Vehicle Optical Device Heating Element Electrical Connection

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Solution Overview

Problem

Current electrical connection solutions for heating elements in outdoor vehicle components are bulky, expensive, and heavy, posing challenges for effective environmental protection against cold and ice stresses.

Innovation Solution

An optical device with a printed circuit board, a lens support, and a heating element where the heating element is electrically connected to the printed circuit board via a conductive trace on the lens support, allowing for a compact and efficient electrical connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional electrical harnesses and connectors are used to connect heating elements to the printed circuit board, then reliable electrical connection is achieved, but the device becomes bulky, expensive, and heavy

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoiddevice weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent merges the electrical connection function directly into the lens support structure by integrating conductive traces onto the lens holder. This eliminates the need for separate electrical harnesses and connectors, thereby reducing weight while maintaining reliable electrical connection between the heating element and the printed circuit board through the integrated trace pathway.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple functions into the lens support structure: mechanical support for the lens, electrical conduction pathway, and structural mounting element. By integrating the conductive trace directly onto the lens holder, the design eliminates separate wiring harnesses and connectors, thereby reducing device complexity and cost while maintaining reliable electrical connection.

Inventive Principle:

Principle #5Merging (Combining)

3Weight of moving object

If conductive traces are integrated on the lens support, then device weight and complexity are reduced, but electrical connection reliability must be maintained

Engineering Contradiction:

Improvedevice weightVSAvoidelectrical connection reliability

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The patent integrates the electrical connection function directly into the lens support structure through conductive traces, eliminating separate wiring components and reducing overall device weight while maintaining reliable electrical connection between the heating element and printed circuit board.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent employs a flexible printed circuit board that can be pinched between the upper and lower housings to establish electrical contact. This flexible film approach allows for reliable electrical connection while maintaining a compact, lightweight design that integrates seamlessly with the lens support structure.

Inventive Principle:

Principle #30Flexible shells and thin films

4Device complexity

If flexible part is pinched between housings to establish electrical contact, then compact design is achieved, but manufacturing precision is required

Engineering Contradiction:

Improvedevice complexityVSAvoidassembly precision

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent uses a flexible printed circuit board that is pinched between the upper and lower housings to establish electrical contact. The flexibility of the thin film allows it to conform to the assembly tolerances, while the pinching action ensures reliable contact without requiring extremely tight manufacturing precision.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The flexible nature of the printed circuit board provides a cushioning effect that compensates for minor variations in assembly precision. The flexible material can deform to accommodate tolerance stack-ups while maintaining reliable electrical contact, thereby reducing the stringency of manufacturing precision requirements.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 provides a lightweight, cost-effective, and efficient electrical connection for heating elements, ensuring reliable operation of outdoor vehicle components in harsh environmental conditions.

Implementation Method 1

a heating element arranged on the lens holder; the heating element being electrically connected to the printed circuit board

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentEP3410199B1Optical device for vehicle comprising a heating element

Publication Date: 2020.01.29 APTIV TECHNOLOGIES LTD

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AI summary

Optical device (10) includes a printed circuit board (26) comprising an image capture electronic circuit (30), a lens holder (16) comprising at least one optical lens (15), the lens holder (16) being mounted on the printed circuit board (26) so as to align, along the optical axis (O) of the device (10), the image capture electronic circuit (30) and the optical lens (15); a heating element (130) arranged on the lens holder (16); the heating element (130) being electrically connected to the printed circuit board (26) by at least one electrically conductive trace (128) arranged on the lens holder (16).