Vehicular Camera PCB Stack With Compliant Thermal Interface
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Solution Overview
Problem
Existing vehicle vision systems face challenges in accommodating dimension deviations and manufacturing tolerances during camera assembly, leading to complex and costly focus/alignment processes.
Innovation Solution
The use of a pliable material between the imager and connector printed circuit boards allows for flexible assembly, accommodating dimension deviations and simplifying the assembly process by compressing to fit together properly, reducing the need for screws and flex cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If rigid mounting methods are used to attach printed circuit boards, then alignment precision is improved, but assembly complexity and cost increase due to need for screws and flex cables
Solution Approach 1:
The patent changes the mechanical properties of the mounting material from rigid to compliant, allowing the material to deform and accommodate dimensional variations while maintaining electrical connectivity. This eliminates the need for precision alignment features and fasteners.
Solution Approach 2:
The patent introduces a compliant mounting material as an intermediary between the printed circuit boards and housing, which absorbs dimensional deviations and eliminates the need for direct rigid mechanical connections, thereby simplifying assembly.
2Device complexity
If compliant material is used between printed circuit boards, then assembly complexity is reduced, but thermal conduction between boards deteriorates
Solution Approach 1:
The patent uses a composite material that combines the properties of compliance (elasticity) and thermal conduction, allowing it to both simplify assembly by accommodating dimensional variations and maintain effective thermal transfer between stacked printed circuit boards.
Solution Approach 2:
The patent modifies the thermal properties of the compliant material to ensure adequate thermal conduction, transforming it from a simple flexible spacer into a thermally conductive compliant material that addresses both assembly simplicity and thermal management requirements.
3Manufacturing precision
If precise alignment features are implemented, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent changes the mounting approach from rigid precision-based to compliant tolerance-based, allowing standard manufacturing tolerances to be used without requiring expensive precision alignment features or post-assembly adjustments.
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 simplifies the camera assembly process, reduces capital expenditures, and enhances component density while maintaining proper alignment and focus, thereby easing manufacturing complexities and costs.
Implementation Method 1
a first thermally conductive pliable material disposed between the imager printed circuit board and the connector printed circuit board
Data Source
AI summary
A vehicular camera includes a lens holder, a first printed circuit board and a second printed circuit board. The first and second printed circuit boards are stacked and overlap one another. 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. Thermally conductive material is disposed between the second printed circuit board and a second side of the first printed circuit board. The thermally conductive material is in thermally-conductive contact with the first and second printed circuit boards. The vehicular camera includes a rear housing, which includes an electrical connector portion. The electrical connector portion of the rear housing may include an electrical plug connector.