Vehicle Camera Resin Sealing for Thermal Management
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Solution Overview
Problem
Existing vehicle vision systems face challenges in cost-effectively sealing camera housings while ensuring a water-tight seal and thermal conductivity for the camera components, which are crucial for reliable image capture and heat dissipation.
Innovation Solution
A camera system utilizing a thermally conductive resin as a sealing compound, dispensed in an uncured state to conform around the printed circuit board and housing, providing a gravity-driven seal that adheres to the components without fasteners, thus reducing costs and enhancing thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sealing methods (such as mechanical seals or adhesives) are used to seal the camera housing, then a water-tight seal can be achieved, but the manufacturing cost increases and thermal conductivity to the components is reduced
Solution Approach 1:
The patent changes the physical state of the sealing compound from solid (traditional adhesives) to liquid (uncured resin) that cures in place. This parameter change allows the sealing material to flow into all gaps and crevices, achieving a complete water-tight seal while reducing manufacturing steps and cost. The liquid state enables gravity-driven filling without requiring additional fasteners or complex application processes.
Solution Approach 2:
The patent uses a composite sealing compound that combines multiple functions: sealing (water-tight barrier), thermal conduction (heat dissipation), and structural bonding (adhesion to PCB and housing). This multi-functional composite material eliminates the need for separate sealing compounds, thermal pastes, and mechanical fasteners, thereby reducing overall manufacturing cost while maintaining reliability.
2Strength
If traditional sealing methods are used, then structural strength can be maintained, but thermal conductivity to the components is insufficient
Solution Approach 1:
The sealing compound is designed to perform multiple functions simultaneously: providing structural bonding strength to hold the PCB in place, creating a water-tight seal, and conducting heat away from the imager and other heat-generating components. This universal material eliminates the need for separate thermal management components while maintaining structural integrity.
Solution Approach 2:
The patent merges the functions of mechanical fastening, sealing, and thermal management into a single integrated sealing compound application. Instead of using separate fasteners, sealants, and thermal pastes, the uncured resin combines all these functions in one material system, achieving both structural strength and effective heat dissipation.
3Stability of the object's composition
If fasteners are used to secure the printed circuit board, then mechanical retention is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent replaces the mechanical fastening system (screws, clips, or snap-fits) with a chemical bonding system using uncured resin. The liquid resin flows around the PCB and connecting terminals, then cures to form a strong mechanical bond. This substitution eliminates all mechanical fasteners and reduces assembly steps to simply dispensing the resin, which then self-levels and cures.
Solution Approach 2:
The uncured sealing compound has the ability to self-level and conform to the PCB and housing geometry without requiring additional alignment fixtures or fastening operations. The material flows under gravity to fill all gaps, then cures in place, providing both sealing and mechanical retention functions automatically without human intervention for fastener installation.
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
The solution achieves a cost-effective, water-tight seal and effective heat dissipation for the camera components, enhancing the reliability and performance of the vehicle vision system by using a thermally conductive resin that adheres to the components without the need for additional fasteners.
Implementation Method 1
The sealing compound comprises a thermally conductive resin
Implementation Method 2
The sealing compound conforms to the at least one printed circuit board and the camera housing portion via gravity
Data Source
AI summary
A camera for a vehicular vision system includes a camera housing, a PCB having circuitry disposed thereat, and a lens assembly. The circuitry includes an imager disposed at one side of the PCB, and the circuitry includes connecting terminals that protrude from the circuit board. The PCB is disposed in the camera housing and retained thereat via a fastener. The camera housing is open at a rear portion, and a sealing material is dispensed in the camera housing to seal the PCB and the connecting terminals in the camera housing. An electrical connector receives the connecting terminals and is disposed at an outer portion of the sealing material at the rear of the camera housing. The sealing material includes a thermally conductive resin and is dispensed in the camera housing in an uncured state. The sealing material, when cured, attaches the electrical connector at the rear portion of the camera.