Vehicle Camera Modular Connector-Plate Alignment
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Solution Overview
Problem
Automotive cameras face challenges in aligning image sensors with lenses due to tolerances, leading to increased size and complexity, with existing solutions like flexible printed circuits and floating housings being costly and cosmetically undesirable.
Innovation Solution
A camera assembly with a modular design using a connector-plate concept that allows for flexible alignment without increasing camera size, integrating the camera housing with the bracket to reduce part count and cost, and enabling interchangeability of bracket-housings and connector-plates for various applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If flexible printed circuits are used to align image sensor with lens, then alignment tolerance is absorbed, but camera size increases and cost increases
Solution Approach 1:
The patent extracts the alignment tolerance absorption function from the camera housing and relocates it to the mounting bracket. The bracket includes a positioning feature that independently compensates for misalignment between the image sensor and lens, separating the alignment function from the housing structure and eliminating the need for flexible printed circuits.
Solution Approach 2:
The patent introduces a positioning feature as an intermediary element between the camera module and the mounting bracket. This positioning feature acts as a mediator that absorbs alignment tolerances and ensures proper alignment between the image sensor and lens without requiring the entire housing to be flexible or oversized.
2Manufacturing precision
If flexible printed circuits are used to align image sensor with lens, then alignment tolerance is absorbed, but device complexity increases
Solution Approach 1:
The patent removes the flexible printed circuit from the system and transfers the alignment tolerance absorption function to a rigid positioning feature integrated into the mounting bracket. This simplifies the device by eliminating complex flexible circuits while maintaining the ability to absorb manufacturing tolerances.
3Manufacturing precision
If floating housing is used to align image sensor with lens, then alignment tolerance is absorbed, but cosmetic appearance deteriorates
Solution Approach 1:
The patent extracts the alignment tolerance absorption function from the camera housing and places it in the mounting bracket's positioning feature. This allows the housing to maintain a fixed, rigid structure with clean lines and professional appearance, while the bracket handles the alignment compensation.
4Adaptability or versatility
If camera housing and bracket are separate components, then adaptability to multiple applications is improved, but part count increases
Solution Approach 1:
The patent merges the camera housing and mounting bracket into a single integrated component. The positioning feature is built into the housing itself, eliminating the separate bracket and reducing part count while maintaining adaptability through the integrated positioning mechanism that can accommodate various mounting scenarios.
Solution Approach 2:
The integrated housing-bracket design incorporates a universal positioning feature that can adapt to multiple mounting applications and vehicle types. The single component serves both as the camera housing and as the mounting interface, providing multi-functionality without requiring separate specialized brackets for different applications.
Data Source
AI summary
A camera assembly for a vehicular vision system includes a housing that accommodates a lens and a circuit board. An imager is disposed at the circuit board and optically aligned with the lens, and circuitry is disposed at the circuit board and electrically connected with the imager. The housing includes a rear housing portion that has an aperture therethrough, with the aperture aligned with an electrical connecting element of the circuit board. A bracket includes a mounting portion configured to attach at the vehicle and at the rear housing portion. With an electrical connector electrically connected to the electrical connecting element of the circuit board, the bracket is attached at the rear housing portion, and a structural element of the electrical connector is clamped between the bracket and the rear housing portion to maintain electrical connection of the electrical connector with the electrical connecting element of the circuit board.