-transparent surface.

The exterior sidewall and the infrared-transparent surface may be formed as one unit. The one unit may be formed by injection molding. In one example, the infrared-blocking member is formed as a second unit by injection molding. Here, the first unit and the second unit can be formed by a double injection molding process.

The interior sidewall and the exterior sidewall may be spaced apart from one another, forming an open area therebetween so that the infrared light is able to pass through the open area unimpeded. The infrared-transparent surface may have a rectangular shape or other geometric shape (e.g., oval, circular, etc.). The opening may be centrally disposed along the infrared-transparent surface.

According to another aspect, a camera module assembly comprises the camera module cover in any of the configuration as described above, along with the infrared emitter of the base unit. In one example, the camera module assembly further comprises the camera module.

According to yet another aspect, a method of fabricating a camera module cover is provided. The method comprises forming an infrared-transparent surface having an opening therein, the opening configured to receive a lens of a camera module, and the infrared-transparent surface being configured to pass infrared light from an infrared emitter of a base unit therethrough to illuminate an external environment; forming an exterior sidewall extending around the infrared-transparent surface; and forming an infrared-blocking member so that the infrared-blocking member is disposed within the opening and coupled to the infrared-transparent surface, the infrared blocking member including an interior sidewall configured to block the infrared light from the infrared emitter from entering the lens of the camera module.

The exterior sidewall may be formed concurrently with the infrared-transparent surface using injection molding. The infrared-blocking member may be formed using injection molding. The method may further comprise securing the infrared-blocking member along the opening of the infrared-transparent surface. Here, securing the infrared-blocking member along the opening of the infrared-transparent surface can be performed during a double injection molding process.

In addition to the above, forming the infrared-blocking member may include forming a beveled edge adjoining the opening of the infrared-transparent surface, the beveled edge angling away from the infrared transparent surface so that the lens of the camera module, when the camera module is covered by the camera module cover, is disposed below a plane of the infrared-transparent surface; and forming a lip that adjoins the beveled edge and is adjacent to the interior sidewall.

