Vehicular Camera Module PCB Stress Relief for Focus Stability

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Solution Overview

Problem

Existing vehicular vision systems face challenges in maintaining peak focus during the installation of imager assemblies into camera modules, due to uneven mating surfaces of the protective cover, which causes deflection of the imager printed circuit board and resulting focus variation.

Innovation Solution

The proposed solution involves an imager assembly with a lens barrel received through an aperture of the camera housing, where the imager printed circuit board is attached via fasteners to the upper housing portion, and optional stress relieving slots or a counter warping ring are used to minimize stress and warping, thereby maintaining focus.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the imager printed circuit board is rigidly attached to the housing to ensure structural stability, then the structural strength is improved, but the focus precision deteriorates due to stress-induced deflection

Engineering Contradiction:
Improvestructural strengthVSAvoidfocus precision
Core Design Contradiction:
StrengthVSManufacturing precision

Solution Approach 1:

The patent applies a flexible printed circuit board (FPC) instead of a rigid PCB to connect the imager to the housing. The FPC can bend and deform to accommodate stress from uneven mating surfaces without transmitting this stress to the imager, thus maintaining focus precision while still providing structural connection. This directly resolves the contradiction by using a flexible material that decouples structural strength from stress transmission.

Inventive Principle:
Principle #30Flexible shells and thin films

Solution Approach 2:

The patent introduces an intermediary flexible circuit board between the rigid housing and the imager assembly. This FPC acts as a mediator that absorbs mechanical stress and prevents it from reaching the imager, thereby protecting the focus precision while maintaining the structural integrity provided by the rigid housing attachment.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Stability of the object's composition

If stress relieving slots are added to the imager printed circuit board to reduce warping, then the focus stability is improved, but the device complexity increases

Engineering Contradiction:
Improvefocus stabilityVSAvoiddevice complexity
Core Design Contradiction:
Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent segments the imager PCB by introducing stress relieving slots that divide the board into separate regions. These slots allow different parts of the PCB to move independently under stress, preventing warping and maintaining focus stability. The segmentation approach solves the problem by creating controlled flexibility zones without requiring entirely separate components.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent applies local quality by creating specific stress relieving slots only in the regions of the PCB most susceptible to warping, while keeping other areas intact. This targeted approach provides focus stability where needed without unnecessarily complicating the entire device structure.

Inventive Principle:
Principle #3Local quality

3Adaptability or versatility

If the lens barrel is received through an aperture in the upper housing portion to enable forward viewing, then the field of view is improved, but the structural rigidity deteriorates due to the opening

Engineering Contradiction:
Improvefield of viewVSAvoidstructural rigidity
Core Design Contradiction:
Adaptability or versatilityVSStrength

Solution Approach 1:

The patent uses a nested structure where the lens barrel is received within the upper housing portion through an aperture. The lens barrel itself acts as a nested component that fits into the housing, providing structural support while maintaining the opening for optical access. This nesting approach resolves the contradiction by using the lens barrel structure to reinforce the area around the aperture.

Inventive Principle:
Principle #7Nested doll (Nesting)

Data Source

PatentUS20250170961A1Vehicular camera module
Publication Date: 2025.05.29 MAGNA ELECTRONICS INC
  • US20250170961A1 patent drawing
  • US20250170961A1 patent drawing
  • US20250170961A1 patent drawing

AI summary

A vehicular camera module includes a housing for mounting at a vehicular windshield, and an imager assembly. The imager assembly includes (i) a lens barrel accommodating a lens and (ii) an imager printed circuit board (imager PCB). An imager is disposed at a first side of the imager PCB. The imager PCB includes an imager portion at which the imager is disposed and attaching portions at respective outboard ends of the imager PCB. The imager PCB includes stress relieving portions that include a stress relieving portion between the imager portion and each of the attaching portions. Each stress relieving portion includes at least one region of the imager PCB that is more flexible than the imager portion and the respective attaching portion of the imager PCB. The attaching portions of the imager PCB are attached at the housing via respective fasteners.