Rearview package with enhanced cooling

Abstract

A rearview assembly includes: a rearview device; a housing supporting the rearview device; a cavity defined by the housing and the rearview device; a first printed circuit board having a processor and disposed within the cavity; a second printed circuit board communicating with the first printed circuit board and disposed within the cavity; at least one rib having an outer edge and extending from the housing into the cavity; and a channel having side walls defined by a portion of the housing, the at least one rib, and a portion of the second printed circuit board. An air moving device can draw air through the channel. A seal can be used to make the side walls of the channel substantially airtight.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 62 / 818,887, filed on March 15, 2019, entitled “Rearview Assembly with Enhanced Cooling.” Technical Field

[0003] The present disclosure relates generally to rearview mirror assemblies, and in particular to rearview mirror assemblies having enhanced cooling capabilities. Background Art

[0004] There are known rear view assemblies. However, it is always a goal in the art to develop improved rear view assemblies. Summary of the invention

[0005] According to some aspects of the present disclosure, a rearview assembly may include: a rearview device; a shell supporting the rearview device; a cavity defined by the shell and the rearview device; a first printed circuit board having a processor and disposed in the cavity; a second printed circuit board having a first surface and a second surface, communicating with the first printed circuit board and disposed in the cavity; at least one rib having an outer edge and extending from the shell into the cavity; and a channel, a side wall of the channel being defined by a portion of the shell, the at least one rib and a portion of the second printed circuit board.

[0006] The rearview assembly may further include an air moving device disposed within the cavity and configured to draw air from an area external to the housing into the cavity. The rearview assembly may further include a seal extending between the outer edge of the at least one rib and a portion of the second printed circuit board; wherein the seal is capable of making the sidewall of the channel airtight. The rearview assembly may further include a seal extending between the second printed circuit board and the air moving device. The outer edge of the at least one rib may contact the second surface of the second printed circuit board. The rearview assembly may further include a memory card holder configured to accommodate a memory card disposed on the first surface of the second printed circuit board. The housing may define at least one vent opening at a first end of the channel and in fluid communication with the channel. The memory card holder may be near the first end of the channel. The housing may define an opening in communication with the memory card holder and configured to receive a memory card.

[0007] According to another aspect, a rear view assembly may include a rear view device, a housing supporting the rear view device, a cavity defined by the housing and the rear view device, a first printed circuit board having a processor and disposed within the cavity, a second printed circuit board in communication with the first printed circuit board and disposed within the cavity, a memory card holder disposed on the second printed circuit board, at least one rib having an outer edge and extending from the housing into the cavity, a channel having side walls defined by a portion of the housing, the at least one rib, and a portion of the second printed circuit board, and an air moving device disposed within the cavity and configured to draw air from an area external to the housing into the cavity. The side walls of the channel may be substantially airtight.

[0008] The rearview assembly may further include a seal; wherein the seal may be disposed between the outer edge of the at least one rib and the second printed circuit board. The rearview assembly may further include a seal; wherein the seal may be disposed between the second printed circuit board and the air moving device. The processor may be in communication with at least one imaging device. The processor may be in communication with at least two imaging devices. The housing may define at least one vent opening; the at least one vent opening may be at one end of the channel and in fluid communication with the channel; and the memory card holder may be adjacent to the vent opening. The housing may further define a memory card opening configured to receive a memory card and in communication with the memory card holder.

[0009] According to another aspect, a rear view assembly may include: a rear view device; a housing supporting the rear view device; a cavity defined by the housing and the rear view device; a first printed circuit board having a processor and disposed in the cavity; a second printed circuit board in communication with the first printed circuit board and disposed in the cavity; a memory card holder in communication with the second printed circuit board; at least one rib having an outer edge and extending from the housing into the cavity; a channel having side walls defined by a portion of the housing, the at least one rib, and a portion of the second printed circuit board; an air moving device disposed in the cavity and configured to draw air from an area outside the housing into the cavity; and a seal disposed between the air moving device and the second printed circuit board. The processor may be in communication with at least two imaging devices. At least a portion of the outer edge of the at least one rib contacts the second printed circuit board. The rear view assembly may further include a vent opening defined by the housing and disposed at one end of the channel. The vent opening may be configured such that, when air is drawn into the cavity from an area external to the housing, the air enters through the vent opening and travels through at least a portion of the passageway. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 showing a perspective view of a partially cut-away rear portion of a rear view assembly according to the present disclosure;

