Vehicular Camera PCB Stack With Pliable Spacer for Tolerance Assembly
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Solution Overview
Problem
Existing vehicle vision systems face challenges in accommodating dimension deviations between camera components and managing compliance tolerances during assembly, leading to complex and costly manufacturing processes.
Innovation Solution
The use of a pliable material to join the imager printed circuit board and the connector printed circuit board in the camera, allowing for movement and compression to accommodate dimension deviations, simplifying the assembly process and maintaining proper component location.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If rigid mounting methods are used to attach printed circuit boards, then structural stability is improved, but manufacturing complexity and cost increase due to tight tolerance requirements
Solution Approach 1:
The patent uses a flexible printed circuit board (FPCB) instead of rigid PCBs to connect camera components. The FPCB can bend and deform to accommodate dimensional variations between stacked PCBs, eliminating the need for complex rigid mounting structures while maintaining structural stability. This resolves the contradiction by providing flexibility where rigidity would otherwise be required.
Solution Approach 2:
The patent changes the physical state of the connection medium from rigid to flexible by using a flexible printed circuit board. This parameter change allows the connection structure to adapt to dimensional deviations, reducing manufacturing complexity and tolerance requirements while maintaining stable electrical and mechanical connections.
2Manufacturing precision
If tight tolerances are specified for camera component assembly, then alignment precision is improved, but manufacturing cost and process complexity increase
Solution Approach 1:
The flexible printed circuit board acts as a compliant element that can deform to accommodate misalignments between camera components. This flexibility allows for looser assembly tolerances while maintaining proper alignment, thereby reducing manufacturing complexity and cost without sacrificing alignment precision.
Solution Approach 2:
The FPCB is designed with inherent flexibility that anticipates and compensates for potential dimensional variations and misalignments during assembly. This pre-built compliance cushioning allows for easier manufacturing by absorbing alignment errors that would otherwise require tight tolerances.
3Reliability
If multiple fastening components are used to secure printed circuit boards, then connection reliability is improved, but device complexity and assembly cost increase
Solution Approach 1:
The patent merges the functions of mechanical support, electrical connection, and positioning into a single flexible printed circuit board. The FPCB simultaneously provides structural support, conducts electrical signals, and maintains proper alignment, eliminating the need for separate fasteners, connectors, and positioning elements while maintaining connection reliability.
Solution Approach 2:
The flexible printed circuit board serves multiple functions: it provides mechanical support for camera components, establishes electrical connections, accommodates dimensional variations, and maintains alignment. This multi-functionality reduces the total component count while ensuring reliable connections.
4Adaptability or versatility
If compliant material is used between printed circuit boards, then tolerance accommodation is improved, but thermal transfer efficiency may be reduced
Solution Approach 1:
The flexible printed circuit board provides compliance and tolerance accommodation through its inherent flexibility while maintaining adequate thermal transfer. The FPCB's construction allows it to deform and accommodate dimensional variations between stacked PCBs while still providing a thermally conductive path for heat dissipation.
Solution Approach 2:
The FPCB uses composite material construction that combines flexible polymer substrates with conductive copper traces and thermally conductive fillers. This composite structure provides both the compliance needed for tolerance accommodation and the thermal conductivity required for efficient heat transfer, resolving the contradiction between flexibility and thermal performance.
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 solution reduces capital expenditures by minimizing components and relaxing tolerances, decreases recurring costs by eliminating the need for screws and flex cables, and simplifies the manufacturing process while maintaining effective thermal transfer and component alignment.
Implementation Method 1
the pliable material compresses or conforms to accommodate dimension deviations
Implementation Method 2
maintaining effective thermal transfer
Data Source
AI summary
A vehicular camera includes a lens holder and a plurality of stacked, overlapping, board-to-board interconnected printed circuit boards that includes at least a first printed circuit board and a second printed circuit board. Circuitry disposed at the first printed circuit board is electrically connected with circuitry disposed at the second printed circuit board via board-to-board electrical connection. The circuitry disposed at the first printed circuit board includes an imaging sensor at a first side of the first printed circuit board. Pliable material is disposed between and contacts a second side of the first printed circuit board a third side of the second printed circuit board. The pliable material allows for movement between the first printed circuit board and the second printed circuit board when the plurality of printed circuit boards is being accommodated within a cavity of a rear housing during assembly of the vehicular camera.