Optical Imager Assembly with PCB Alignment for Rotational Accuracy

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Solution Overview

Problem

Conventional optical device assembly methods are costly and prone to positional inaccuracies, particularly rotational variance of the imager relative to the lens holder or housing, which is critical for achieving consistent and accurate image framing in automotive applications.

Innovation Solution

A method involving a two-part housing assembly with clamping formations and manipulators to precisely align the circuit board with the imager's active region, using projected images for alignment and securing without screws or adhesives.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional assembly methods with multiple steps including active alignment and adhesive curing are used, then the assembly process can be completed, but the manufacturing cost increases and positional accuracy deteriorates due to rotational misalignment

Engineering Contradiction:

Improveimage frame rotational accuracyVSAvoidassembly process steps

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The PCB is pre-positioned on the support structure with adjustable mechanisms before final assembly, allowing precise alignment to be established in advance. The support structure includes adjustment mechanisms that enable the PCB to be positioned at predetermined locations, ensuring accurate alignment between the imager and lens optical axis before the lens is secured

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The conventional mechanical fastening method using screws is replaced with a support structure that uses positioning features and adjustment mechanisms to secure the PCB in the correct position. This mechanical substitution eliminates the need for iterative active alignment and screw tightening, directly achieving both accuracy and simplified assembly

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Stability of the object's composition

If screws are used to secure the PCB to the lens holder, then the PCB can be fixed in place, but the PCB may shift during tightening causing rotational inaccuracy

Engineering Contradiction:

ImprovePCB fixation stabilityVSAvoidimage frame rotational accuracy

Core Design Contradiction:

Stability of the object's compositionVSManufacturing precision

Solution Approach 1:

The support structure incorporates self-positioning features that automatically maintain PCB alignment during the fastening process. The positioning features are designed to work with the fastening mechanism to ensure that tightening does not cause shifts, as the structure itself provides the positioning function rather than relying solely on the fastening action

Inventive Principle:

Principle #25Self-service

Data Source

PatentEP4290850B1Method of assembling an optical device and optical device assembled according to the same

Publication Date: 2026.04.29 APTIV TECHNOLOGIES AG

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AI summary

Method of assembling an optical device (1) including providing a circuit board (3) having an imager (8) mounted thereto, wherein the imager has an active region (81). A housing (2,4) is provided having a support (7) for supporting the circuit board (2) and an opening (6) for an optical path to form an image (9) at a known image position relative to the opening (3). The circuit board (3) is placed on the support and its position is adjusted using one or more manipulators (10) to align the active region with the image position (9). The circuit board may then be secured in an aligned position.