[0011] Figure 2 A perspective view of the rear view assembly is shown;

[0012] Figure 3A showing a perspective view of a partially cut-away rear portion of a rearview assembly;

[0013] Figure 3B A portion of the assembly is shown showing a rear view of at least one rib of the housing;

[0014] Figure 4 an exploded view showing one configuration of a portion of a rear view assembly; and

[0015] Figure 5 An exploded view of a second configuration of a portion of a rear view assembly is shown. DETAILED DESCRIPTION

[0016] According to the present disclosure, a rearview assembly may include an enhanced cooling system to allow for the addition of image storage and other capabilities without overheating components of the rearview assembly.

[0017] refer to Figure 1, a rearview assembly, generally indicated by 10, may include a housing 20, a rearview device 24, and a first printed circuit board 28 having a processor (not shown). The rearview device 24 may include at least one of a light source such as a light emitting diode, a mirror element, and an electro-optical device. The housing 20 may support the rearview device 24, and a cavity 32 may be defined by the housing 20 and the rearview device 24. The first printed circuit board 28 may be disposed within the cavity 32. The rearview device 24 may further include a connecting element 36 configured to mate with a corresponding connecting element (not shown) on the housing 20, wherein the connecting element 36 allows the rearview device 24 to be connected to the housing 20.

[0018] In some embodiments, the processor can be in communication with a plurality of cameras or imaging devices and configured to receive input from a plurality of cameras or imaging devices. In some embodiments, the rear-view assembly in the vehicle can capture, display and store images of the scene at the rear of the vehicle, wherein the image can be collected from a first camera or other imaging device (not shown). The rear-view assembly can also capture and store images collected from a second camera or other imaging device. In some embodiments, the second camera or other imaging device can be configured to capture images of the scene at the front of the vehicle. In some embodiments, the second camera or other imaging device can be configured to capture images of the scene inside the vehicle.

[0019] The first printed circuit board 28 of the rearview assembly 10 can be in communication with a first camera or other imaging device via an input received through a first wiring harness or flexible harness 44. The first printed circuit board 28 can be further in communication with the rearview device 24. The processor of the first printed circuit board 28 can be configured to process image data captured by the first imaging device. The image data can be processed so that the captured image can be displayed on the rearview device 24. In some embodiments, the processor can be a high-speed processor. When the rearview assembly 10 is used in a full display mirror mode, the processor can generate a high thermal load, wherein the image displayed on the rearview element is captured by a rear-facing camera or other imager.

[0020] The first printed circuit board 28 can also be connected to a second camera or other imaging device (not shown), and can receive input via a second wiring harness or flexible harness 48 connected to the second imaging device. The processor can be configured to process image data from the image captured by the second imaging device. As shown, the rearview assembly 10 is configured to receive input from two cameras or imaging devices, but more or less cameras or imaging devices can be used and still within the scope of the present disclosure. For example, a third imaging device (not shown) can be arranged to capture image data of a scene outside the passenger side of the vehicle. The third imaging device can be connected to the processor, and the processor can be configured to process image data received from the third imaging device. Continuing the example, the fourth imaging device can be arranged to capture image data from a scene outside the driver's side of the vehicle. The fourth imaging device can be connected to the processor, and the processor can be configured to process image data received from the fourth imaging device.

[0021] The rearview assembly 10 may include a memory card holder 52 and may be configured to allow a memory card to store image data from an image captured by at least one of the first imaging device and the second imaging device. The memory card holder 52 may be configured to receive a memory card and may be in communication with at least one printed circuit board of the rearview assembly 10. The housing 20 may define a memory card opening 56, such as Figure 2 As shown, the memory card opening communicates with the memory card holder 52 and is configured to allow a memory card to be inserted therethrough.

[0022] The rearview assembly 10 can be configured to use a high capacity memory card (not shown). The high capacity memory can include a high capacity flash memory card, such as a secure digital (SD) card or a micro SD card, but the rearview assembly 10 can be configured to use other types of memory cards and still be within the scope of the present disclosure.

