Vehicle Camera Housing Assembly Using Cold-Deformed Connectors

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing vehicle camera manufacturing processes require significant material, mounting, and tooling expenditures due to the use of hot deformation methods like hot stamping or vibration welding for connecting components.

Innovation Solution

Employing cold-deformable projection connecting elements made of materials like metal alloys to connect housing parts of vehicle cameras, allowing for assembly through cold deformation techniques such as chiseling or pressing, reducing the need for heating and associated tooling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If hot deformation methods like hot stamping or vibration welding are used to connect housing parts, then secure and stable connections are achieved, but manufacturing costs and tooling requirements increase significantly

Engineering Contradiction:

Improveconnection strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent changes the temperature parameter from hot deformation to cold deformation. The projection connecting element is deformed at room temperature rather than requiring heating, which eliminates the need for hot stamping or vibration welding processes. This parameter change reduces manufacturing costs and tooling requirements while still achieving secure connections through the deformation of the projection connecting element that engages with the reception connecting element.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces thermal or vibrational mechanical systems with a simple cold deformation mechanism. Instead of using hot stamping (thermal field) or vibration welding (vibrational mechanical field), the invention uses cold deformation where the projection connecting element is elastically deformed during insertion and then engages with the reception connecting element. This substitution eliminates complex heating and vibration equipment requirements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If hot deformation methods are used to connect housing parts, then secure connections are achieved, but tooling requirements and complexity increase

Engineering Contradiction:

Improveconnection strengthVSAvoidtooling complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If cold deformation methods are used to connect housing parts, then manufacturing costs and tooling requirements are reduced, but connection stability may be compromised

Engineering Contradiction:

Improvemanufacturing costVSAvoidconnection stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent employs dynamic deformation behavior of the projection connecting element. The element is designed to be elastically deformable during insertion, allowing it to be pushed through the reception connecting element, and then it deforms plastically or elastically to create a stable engaged state. This dynamic behavior ensures that the connection is both easy to manufacture and stable in service.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The projection connecting element is made from a material that combines elasticity and plasticity properties, allowing it to undergo controlled deformation. The material choice is critical to ensure that the element can be deformed during assembly but maintains stable engagement afterward. This composite material approach balances manufacturability with connection reliability.

Inventive Principle:

Principle #40Composite materials

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

This approach minimizes manufacturing costs and tooling requirements while ensuring secure and stable connections, enabling efficient production of vehicle cameras for various applications, including autonomous or semi-autonomous vehicle systems.

Implementation Method 1

at least one projecting projection connecting element, which consists of a deformable material at least at one end, is arranged on the at least one connecting portion

Methodology Applied

Scientific EffectCold deformation: Cold-forming

Implementation Method 2

the at least one projection connecting element has a deformed grip portion, which engages behind the at least one connecting portion with the at least one reception connecting element

Methodology Applied

Scientific EffectPlasticity: Plasticity

Data Source

PatentUS20260010056A1Housing part for the housing of a vehicle camera, optical module for a vehicle camera, vehicle camera, vehicle comprising at least one vehicle camera, and method for producing a vehicle camera

Publication Date: 2026.01.08 VALEO SCHALTER & SENSOREN GMBH

AI summary

A housing part (18) for a housing (16) for a vehicle camera (14), an optical module for a vehicle camera, a vehicle camera, a vehicle with at least one vehicle camera and a method for producing a vehicle camera are described. The housing part (18) has at least one connecting portion (36) for mechanical connection of the housing part (18) to at least one other part (22) of the vehicle camera (14), at least one projecting projection connecting element (38), which consists of a deformable material at least at one end, being arranged on the at least one connecting portion (36). The at least one projecting projection connecting element (38) consists of a cold-deformable material at least at one end.