Sensor Module Laser Welding Bracket Design

Solution Overview

Problem

Conventional camera units mounted on vehicles require a screw hollow for attachment, limiting design freedom, increasing operational complexity, and raising production costs due to the need for additional components.

Innovation Solution

A sensor module where the second casing is welded to the first casing and the bracket, eliminating the need for screw attachment and reducing the number of components, thereby enhancing design flexibility, simplifying operations, and lowering costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If screw attachment is used to fix the camera unit to the bracket, then the connection is secure, but the design freedom is limited and the number of components increases

Engineering Contradiction:

Improveconnection strengthVSAvoiddesign freedom

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The patent replaces the mechanical screw attachment system with a laser welding system. The laser welding process directly fuses the camera unit housing to the bracket, eliminating the need for screws and screw hollows. This substitution maintains connection strength while significantly improving design freedom and reducing component count.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent merges the camera unit housing and bracket into a single integrated structure through laser welding. By combining these previously separate components into one unified assembly, the design eliminates the need for separate fastening elements and reduces the overall number of parts while maintaining structural integrity.

Inventive Principle:

Principle #5Merging (Combining)

2Strength

If screw attachment is used to fix the camera unit to the bracket, then the connection is secure, but the operational complexity increases and productivity decreases

Engineering Contradiction:

Improveconnection strengthVSAvoidassembly efficiency

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent replaces the mechanical screw attachment system with a laser welding system. The laser welding process directly fuses the camera unit housing to the bracket, eliminating the need for screws and screw hollows. This substitution maintains connection strength while significantly improving design freedom and reducing component count.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent extracts and removes the screw fastening system from the assembly process. By eliminating screws, screw hollows, and associated sealing components, the design simplifies the overall structure and reduces the number of parts that need to be handled, installed, and secured during assembly operations.

Inventive Principle:

Principle #2Taking out (Extraction)

3Object-affected harmful factors

If screw attachment with packing is used, then water sealing is achieved, but the number of components increases and costs rise

Engineering Contradiction:

Improvewater sealingVSAvoidnumber of components

Core Design Contradiction:

Object-affected harmful factorsVSQuantity of substance

Solution Approach 1:

The patent merges the camera unit housing and bracket into a single integrated structure through laser welding. By combining these previously separate components into one unified assembly, the design eliminates the need for separate fastening elements and reduces the overall number of parts while maintaining structural integrity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces the mechanical screw attachment system with a laser welding system. The laser welding process directly fuses the camera unit housing to the bracket, eliminating the need for screws and screw hollows. This substitution maintains connection strength while significantly improving design freedom and reducing component count.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 allows for improved design freedom, simplified operation, and reduced costs by eliminating the need for screw attachment and minimizing the number of components, while also enabling a more compact sensor module design.

Implementation Method 1

a laser beam is used to weld the first casing and the bracket to the second casing

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Implementation Method 2

the first casing and the bracket are made of a resin material that has absorptive properties with respect to laser light of a specified wavelength

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentEP4109052B1Sensor module and method for manufacturing sensor module

Publication Date: 2025.05.21 SONY SEMICON SOLUTIONS CORP

Figure 1
Figure 2
Figure 3(A)~3(B)

AI summary

A sensor module according to an embodiment of the present technology includes a sensor element, a first casing, a bracket, and a second casing. The first casing includes an opening end and accommodates therein the sensor element. The bracket fixes the first casing to an attachment target. The second casing includes a first surface that includes a first welding portion welded to the opening end, and a second surface that includes a second welding portion welded to the bracket, the second casing being fixed between the first casing and the bracket.