Automotive Camera Lens Holder with Integrated Induction Heater

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Solution Overview

Problem

Conventional automotive external camera lens heating systems are costly, bulky, and suffer from complex assembly issues due to external resistive heating elements, which are inefficient and difficult to secure.

Innovation Solution

An automotive camera with an integrated induction heater, where an induction coil is etched into the internal surface of the lens holder via laser direct structuring, allowing for efficient and safe heating, eliminating wire fixation issues and enabling a compact, scalable, and mass-producible design.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional external resistive heating elements are used for lens defrosting, then heating function is provided, but device size increases and assembly complexity increases

Engineering Contradiction:

Improvelens defrosting capabilityVSAvoidassembly complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The heating function is merged with the lens holder structure by integrating the induction coil directly into the lens holder component. This eliminates the need for separate external heating elements and their associated wiring, reducing assembly complexity while maintaining the lens defrosting capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The lens holder acts as an intermediary structure that incorporates the induction coil to provide heating. This mediator approach allows the heating function to be embedded within the existing structural component rather than adding external heating elements.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If conventional external resistive heating elements are used for lens defrosting, then heating function is provided, but device size increases

Engineering Contradiction:

Improvelens defrosting capabilityVSAvoidcamera size

Core Design Contradiction:

TemperatureVSVolume of moving object

Solution Approach 1:

The heating coil is merged with the lens holder structure, eliminating the need for separate external heating components. This integration reduces the overall camera volume by consolidating the heating function within the existing structural component.

Inventive Principle:

Principle #5Merging (Combining)

3Temperature

If conventional external resistive heating elements are used for lens defrosting, then heating function is provided, but manufacturing cost increases

Engineering Contradiction:

Improvelens defrosting capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The induction coil is merged with the lens holder as an integrated component, reducing the total part count and assembly steps. This simplification lowers manufacturing costs by eliminating separate heating elements, wiring harnesses, and associated assembly operations.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The lens holder structure itself serves the dual purpose of mechanical support and heat generation through the integrated induction coil. This self-service approach eliminates the need for separate external heating components, reducing manufacturing complexity and cost.

Inventive Principle:

Principle #25Self-service

4Temperature

If external resistive heating elements are used, then lens defrosting is achieved, but heating efficiency decreases

Engineering Contradiction:

Improvelens defrosting capabilityVSAvoidheating efficiency

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The lens holder serves as an intermediary that directly couples the induction coil's magnetic field to the lens structure. This intermediary approach enables more efficient energy transfer compared to external resistive heating, as the induction heating occurs directly within the integrated structure rather than through external contact.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 integrated induction heater provides fast and safe lens defrosting, reducing size and assembly complexity while improving efficiency and compatibility with surface mount technology and moldable assembly.

Implementation Method 1

an induction coil configured to generate heat energy to defrost the lens

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

an induction coil configured to generate heat energy to defrost the lens

Methodology Applied

Scientific EffectInduction heating: Induction Heating

Implementation Method 3

the induction coil is formed in the inner surface of the lens holder via laser direct structuring (LDS)

Methodology Applied

Scientific EffectLaser direct structuring: Laser

Data Source

PatentUS11586099B2Automotive camera with integrated induction heater

Publication Date: 2023.02.21 APTIV TECHNOLOGIES AG

AI summary

An external camera for a vehicle and its method of manufacture involve providing a camera assembly comprising a lens assembly comprising a lens and a lens holder that houses at least a portion the lens assembly and defining an inner surface, forming an induction coil integrated in the inner surface of the lens holder, the induction coil being configured to generate heat energy to defrost the lens, providing a camera housing that houses the camera assembly, and housing the camera assembly within the camera housing to form the external camera.