Extruded Aluminum Camera Housing With Integral Mounting Posts
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Solution Overview
Problem
Existing vehicle vision systems face challenges in securely mounting cameras without fasteners, which can lead to instability and potential electrical connectivity issues, affecting the reliability of image data capture and processing.
Innovation Solution
A camera system with a metallic body, such as an extruded aluminum body, uses posts formed as part of the body to secure the printed circuit board and connector structure, where the post ends are flattened via punching or vibration welding to provide a secure and fastener-free assembly, ensuring stable image data capture and processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fasteners are used to mount the printed circuit board and connector structure, then secure mounting is achieved, but device complexity and assembly steps increase
Solution Approach 1:
The patent integrates the mounting function directly into the camera body by forming posts as integral parts of the housing. These posts combine structural support and mounting functions, eliminating the need for separate fasteners. The posts are inserted through holes in the PCB and connector structure, and their ends are flattened to secure these components, merging the housing structure with the mounting mechanism.
Solution Approach 2:
The camera body posts serve dual purposes: providing structural support and performing the mounting function. The posts are formed as part of the body itself and automatically provide the mounting function when inserted and flattened, making the structure self-sufficient and eliminating the need for additional fastening components.
2Reliability
If posts are flattened to secure components, then secure mounting is achieved, but manufacturing complexity increases
Solution Approach 1:
The posts are pre-formed as integral parts of the camera body housing during the housing manufacturing process. This preliminary formation of the posts with their flattened ends eliminates the need for separate fastening operations, as the mounting capability is already built into the structure before assembly begins.
Solution Approach 2:
The manufacturing process for the housing is merged with the creation of the mounting posts. The posts are formed as part of the extrusion or molding process that creates the housing, combining what would traditionally be separate manufacturing steps into a single integrated process.
3Reliability
If fasteners are used to secure the connector structure, then electrical connectivity is ensured, but the number of parts and assembly steps increase
Solution Approach 1:
The housing posts are merged with the mounting function for the connector structure. The same posts that provide structural support for the housing also serve to secure the connector structure, eliminating the need for separate fasteners and reducing the total component count.
Solution Approach 2:
The posts serve multiple functions: providing structural support for the housing, mounting the printed circuit board, securing the connector structure, and maintaining electrical connectivity. This multi-functionality reduces the number of separate components needed while ensuring reliable connections.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a stable and secure camera assembly that enhances the reliability of image data capture and processing, improving the overall performance of the vehicle vision system by eliminating the need for fasteners and ensuring reliable electrical connections.
Implementation Method 1
the ends of the posts are then flattened (such as via punching or vibration welding or the like) to secure the PCB at the posts
Data Source
AI summary
A method of assembling a camera for a vehicular vision system includes providing a camera housing and forming a post at an interior portion of the camera housing, and positioning a printed circuit board in the camera housing so that the post is received through a hole through the printed circuit board such that a protruding end of the post protrudes from the side of the printed circuit board opposite the imager. Circuitry disposed at one side of the printed circuit board includes an imager. The protruding end of the post is adapted to limit retraction of the post from the hole through the printed circuit board so as to secure the printed circuit board relative to the post and the camera housing. A lens is provided at the camera housing.