Flexible Vehicle Camera Module Design for Compact Installation
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Solution Overview
Problem
Current vehicle cameras are bulky, making it difficult to minimize size in all directions (X, Y, Z axes) and limiting their interchangeable use across different vehicle positions, which can require design changes.
Innovation Solution
A camera module design featuring a lens unit, a first housing, a flexible second housing, and substrate units, including FPCBs, allowing for reduced size in all directions and flexibility for installation at various positions, with optional electromagnetic wave shielding or absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If multiple PCBs are overlapped to increase the number of layers, then the size in X and Y directions is reduced, but the size in Z direction increases
Solution Approach 1:
The patent transitions from a multi-layer PCB architecture (stacking in Z direction) to a planar substrate layout (expanding in X-Y plane). The substrate is designed as a single-layer or low-layer structure where electronic components are arranged horizontally rather than vertically stacked, thereby reducing Z-direction height while maintaining X-Y area efficiency.
Solution Approach 2:
The patent employs a flexible housing structure that can adapt its shape to accommodate the substrate and lens unit. This flexibility allows the camera module to achieve a compact form factor by dynamically adjusting the housing configuration rather than relying on rigid multi-layer stacking.
2Volume of moving object
If the camera size is reduced to fit specific vehicle positions, then the camera can be installed in more locations, but the same camera cannot be interchangeably used at other positions
Solution Approach 1:
The patent designs the camera module with a flexible housing and standardized mounting interface that enables universal installation across different vehicle positions. The flexible housing can be configured to fit various spatial constraints, while the substrate layout accommodates different lens units and component arrangements, allowing the same camera module to be interchangeably installed at front, rear, side, or other vehicle positions.
Solution Approach 2:
The patent utilizes parameters such as flexible housing deformation and adjustable component positioning to adapt the camera module to different installation environments. By changing the physical configuration parameters of the housing and substrate assembly, the same camera module can fit various vehicle positions without requiring design changes.
3Manufacturing precision
If the camera module uses rigid PCB structures, then manufacturing precision is improved, but flexibility for installation is reduced
Solution Approach 1:
The patent replaces rigid PCB structures with flexible substrates that maintain manufacturing precision through controlled flexibility. The flexible substrate can be precisely manufactured with accurate component placement while still allowing the housing to deform for installation. This flexible substrate acts as both a structural support and a flexible element that enables adaptation to different installation positions.
Data Source
AI summary
The present embodiment may comprise a lens unit; a first housing coupled to the lens unit; a first substrate unit which has an image sensor mounted thereon and is accommodated in the first housing; a second housing which is coupled to the first housing and has flexibility on at least a partial area thereof; and a second substrate unit which is accommodated in the second housing and is electrically connected to the first substrate unit.