Vehicle Camera Module Mounting for Thermal-Stable Alignment
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Solution Overview
Problem
Current camera modules in vehicles face alignment issues due to thermal deformation of aluminum housings, leading to reading errors and increased production costs, especially when using vee-groove designs and three spheres, which complicate mounting and are affected by temperature changes.
Innovation Solution
A camera module design featuring a printed circuit board with a carrier having rails and flexible wings for form and force fitting the camera, along with an illumination device, which simplifies alignment and assembly, and is housed in an EMI shielding material with cooling features to mitigate thermal effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a camera is mounted directly in an aluminum housing with vee-groove design, then the housing provides structural support and thermal dissipation, but thermal deformation causes alignment deviation and reading errors
Solution Approach 1:
The housing is divided into two separate parts: an aluminum housing for thermal dissipation and a plastic housing for precise camera mounting. This segmentation allows each material to perform its optimal function without the negative effects of thermal deformation affecting alignment precision.
Solution Approach 2:
A plastic housing acts as an intermediary between the aluminum housing and the camera. The plastic housing absorbs thermal expansion differences and maintains stable alignment, mediating between the thermally active aluminum structure and the precision-required camera mounting.
2Manufacturing precision
If three spheres and vee-groove design are used for camera mounting, then the mounting structure provides positioning, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The complex three-sphere and vee-groove mounting structure is extracted and replaced with a simplified plastic housing design that integrates positioning features directly into the housing structure, eliminating the need for separate mounting components and reducing assembly steps.
Solution Approach 2:
The positioning and mounting functions are merged into a single integrated plastic housing structure, combining the positioning features and camera mounting into one component that simplifies the assembly process while maintaining positioning accuracy.
3Manufacturing precision
If tight tolerances are required for camera housing, then alignment precision is maintained, but production costs increase significantly
Solution Approach 1:
The plastic housing provides localized precision mounting features exactly where the camera requires accurate positioning, while the aluminum housing provides general structural support and thermal management. This local application of precision features reduces overall manufacturing tolerances required and lowers production costs.
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 solution ensures camera alignment is not affected by temperature changes, reduces assembly time and costs, and provides a robust, efficient mounting system for camera modules in vehicles.
Implementation Method 1
The housing is made from an EMI shielding material and has cooling features to mitigate thermal effects
Data Source
AI summary
A camera module (1) for a vehicle (2). A printed circuit board (11) of the camera module (1) has a carrier (10) for at least one camera (14, 141, 142, . . . , 14N). The carrier (10) is mounted directly to the printed circuit board (11). The printed circuit board (11) carries as well electronic components (18) and a connector (19).