Sensor unit and method for assembling the sensor unit

Abstract

The invention relates to a sensor unit and a method for assembling the same. A sensor unit (10) has a housing (12) configured for selecting a position of an opening (22-24, 29-31) through a sidewall aligned with a terminal portion of a printed circuit board. A connector device (14) is positionable through the selected opening for electrical communication between the terminal portion and the external connector.

Description

Technical Field

[0001] The present disclosure relates to a sensor unit, in particular for a camera unit / housing for use in the automotive field, and a method for assembling the sensor unit. Background Art

[0002] Sensors such as cameras are now common in automotive environments. A particular model of camera typically has a predetermined component configuration and housing that is sized to efficiently house the electronics and optics therein. However, while multiple automakers may specify the same camera model, they often need to modify the configuration in order to fit it into their vehicles. Therefore, it is a concern for suppliers of camera units that the power / data cable connectors may need to be located at different sides / directions / angles of the unit / housing, depending on the customer (automaker) specifications.

[0003] According to known assembly methods, it is necessary for the supplier to develop a separate housing / casement design for each connector orientation required by the end user / manufacturer. Deviations from the standard design result in higher tooling costs to produce a range of sub-models. Summary of the invention

[0004] The present disclosure is intended to solve the above-mentioned problems of conventional solutions and assembly methods, or at least provide an alternative solution to the public and suppliers / manufacturers of sensor devices.

[0005] According to a first aspect, a sensor unit is provided. For example, the sensor unit may include a walled housing, the housing including or adapted to form an opening at a selectable position, the opening being capable of being substantially aligned with a connector / terminal portion, and thereby communicating with a printed circuit board (PCB) contained in the housing. In the case of pre-formed openings, there will be more than one opening, so that the position of the opening providing a connection point (connector site) from a particular direction can be selected according to construction requirements. The housing may be provided with at least one connector element for insertion into the formed opening, thereby cooperating with a connector / terminal position on the PCB.

[0006] In one form, a configurable housing for a sensor device is provided, the housing comprising: a plurality of opening positions formed into the housing; and a connector device. The plurality of opening positions enables selection of the position and direction of entry of the connector device into the housing. In use, one end of the connector device will be in electrical communication with a terminal portion of the sensor device within the housing, and at the other end, compatible with an external connector. In this way, the housing is prefabricated so that connector holes (in more than one position) can be drilled / milled into the housing in the direction required by the customer, or is provided with pre-drilled holes (compatible with all planned variants) so that any unnecessary holes can be blocked during unit assembly or at the time of final use.

[0007] In embodiments, the plug may be made of aluminum (e.g., for laser welding to the housing), plastic, rubber, or any suitable material that is suitable for insertion into a hole in the housing and forming a closure for the hole in the housing. The plug provides a seal to prevent the ingress of dust, fluids, or similar contaminants. The plug may be provided in each hole, and the plug may be removed if selected as a connection point, or after a connection point is selected, as a way to plug an unselected hole.

[0008] In an embodiment, one or more surface markings on the housing may indicate the location of the connector hole.

[0009] In embodiments where the housing is combined with a PCB, or as part of the assembly method, the PCB can be manufactured for each planned connector orientation (this is current practice, but at least saves tooling for the universal housing described above). Alternatively, the PCB can be manufactured with multiple terminal / connector locations to couple the connector in each planned orientation.

[0010] The former solution requires production of multiple PCB layouts for implementation into a common housing, while the latter implementation requires one PCB layout, but may increase cost as it has unused connector locations. Which solution for the PCB is preferred can be determined during production planning, as it is a trade-off between tool setup and component cost / space on the PCB.

[0011] In an embodiment, each of the more than one openings is located near a common corner of the housing, i.e., near where the side walls meet. In this way, the potential connector opening positions are close to each other, but offset by a corner angle (e.g., 90 degrees). At a given corner, there may be two, three, or four angularly offset connector opening positions.

[0012] In an embodiment, the housing is provided with at least one connector element for being inserted into the formed opening and cooperating with a corresponding connector position on the PCB. In this way, the assembled sensor unit comprises an externally accessible connector protruding from the housing side wall at a position picked / selected according to customer requirements. At the same time, other connector / opening positions are either not formed or blocked.

[0013] It will be apparent that the housing may be provided with a plurality of connector locations / connector elements to communicate with the PCB connection features if operation of the unit requires.

