Sensor Module Housing Welding and Direct Connector Integration
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Solution Overview
Problem
Existing camera apparatuses for vehicles face issues with increased costs, reduced signal quality due to redundant wiring, and instability in electrical connections, particularly when using flexible printed circuits (FPCs) or floating connectors, which also affect electromagnetic compatibility (EMC) and require additional fixation mechanisms.
Innovation Solution
A sensor module design that includes a housing with a first and second case welded together, a board unit with a sensor element, and an external connector with elastically deformable terminals, where the board unit and housing are joined using a joining member, eliminating the need for screws or springs, and the external connector provides a stable connection without being affected by tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flexible printed circuit (FPC) is used to connect the external connector and the board, then a stable electrical connection is ensured, but the costs increase and signal quality is reduced due to redundant wiring
Solution Approach 1:
The patent extracts and eliminates the FPC component from the system, replacing it with a direct rigid connection between the external connector and the board. This removes the redundant wiring layer while maintaining electrical connection stability through precise positioning structures and direct soldering joints.
Solution Approach 2:
The patent merges the functions of the external connector and the board into a single integrated assembly, where the connector is directly mounted on the board without an intermediate FPC. This consolidation eliminates the wiring complexity and cost associated with FPC while preserving the electrical connection function.
2Object-affected harmful factors
If a shield case is used to take electromagnetic-compatibility (EMC) measures, then EMC performance is improved, but the component costs and device complexity increase
Solution Approach 1:
The patent removes the separate shield case component and integrates EMC protection directly into the housing structure and circuit board design. The housing itself serves as the shielding enclosure, eliminating the need for an additional shield case layer while maintaining electromagnetic compatibility.
Solution Approach 2:
The housing is designed to serve multiple functions simultaneously: it provides mechanical protection, structural support, and electromagnetic shielding. This multi-functionality eliminates the need for separate shield case components while maintaining EMC performance.
3Strength
If a plurality of coupling pieces such as screws are used to fix the board to the housing, then the board is securely fixed, but the number of components increases and operation efficiency is reduced
Solution Approach 1:
The patent merges the fixation function into the housing structure itself, which is designed with integrated mounting features that secure the board without requiring separate coupling pieces. The housing structure incorporates recesses, clips, or integrated fastening mechanisms that eliminate the need for additional screws or coupling pieces.
Solution Approach 2:
The patent extracts and removes the coupling pieces (screws, clips, etc.) from the assembly, replacing them with an integrated fixation system built into the housing. This reduces the component count while maintaining secure board attachment through the housing's structural design.
4Adaptability or versatility
If a floating connector is used to electrically connect the external connector and the board, then connection flexibility is improved, but the component cost increases and connection stability is reduced
Solution Approach 1:
The patent removes the floating connector component and replaces it with a rigid direct connection between the external connector and the board. The positioning structures and mounting features provide the necessary alignment and stability without requiring a floating or flexible connector mechanism.
Solution Approach 2:
Instead of using a floating connector to accommodate misalignment, the patent inverts the approach by designing precise positioning structures that prevent misalignment in the first place. The connector and board are positioned with high precision during assembly, eliminating the need for floating or flexible connection mechanisms.
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 design reduces component costs, enhances signal quality, and improves electromagnetic compatibility by stabilizing the electrical connection between the imaging device and the external connector, while also simplifying the assembly process and reducing the number of components.
Implementation Method 1
The external connector is provided to the second case, and includes an elastically deformable terminal that is electrically connected to the board unit
Implementation Method 2
The joining member is mounted on the board unit and welded to the housing
Data Source
AI summary
A sensor module includes a housing, a board unit, an external connector, and a joining member. The housing includes a first case, and a second case that is welded to the first case. The board unit includes a sensor element, and is arranged in the housing. The external connector is provided to the second case, and includes an elastically deformable terminal that is electrically connected to the board unit. The joining member is mounted on the board unit and welded to the housing.