[0023] In operation, the memory card can be used to record image data from a scene captured by at least one of the first imaging device and the second imaging device. The image data can be processed by a processor of the rearview assembly 10, thereby allowing the rearview assembly 10 to selectively act as a digital video recorder to store image data from images captured by one or more imaging devices. However, the use of a memory card in the rearview assembly 10, especially in a rearview assembly 10 with a full display mirror function, may increase the power consumption of the rearview assembly 10 by about thirty percent or more. The additional power consumption stems from the power requirements of the memory card itself and the additional video processing required to process the image data from the captured image to be stored on the memory card. The use of a memory card may increase the thermal load in the rearview assembly 10, making the memory card or other components susceptible to damage or failure.

[0024] In some embodiments, inputs from additional cameras or imaging devices may be added to the rearview assembly 10, and the additional image data to be processed may also increase the power requirements of the rearview assembly 10. Increased power consumption may be accompanied by increased heat generation within the rearview assembly 10. However, memory cards have an upper temperature limit at which they can operate, typically no higher than 85°C. In addition, it may be desirable to limit the temperature within the rearview assembly 10 to prevent the housing 20 of the rearview assembly 10 from being uncomfortably hot to a user who may need to adjust or otherwise handle the rearview assembly 10. Therefore, it may be desirable to limit the temperature within the rearview assembly 10, and to limit the temperature of any processors and / or printed circuit boards and other heat-generating components that may be within the rearview assembly 10.

[0025] In some embodiments, the components of the rearview assembly 10 can be arranged to minimize temperature. For example, in some embodiments, the rearview assembly 10 can further include a second printed circuit board 60. The second printed circuit board 60 can have a first surface 64 and an opposing second surface 68. The memory card holder 52 can be disposed on the first surface 64 of the second printed circuit board 60. The memory card holder 52 and the second printed circuit board 60 can be in communication with the first printed circuit board 28. In some embodiments, the first printed circuit board 28 can be connected to the second printed board via a wiring harness or wiring 72. In some embodiments, the first printed circuit board 28 can be connected to the second printed circuit board 60 via a board-to-board connection (not shown).

[0026] During operation, memory cards can generate significant amounts of heat. Positioning the memory card holder 52 on the second printed circuit board 60 rather than on the first printed circuit board 28 can reduce or eliminate the temperature increase that exists on the first printed circuit board 28 due to the memory card during operation. However, it may be desirable to dissipate the heat that may be generated by the memory card on the second printed circuit board 60 to ensure that the memory card and other components of the rearview assembly 10 that may be sensitive to high temperatures do not fail.

[0027] refer to Figure 3B , the housing 20 may include at least one rib 80 extending into the cavity 32. The at least one rib 80 may have an outer edge 84 extending along at least a portion of its length. The sidewall portion of the channel 88 may be defined by at least a portion of the at least one rib 80, a portion of the housing 20, and a portion of the second printed circuit board 60. The housing 20 may define at least one vent opening 100. The at least one vent opening 100 may be disposed at a first end of the channel 88 and in fluid communication with the channel. The memory card holder 52 may be disposed on the first surface 64 of the second printed circuit board 64 at a position proximate to the at least one vent opening 100.

[0028] In some embodiments, an outer edge 84 of the at least one rib 80 can be seated against the second surface 68 of the second printed circuit board 60. A channel 88 can extend from the at least one vent opening 100 across at least a portion of the second surface 68 of the second printed circuit board 60. Sidewall portions of the channel 88 can include the housing 20, the at least one rib 80, and a portion of the second printed circuit board 60. Thus, a portion of the second printed circuit board 60 that may be in contact with the memory card holder 52 can be exposed to incoming air shortly after the air enters the cavity 32 and before the air has been exposed to other components of the rearview assembly 10 and thus begins to heat up.

[0029] The sidewall portions of the channel 88 may be substantially airtight to allow maximum airflow through the channel 88 and across the second surface 68 of the second printed circuit board 60, thereby providing maximum cooling for the second printed circuit board 60. After passing through the second printed circuit board 60, the air may be directed to the remainder of the cavity 32, where it may be used to cool other components of the rearview assembly 10. Directing the incoming air to the second printed circuit board 60 first may allow the coolest air to be directed through the second printed circuit board 60 to cool it.

