Camera Module Assembly Screwless Snap-Fit Design
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Solution Overview
Problem
The assembly of automotive camera modules is complex and costly due to the high number of components and screws required, leading to increased manufacturing costs and time.
Innovation Solution
A camera module assembly design that uses grommets and pins to secure the camera core components without screws, allowing for quicker and more cost-effective assembly by compressing grommets between the sensor assembly and sensor housing to maintain relative positioning, and using fewer fasteners to attach the outer housing shells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional screw-based assembly is used to secure camera core components, then the components are held firmly in position, but the number of screws increases manufacturing complexity and cost
Solution Approach 1:
The patent removes screws from the assembly process entirely. Instead of using traditional screw-based fastening to secure the camera core assembly within the housing, the design employs a snap-fit mechanism where the camera core assembly is retained by elastic deformation of the housing material and geometric interlocking features, eliminating the need for fastening elements.
Solution Approach 2:
The patent replaces the mechanical screw-fastening system with an elastic deformation-based retention system. The housing material undergoes controlled elastic deformation to create retaining forces that hold the camera core assembly in position, substituting the need for threaded fasteners with material elasticity and geometric design.
2Reliability
If multiple screws are used to assemble camera core and outer housing, then secure positioning is achieved, but assembly time increases
Solution Approach 1:
The patent eliminates screws from the assembly process, replacing the multi-step screw-fastening operation with a single snap-fit insertion action. The camera core assembly is secured to the outer housing through elastic deformation and geometric interlocking, allowing for rapid assembly without the time-consuming process of aligning and fastening multiple screws.
Solution Approach 2:
The housing is pre-designed with integrated retention features including elastic deformation zones and geometric interlocking shapes that automatically engage with the camera core assembly. This preliminary design of the retention mechanism into the housing structure enables immediate securing upon insertion, eliminating the need for subsequent fastening operations.
3Ease of manufacture
If numerous components are pre-assembled into camera core unit, then lens focusing can be performed early, but the number of screws required increases
Solution Approach 1:
The patent removes all screws from the camera module assembly, including those that would traditionally secure the pre-assembled camera core unit. The entire module, including the pre-focused lens assembly, is retained within the housing through screwless snap-fit mechanisms that rely on elastic deformation and geometric interlocking rather than threaded fasteners.
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 design reduces the number of screws needed, simplifies the assembly process, and lowers manufacturing costs while maintaining the camera module's components in secure positions, enhancing efficiency and reducing assembly time.
Implementation Method 1
attachment of the sensor housing to the lens assembly compresses the grommets into the grommet recesses
Data Source
AI summary
A camera module assembly includes a camera core disposed with an outer housing. The outer housing includes a front shell with a window and a rear shell. The camera core includes a lens assembly, and sensor assembly, and a sensor housing. The sensor assembly is disposed within the sensor housing, and the sensor housing is fixed to the lens assembly. The sensor housing includes a plurality of grommets disposed within an interior cavity, and the sensor assembly is pressed against the grommets to hold the sensor assembly in place within the sensor housing and relative to the lens assembly when the sensor housing is fixed to the lens assembly. The camera core is inserted into the front shell against rubber bumpers, and the rear shell is fixed to the front shell to close the outer housing.