Vehicle Headlining Module Assembly with Stacked PCBs
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Solution Overview
Problem
The existing methods for mounting a digital key module version 2.0 on a vehicle roof face difficulties in configuration and secondary injury risks due to the use of iron structures like brackets, bolts, and nuts, and face challenges in determining the installation location, especially when combined with a rear occupant alert system and panorama sunroof installations.
Innovation Solution
An integrated module assembly that combines a digital key module with a rear occupant alert module, utilizing a base with open upper portions, stacked printed circuit boards connected by flexible cables or connectors, and a cover to secure the assembly without the need for brackets, bolts, or nuts, allowing for easy insertion and detachment, and using a mounting plate with hot-melt adhesive for attachment to the vehicle headlining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a digital key module is mounted on a vehicle roof using brackets, bolts, and nuts configuring an iron structure, then the module can be securely fixed, but it becomes difficult to configure the package and secondary injury may occur when the vehicle is overturned
Solution Approach 1:
The patent integrates the digital key module with the rear occupant alert module into a single integrated module assembly. The digital key module is positioned in the dead storage space of the rear occupant alert module, eliminating the need for separate mounting structures and reducing overall package complexity while maintaining secure fixation.
Solution Approach 2:
The digital key module is nested within the dead storage space of the rear occupant alert module. This nesting arrangement allows the digital key module to be housed within the existing structure without requiring additional external mounting components, thereby simplifying the package configuration.
2Strength
If a digital key module is mounted on a vehicle roof using brackets, bolts, and nuts configuring an iron structure, then the module can be securely fixed, but detached components may cause secondary injury when the vehicle is overturned
Solution Approach 1:
By integrating the digital key module with the rear occupant alert module into a single assembly, the patent eliminates separate detachable components such as brackets, bolts, and nuts. The integrated structure ensures that all components remain unified during vehicle overturning, preventing secondary injury from detached parts.
Solution Approach 2:
The integrated module assembly acts as an intermediary structure that securely holds the digital key module within the rear occupant alert module. This unified structure prevents individual components from detaching and causing harm during vehicle accidents.
3Adaptability or versatility
If a rear occupant alert system is installed in the headlining, then rear occupant monitoring is enabled, but it becomes difficult to determine a mounting place for the digital key module due to limited space
Solution Approach 1:
The patent utilizes the dead storage space within the rear occupant alert module to house the digital key module. This nesting approach allows both modules to coexist in the limited headlining space without requiring additional mounting areas, effectively solving the space constraint problem.
Solution Approach 2:
The patent positions the digital key module in the vertical dead storage space of the rear occupant alert module rather than attempting to mount it on the horizontal surface. This three-dimensional utilization of space allows both modules to be accommodated within the limited headlining area.
4Adaptability or versatility
If a rear room lamp and ROA system are mounted on a headlining of a panorama sunroof vehicle, then lighting and monitoring functions are provided, but it becomes very difficult to determine a mounting place for the digital key module
Solution Approach 1:
The patent integrates the digital key module with the rear occupant alert module into a single assembly that can be mounted in the limited headlining space of panorama sunroof vehicles. This integration eliminates the need for separate mounting locations and reduces overall mounting complexity despite the presence of multiple functional modules.
Data Source
AI summary
A module assembly is attached on a headlining of a vehicle and includes a base where an upper portion thereof is open, a first printed circuit board (PCB) and a second PCB sequentially stacked on a plurality of supporting pillars extending in a vertical direction to an inner bottom surface of the base and electrically connected to each other by a flexible cable, and a cover assembled with the base to cover the first and second PCBs stacked on the base.