Vehicle Camera PCB Assembly Using Twisted Frame Tabs
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Solution Overview
Problem
Existing methods for assembling electronic devices, such as cameras for vehicles, are inefficient due to the need for high precision tooling and time-consuming screwing processes, and are not suitable for thin, flexible, or fragile components like printed circuit boards.
Innovation Solution
The use of projecting tabs on a supporting frame that can be bent to attach electronic substrates without screws, providing a fast, reliable, and low-cost assembly method, with the tabs acting as both a visual indicator for correct attachment and a mistake-proofing mechanism to prevent incorrect assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If screws are used to assemble electronic substrates to the supporting frame, then the connection strength is improved, but the assembly time and manufacturing complexity increase
Solution Approach 1:
The patent extracts the fastening function from separate screws and integrates it into the supporting frame structure itself through projecting tabs. These tabs are formed as integral parts of the supporting frame and provide both mechanical support and attachment functionality, eliminating the need for separate fastening components and reducing assembly steps.
Solution Approach 2:
The patent combines multiple functions into the projecting tabs: they provide structural support, enable attachment of electronic substrates, and serve as visual indicators for assembly status. By merging these functions into a single integrated feature, the design reduces the number of components and simplifies the assembly process while maintaining connection strength.
2Manufacturing precision
If high precision tooling is used for screwing, then the assembly precision is improved, but the manufacturing cost and complexity increase
Solution Approach 1:
The projecting tabs are designed to be self-aligning and self-explanatory. Their visual visibility provides automatic guidance to operators about where assembly is needed and whether it has been completed, eliminating the need for complex tooling or precision measurement equipment. The structure itself communicates the assembly requirements.
3Productivity
If elastic or snap fit couplings are used, then the assembly speed is improved, but the reliability of attachment for fragile components deteriorates
Solution Approach 1:
The patent segments the attachment function into multiple projecting tabs distributed across the supporting frame. Each tab provides independent attachment points, distributing the mechanical load and reducing stress concentration on any single point. This segmentation allows for simple assembly while maintaining reliable attachment through distributed support.
Data Source
AI summary
Electronic device such as a camera for a vehicle, including: a supporting frame, a main electronic substrate, provided with at least one electric or electronic component or circuit and coupled to the supporting frame; a secondary electronic substrate, provided with at least one electric or electronic component or circuit and coupled to the supporting frame; wherein the supporting frame has at least one main projecting tab and at least one secondary projecting tab, each capable to occupy a non-twisted position or a twisted position, wherein the main projecting tab, when in the twisted position, is providing an attachment of the main electronic substrate to the supporting frame, and wherein the secondary projecting tab, when in the twisted position, is providing an attachment of the secondary electronic substrate to the supporting frame.