Vehicular Camera PCB Connectors for Tolerance-Stable Alignment
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Solution Overview
Problem
Vehicle vision systems face challenges in maintaining stable electrical connections between camera connectors and circuitry, leading to potential misalignment and poor picture quality due to tolerance variations and mechanical stress during assembly and use.
Innovation Solution
The implementation of self-adjusting electrical connectors, such as spring-loaded or flexible pins, that can extend, retract, or flex to maintain alignment and secure engagement between the camera housing connector and the imager PCB, decoupling the lens holder structure from mechanical influences and accommodating tolerance changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If rigid electrical connectors are used to connect camera housing to circuitry, then manufacturing precision can be improved, but the reliability deteriorates due to tolerance variations and mechanical stress during assembly and use
Solution Approach 1:
The patent applies the dynamics principle by making the electrical connector elements flexible rather than rigid. The connector elements can dynamically adjust their position through flexing, extending, or retracting to compensate for tolerance variations and mechanical stress during assembly and use, thereby maintaining reliable electrical connections while accommodating manufacturing precision variations.
Solution Approach 2:
The patent applies parameter changes by allowing the electrical connector elements to change their physical state (flexed, extended, retracted) in response to mechanical stress and alignment requirements. This enables the connectors to adapt their parameters (position, shape) to maintain optimal electrical connection despite variations in manufacturing tolerances and environmental conditions.
2Reliability
If self-adjusting electrical connectors are implemented, then the reliability of electrical connection is improved, but the device complexity increases
Solution Approach 1:
The patent applies flexible shells and thin films by using flexible electrical connector elements that can bend, flex, and deform to maintain contact. These flexible elements provide self-adjusting capability without requiring complex mechanical structures, springs, or actuators, thereby improving reliability while minimizing the increase in device complexity.
3Adaptability or versatility
If flexible electrical connector elements are used, then adaptability to tolerance variations is improved, but the manufacturing precision deteriorates due to potential misalignment
Solution Approach 1:
The patent applies self-service by enabling the electrical connector elements to automatically adjust their own position and orientation through their flexible properties. During assembly, the flexible connectors self-align with the corresponding circuitry contacts through flexing and deformation, eliminating the need for precise pre-alignment or complex alignment mechanisms, thereby achieving both adaptability and manufacturing simplicity.
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 enhances the manufacturing efficiency and assembly of camera modules by providing reliable and durable electrical connections over the camera's lifespan, reducing misalignment and maintaining image quality across various environments and conditions.
Implementation Method 1
The electrical connector elements self-adjust to engage the circuitry and maintain engagement with the circuitry during assembly of the camera housing and during use of the camera on a vehicle. The self-adjustment of the electrical connector elements comprises at least one of (i) extending toward an extended state, (ii) retracting toward a retracted state, and (iii) flexing toward a flexed state.
Data Source
AI summary
A vehicular camera assembly includes a camera housing having a front housing portion and a rear housing portion that joins the front housing portion. A first printed circuit board (PCB) is disposed at the front housing portion, with an imager disposed at a front side of the first PCB and a first electrical connector disposed at a rear side of the first PCB. A second PCB has a second electrical connector disposed at a front side of the second PCB. Board-to-board electrical connection of circuitry of the second printed circuit board to circuitry of the first printed circuit board is made via electrical connection of the first and second electrical connectors. The connector portion of the rear housing portion includes a multi-pin connector comprising a plurality of solid terminal pins. A connector portion of the rear housing portion is configured for connecting to a vehicle wiring connector.