[0030] like Figure 4 and 5 As shown, in some embodiments, seal 92 can be positioned to substantially airtightly seal the sidewall portion of channel 88. Seal 92 can include a soft material such as neoprene foam, polyurethane, polyethylene foam, polystyrene, polyester foam, polyether foam, silicone foam, soft rubber, elastomer, or another suitable material.

[0031] In some embodiments, Figure 4 As shown, the seal 92 can be disposed between the outer edge 84 of at least one rib 80 and the second printed circuit board 60. In some embodiments, as shown in FIG. Figure 5As shown, the seal 92 can be disposed between the second printed circuit board 60 and the rear view device 24. The seal 92 can be disposed between the first printed circuit board 28 and the second printed circuit board 60, between the first printed circuit board 28 and the heat sink 96, or in another suitable location. The seal 92 can be compressible. Having a compressible seal 92 can allow for easier manufacturing of the rear view assembly 10, wherein the at least one rib 80 contacts the second printed circuit board 60, thereby forming a channel 88 with a substantially airtight sidewall for airflow. The seal 92 can be configured to, when in position, cause the outer edge 84 of the at least one rib 80 to press against the second printed circuit board 60, thereby holding the second printed circuit board 60 in position against the at least one rib 80 to achieve a substantially airtight seal 92, while allowing the rear view device 24 to be connected to the housing 20 during manufacturing without damaging the components, the rear view device 24, or the housing 20. Positioning the seal 92 between the first and second printed circuit boards 28 , 60 may isolate the second printed circuit board 60 from heat generated by other components of the rearview assembly 10 , thereby reducing heat transfer from other components of the rearview assembly 10 and limiting heating of the second printed circuit board 60 .

[0032] In some embodiments, a cooling system may be implemented within rearview assembly 10. Air moving device 104 may be positioned within cavity 32 and proximate vent opening 100. In some embodiments, air moving device 104 may be configured to draw ambient air from an area external to housing 20 into cavity 32. Air may be drawn into cavity 32 through at least one vent opening 100. The temperature of the incoming air may be lower than the temperature of the air inside cavity 32.

[0033] Air drawn in by the air moving device 104 through the at least one ventilation opening 100 may be drawn onto the second surface 68 of the second printed circuit board 60. Since the memory card holder 52 may be positioned on the first surface 64 of the second printed circuit board 60 and adjacent to the at least one ventilation opening, the memory card holder may be cooled.

[0034] The housing 20 may further include an exhaust opening 108. In some embodiments, the exhaust opening 108 may be disposed around a mounting element 112 that enables the rearview assembly 10 to be mounted to a vehicle. Additionally or alternatively, air may exit the cavity 32 through the seams or gaps in the rearview assembly 10 because the seams or gaps of the rearview assembly 10 may not be airtight.

[0035] The rear view assembly 10 may be suitable for use in a vehicle interior. The rear view assembly 10 may be operably coupled to an interior surface of a windshield, a vehicle headliner, a vehicle ceiling, operably coupled to a vehicle dashboard, or directly coupled to a vehicle support structure or frame.

[0036] The above description is considered to be a description of preferred embodiments only. Modifications to the present disclosure will occur to those skilled in the art and those who make or use the present disclosure. Therefore, it should be understood that the embodiments shown in the drawings and described above are for illustrative purposes only and are not intended to limit the scope of the present disclosure, which is defined by the appended claims interpreted in accordance with patent law including the doctrine of equivalents.

[0037] In this document, relational terms such as first and second, top and bottom, front and back, etc. are used only to distinguish one entity or action from another entity or action, and do not necessarily require or imply any actual such relationship, order, or number between such entities or actions. These terms are not intended to limit the elements they describe, as various elements can be oriented in different ways in different applications.

Claims

1. A rearview assembly, comprising: Rear view device; a housing supporting the rearview device; a cavity defined by the housing and the rear view device; a first printed circuit board having a processor and disposed within the cavity; a second printed circuit board, the second printed circuit board having a first surface and a second surface opposite to the first surface, the second printed circuit board being in communication with the first printed circuit board and disposed in the cavity; at least one rib having an outer edge and extending from the housing into the cavity; a memory card holder configured to receive a memory card, the memory card holder being disposed on the first surface of the second printed circuit board; as well as a channel having side walls defined by a portion of the housing, the at least one rib, and a portion of the second surface of the second printed circuit board opposite the location of the memory card holder, wherein the channel is configured to cool the memory card holder by moving air from the memory card holder through the channel outside the second printed circuit board.

