Vehicular Camera Connector Assembly for Mounting Misalignment
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Solution Overview
Problem
Rearview cameras for vehicles face challenges due to space restrictions, complexity, reliability issues from numerous components and electrical connections, and misalignment during mounting, leading to potential circuit failures and increased costs.
Innovation Solution
A camera design featuring a front and rear housing member with direct electrical connectors, eliminating the need for jumper wires, and incorporating a rear alignment structure to align connectors without aligning the housing members, along with conductive coatings to prevent static buildup, and a locking mechanism for secure mounting without fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional cameras use separate front and rear housing members that are aligned with respect to each other, then the housing structure is stable and rigid, but the mounting position can be significantly out from the intended position due to stack up of tolerances
Solution Approach 1:
The housing is divided into front and rear housing members that are not aligned with respect to each other, allowing independent positioning of each segment to accommodate tolerance variations and achieve accurate overall mounting position
Solution Approach 2:
Electrical connectors serve as intermediary alignment features between the front and rear housing members, providing a reference interface that ensures proper relative positioning without requiring precise alignment of the housing members themselves
2Reliability
If traditional cameras use jumper wires to connect electrical components, then the camera can be assembled with standard components, but jumper wires introduce potential sources of circuit failures and increase cost
Solution Approach 1:
The electrical connectors are integrated directly into the housing members, merging the electrical connection function with the structural housing components and eliminating the need for separate jumper wires
Solution Approach 2:
Jumper wires are extracted and removed from the system entirely, replacing them with built-in electrical connectors that are an integral part of the housing structure
3Adaptability or versatility
If traditional cameras have numerous components and individual electrical connections, then the camera can perform multiple functions, but the camera suffers from reliability problems due to the number of components and connections
Solution Approach 1:
Multiple functions are combined into integrated components, such as electrical connectors that serve both structural and electrical connection purposes, reducing the total number of separate components while maintaining functionality
4Ease of operation
If traditional cameras use aligned front and rear housing members, then the assembly is straightforward, but the connectors cannot accommodate misalignment during mounting
Solution Approach 1:
The electrical connectors are designed with flexible or adjustable characteristics that allow them to accommodate misalignment between housing members during assembly, providing tolerance for positioning variations
Data Source
AI summary
A vehicular camera includes a camera housing having a first portion and a second portion joined together to form a cavity within the camera housing. A first electrical connector is disposed at a circuit board and is in electrically-conductive connection with an imager. The first electrical connector includes a plurality of pin-receiving sockets. A second electrical connector includes a plurality of pins, each including a first end and a second end opposite the first end. When the second portion of the camera housing is being joined with the first portion of the camera housing, respective first ends of pins insert into and electrically-conductively connect with respective pin-receiving sockets at the second side of the circuit board. The first electrical connector and the second electrical connector cooperate to allow for misalignment of the second electrical connector relative to the first electrical connector when the first and second portions are being joined.