[0014] A second aspect of the invention is embodied by a method for assembling a sensor unit, for example, for supplying a camera unit suitable for a range of vehicle requirements. The method for assembling a sensor unit (which includes a housing and a sensor device at least partially accommodated by the housing) may include the following steps: configuring the position and orientation of the connection point by (i) selecting the position of the connection point and drilling / milling an opening through the wall of the housing, or (ii) selecting an opening from a plurality of pre-formed openings through the wall of the housing; installing the sensor device into the housing and aligning the terminal portion with the selected connection point; inserting a connector device through the selected opening to electrically connect with the terminal portion. The common concept between the method described herein and the configurable housing enables the use of a common housing design and configuring the connection point according to the position and orientation of the connector which will depend on the final use. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Exemplary embodiments will now be described with reference to the accompanying drawings, in which:

[0016] Figure 1 A camera unit is illustrated with three possible positions for mounting the connector;

[0017] Figure 2 A camera unit with prefabricated connector opening locations, connector interfaces and hole plugs is illustrated;

[0018] Figure 3 Illustrated Figure 2 The complete camera unit assembly; and

[0019] Figure 4 A cross-sectional view showing interior details of the housing is illustrated. DETAILED DESCRIPTION

[0020] The following description presents exemplary embodiments and is related to these Figure 1The present invention is intended to explain the principles of the invention. However, the scope of the invention is not intended to be limited to the exact details of the present embodiment or to strict adherence to all system features and / or method steps, as variations are obvious to the skilled person and are considered to be covered by the present description. The terms used for components used herein should be interpreted broadly, which also includes equivalent functions and features.

[0021] In some cases, several alternative terms (synonyms) for structural and system features have been provided, but these terms are not intended to be exhaustive. For the avoidance of doubt, any term separated by the " / " symbol generally refers to an alternative "or" expression, in which these terms can be used interchangeably. Descriptive terms should also be interpreted as widely as possible; for example, as used in this specification, the term "includes" means "at least partially includes", so that when interpreting each statement including the term "includes" in this specification, there may also be features outside the term or those features at the beginning of the term. Related terms such as "include" and "include" are interpreted in the same way. Any directional terms such as "vertical", "horizontal", "upward", "downward", "lateral", "upper" and "lower" are usually used for convenience of explanation with reference to the forms shown in the accompanying drawings, and if equivalent functions can be achieved by alternative sizes and / or directions, these terms are not intended to be ultimately limited. All directional terms are relative.

[0022] The description herein relates to embodiments with specific step or feature combinations, however, it is contemplated that further combinations and cross-combinations of compatible steps or features between embodiments are possible. In fact, independent features can function as inventions independently of other features and do not necessarily need to be implemented as a complete combination.

[0023] It will be appreciated that the illustrated embodiments show applications for explanation purposes only. In practice, the present invention may be applied to many different configurations, wherein the embodiments are straightforward to implement for those skilled in the art.

[0024] Figure 1 A sensor assembly is illustrated, such as a camera unit 10, which includes a barrel 11 and housing 12 for associated components such as a PCB (not shown) and serves as a mounting device. The distal end of the barrel houses a lens 13, which is held on an internal PCB at a focal distance from the imager. Three connector elements 14 are also shown in the exploded view. However, in practice, only one connector 14 may be incorporated into the assembly.

[0025] The housing 12 may be formed as a box-shaped enclosure for receiving a PCB therein and has side wall surfaces 15, 16, 17, 18, 19 and 20. In the illustrated form, surfaces 17, 18 and 20 are obscured from view due to their location behind or below the housing, but are marked for completeness. The barrel 11 extends from a base end 21 mounted at an upwardly facing wall 19 of the housing. The housing itself may be snap-fitted together in two parts or secured by fasteners or the like.

[0026] The housing 12 may be manufactured with a barrel 11 attached as shown, for example over a circular opening, and one or more side access openings 22, 23, 24 (shown in phantom) formed through the walls of the housing to enable communication with connectors / terminals over an internal PCB.

[0027] Figure 1 The general embodiment of the present invention may not have pre-made connector holes, so it can be drilled in the unit later to complete the assembly. In other words, the openings 21, 22 or 23 can be drilled / milled in one location by the supplier, or as a subsequent step in manufacturing the housing 12.

[0028] Once opening 22, 23 or 24 is formed, connector 14 may be aligned with the aperture, such as by insertion end 25, and defined by flange 26. Surface features 27 of connector 14, such as extending from the barrel of the connector and / or flange 26, may provide interface features to secure an external connector (not shown) from the vehicle in place.

[0029] As mentioned above, the connector element 14 will be in electrical communication with the terminal contact portion of the PCB at one end and compatible with an external connector at the other end for electrical communication. The connector 14 is attached to the housing 12 to provide a permanent connection port, for example, by adhesive, welding, snap fit, bayonet connection, etc.

[0030] After the connector element 14 is secured in place on the housing wall, the PCB and / or lens barrel 11 can be installed in / on the housing 12. Appropriate connections are made to the terminal pins of the PCB so that the center pin 28 etc. can be used for operational purposes, such as for power and data communication (PLC) connection with the vehicle's ECU and camera electronics. The assembly of the unit 10 is then complete and ready for installation in a vehicle.