2. The rearview assembly of claim 1 , further comprising a seal extending between the outer edge of the at least one rib and a portion of the second printed circuit board; wherein the seal is capable of making the side wall of the channel between the outer edge of the at least one rib and the portion of the second printed circuit board airtight.

3. The rear view assembly of one of claims 1 to 2, wherein the outer edge of the at least one rib contacts the second surface of the second printed circuit board.

4. The rearview assembly of one of claims 1 to 2, wherein the housing defines at least one vent opening at the first end of the passage and in fluid communication with the passage.

5. The rear view assembly of claim 4, wherein said memory card holder is proximate said first end of said channel.

6. The rear view assembly of one of claims 1 to 2, wherein the housing defines an opening; wherein the opening is in communication with the memory card holder and is configured to receive a memory card.

7. A rear view assembly comprising: Rear view device; a housing supporting the rearview device; a cavity defined by the housing and the rear view device; a first printed circuit board having a processor and disposed within the cavity; a second printed circuit board having a first surface and a second surface and communicating with the first printed circuit board and disposed in the cavity; a memory card holder disposed on the first surface of the second printed circuit board; at least one rib having an outer edge and extending from the housing into the cavity; a channel having side walls defined by a portion of the housing, the at least one rib, and a portion of the second surface of the second printed circuit board opposite the location of the memory card holder; as well as an air moving device disposed within the cavity and configured to draw air from an area external to the housing into the cavity, wherein the channel is configured to cool the memory card holder by moving air from the memory card holder through the channel outside of the second printed circuit board.

8. The rearview assembly of claim 7, wherein the sidewalls of the channel are substantially airtight.

9. The rear view assembly of one of claims 7 to 8, further comprising a seal disposed between the outer edge of the at least one rib and the second printed circuit board.

10. The rearview assembly of one of claims 7 to 8, further comprising a seal disposed between the second printed circuit board and the air moving device.

11. The rearview assembly of one of claims 7 to 8, wherein the processor is in communication with at least one imaging device.

12. The rearview assembly of one of claims 7 to 8, wherein the processor is in communication with at least two imaging devices.

13. A rearview assembly according to one of claims 7 to 8, wherein the housing defines at least one ventilation opening; wherein the at least one ventilation opening is disposed at one end of the channel and is in fluid communication with the channel; and wherein the memory card holder is adjacent the ventilation opening.

14. The rear view assembly of one of claims 7 to 8, wherein the housing further defines a memory card opening configured to receive a memory card and in communication with the memory card holder.

15. A rear view assembly comprising: Rear view device; a housing supporting the rearview device and defining at least one ventilation opening; a cavity defined by the housing and the rear view device; a first printed circuit board having a processor and disposed within the cavity; a second printed circuit board, the second printed circuit board having a first surface and a second surface, the second printed circuit board being in communication with the first printed circuit board and disposed in the cavity; a memory card holder disposed on the first surface of the second printed circuit board; at least one rib having an outer edge and extending from the housing into the cavity; a channel having side walls defined by a portion of the housing, the at least one rib, and a portion of the second surface of the second printed circuit board opposite the location of the memory card holder; an air moving device disposed within the cavity and configured to draw air from an area external to the housing into the cavity; as well as a seal disposed between the air moving device and the second printed circuit board, wherein the channel is configured to cool the memory card holder by moving air from the memory card holder through the channel outside the second printed circuit board; and Wherein the processor is in communication with at least two imaging devices.

16. The rear view assembly of claim 15, wherein at least a portion of the outer edge of the at least one rib contacts the second printed circuit board.

17. A rearview assembly according to one of claims 15 to 16, further comprising a ventilation opening defined by the shell and disposed at one end of the channel; wherein the ventilation opening is configured so that when air is drawn into the cavity from an area outside the shell, the air enters through the ventilation opening and travels through at least a portion of the channel.

Images