Vehicular Camera Thermal Interface Elastomer for Focus-Safe Assembly

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Solution Overview

Problem

Existing vehicle vision systems face challenges in efficiently managing thermal interfaces between camera components, leading to assembly difficulties and potential interference with image focus due to the use of non-compliant thermal pads.

Innovation Solution

Incorporating a thermally conductive, two-shot rubber over-molded thermal interface elastomer with a custom geometric shape that conforms to the printed circuit board (PCB) and housing components, providing enhanced thermal conductivity and flexibility while minimizing stress and interference with camera focus.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional silicone thermal pads are used, then thermal interface is provided, but assembly is difficult and image focus may be interfered with due to non-compliant material

Engineering Contradiction:

Improvethermal interface effectivenessVSAvoidassembly ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the material parameter from non-compliant silicone thermal pads to compliant thermal interface elastomer, which allows the material to conform to varying component heights while maintaining thermal conductivity. This resolves the contradiction by enabling both effective thermal interface and easy assembly through molding.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses a two-shot rubber over-molded construction combining different materials: a rigid substrate and a compliant thermal interface elastomer. This composite structure provides both structural support and compliant thermal conduction, resolving the contradiction between thermal effectiveness and assembly ease.

Inventive Principle:

Principle #40Composite materials

2Reliability

If traditional silicone thermal pads are used, then thermal conduction is achieved, but stress interference with camera focus occurs

Engineering Contradiction:

Improvethermal conductionVSAvoidimage focus precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent changes the compliance parameter of the thermal interface material from non-compliant to compliant, allowing it to accommodate variations in component heights without transmitting stress to the camera lens assembly. This maintains thermal conduction while protecting image focus precision.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The compliant thermal interface elastomer acts as an intermediary between the rigid housing/PCB components and the camera assembly. It mediates the mechanical interface by absorbing stress and preventing transmission of forces that could interfere with camera focus, while still providing thermal conduction.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If custom geometric shape elastomer is molded onto PCB and housing, then adaptability to different configurations is improved, but device complexity increases

Engineering Contradiction:

Improveadaptability to housing geometries and PCB configurationsVSAvoidmolding process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges the thermal interface function with the structural housing and PCB assembly by molding the elastomer directly onto these components. This integration eliminates the need for separate thermal pad components and simplifies the overall assembly process despite the custom geometry, resolving the contradiction between adaptability and complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The two-shot rubber over-molded elastomer serves multiple functions: structural attachment, stress distribution, and thermal conduction. This multi-functionality allows a single component to adapt to different housing geometries and PCB configurations while maintaining thermal performance, reducing the need for multiple specialized components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 camera assembly, enhances thermal interface effectiveness, and maintains image focus by conforming to varying component heights, replacing traditional silicone pads and allowing for easier adaptation to different housing geometries and PCB configurations.

Implementation Method 1

The thermal interface elastomer comprises a thermally conductive material

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11792496B2Vehicular camera with thermal interface

Publication Date: 2023.10.17 MAGNA ELECTRONICS INC

AI summary

A vehicular camera module for a vehicular vision system includes a housing having a front housing portion and a rear housing portion. A circuit board includes a circuit board substrate having electronic circuitry disposed thereat. A thermal interface elastomer material is at an inner surface of the front housing portion. The front housing portion, with the thermal interface elastomer material thereat, is disposed at the circuit board. With the lens assembly optically aligned with the imager, the circuit board is attached at the front housing portion. The rear housing portion is mated with the front housing portion to encase the circuit board. The thermal interface elastomer material interfaces with electronic components of the circuit board when the circuit board is attached at the front housing portion. A connector element in electrical contact with circuitry of the circuit board is configured to connect to a vehicle wire harness.