[0031] Depend on Figure 2 and Figure 3A variation of the above is shown, for example, in which the housing 12 is provided with pre-drilled / formed holes 29, 30, 31 at all or some of the predicted locations where the connectors 14 will be needed. The unnecessary holes are then plugged by suitable plugs 32. "Plugs" is used as a general term for interference fit plugs, but the unused holes in the housing may be closed by welding or any other suitable method.

[0032] As previously described, once the open position is prepared, the connector 14 is inserted into or removed from the housing 12. Likewise, the further assembly of the PCB is described above.

[0033] Depend on Figure 4 Another variant is shown, in which a connector element 33 is shown connected at one end thereof to a PCB 34, while the other end protrudes through an opening 30 in the corner of the housing 12. The connector 33 may be enclosed by another coaxial cover having a similar appearance to the connector 14 of the previous embodiment. The principle of assembly is the same as described above, i.e. the position of the holes is selected based on the orientation of the connector relative to its contact point on the PCB 34.

[0034] Each of the illustrated embodiments shows an exemplary form in which the connector access holes 22 to 24 and 29 to 31 are formed close to the corners (in which the housing is box-shaped) because this configuration can provide the best compatibility with vehicle connector options.

[0035] Regardless of the process assembly used, there may also be two PCB variants available for use with the housing described above, for example, (i) a dedicated PCB for each variant of connector locations, or (ii) a PCB with terminals at all predicted connector locations, or at a portion or some of them.

[0036] By summarizing the advantages of the present disclosure, in the prior art, automotive camera models are configured for only one connector orientation. If another connector orientation is required later, new parts need to be developed. To address this problem, the present camera housing unit is prepared for many connector (e.g., German standard FAKRA, Fachkreis Automobil) orientation variants, and does not require a new housing configuration for each possibility, only customized during the assembly process by plugging holes or drilling / milling specific holes in the wall suitable for such formation. Surface markings can be provided to assist in the formation of positioning holes, since the planned range of variants (e.g., in vehicle configuration) is typically predetermined.

[0037] The exemplary embodiments herein relate to a camera unit, e.g., having a lens and imager, but other sensor types may benefit from an adaptable housing (e.g., a subassembly) that is configurable according to the direction of entry of a connector that will need to interface with the connector when assembled into a vehicle or similar assembly. Thus, more generally, the present disclosure relates to a sensor housing intended to house associated electronics with or without the sensor itself.

[0038] As a further summary, the concepts herein relate to a sensor unit having a housing configured to select a position through an opening in a side wall aligned with a connection portion of a printed circuit board. A connector device can be positioned through the selected opening for electrical communication between the PCB and an external connector.

Claims

1. A housing for accommodating at least a portion of a sensor device, the housing comprising: a plurality of opening locations formed into the housing; and Connector device; The plurality of opening positions enable selection of the position and direction of entry of the connector device into the housing so as to electrically communicate with a terminal portion of the sensor device within the housing at one end and be compatible with an external connector at the other end.

2. The housing according to claim 1, wherein: There are at least two side walls of the housing, which are arranged at an angle to each other, each side wall comprising an opening in the plurality of opening positions, thereby enabling different orientations for the selectable positions of the connector device.

3. The housing according to claim 2, wherein: The at least two side walls include a corner of the housing, and at least two of the plurality of opening locations are located proximate to the corner.

4. A housing according to any one of the preceding claims, comprising a plug element for covering each unselected opening of the plurality of opening positions.

5. The housing according to claim 4, wherein: The plug element provides a seal against the ingress of dust and / or fluids.

6. A sensor unit according to any one of the preceding claims, wherein: The connector device includes an insertion end for insertion into a selected opening.

7. A sensor unit according to any one of the preceding claims, wherein: The connector device includes an engagement feature for securing to the external connector.

8. A sensor unit comprising a housing according to any one of the preceding claims and a sensor device at least partially accommodated by the housing, wherein: The sensor device comprises a PCB having a plurality of terminal portions, wherein one of the terminal portions is alignable with a selected location of the connector device.

9. The sensor unit according to claim 8, wherein: The PCB includes an imager for alignment with a lens barrel of the sensor device extending from the housing.

10. A method of assembling a sensor unit comprising a housing and a sensor device at least partially accommodated by the housing, the method comprising the following steps: configuring the location and orientation of the connection point by (i) selecting the location and drilling / milling an opening through the wall of the housing, or (ii) selecting an opening from a plurality of preformed openings through the wall of the housing; installing the sensor device into the housing and aligning the terminal portion with the selected connection point; A connector device is inserted through the selected opening to electrically connect with the terminal portion.

11. The method according to claim 10, wherein: The connector device is secured into the selected opening by adhesive or welding to the housing.

12. The method according to claim 10 or 11, wherein: In option (ii), the unselected preformed openings are closed by plugs.

13. The method according to any one of claims 10 to 12, wherein: The sensor device includes a lens barrel extending from the housing and alignable with an imager of a PCB housed within the housing.

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