Unitarily Molded Vehicle Accessory Module for Camera Alignment
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Solution Overview
Problem
Existing accessory modules for vehicles, particularly those with cameras mounted on windshields, often have multiple components that are difficult to arrange for a desired field of view, and typically include a camera and lens as a unit, making assembly complex for electronics suppliers.
Innovation Solution
A unitarily molded accessory module with a mounting element and an integrated support structure that holds an imaging sensor and lens, along with circuitry, allowing for easy assembly and adjustment of the camera's field of view by providing a modular design with different lens mounting angles for various windshield angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple separate components are used for mounting the camera and lens, then the desired field of view can be achieved, but the assembly complexity increases and manufacturing becomes difficult
Solution Approach 1:
The patent combines the camera mounting plate and lens mounting structure into a single integrally molded polymeric component. This unified structure eliminates the need for separate mounting brackets and alignment fixtures, reducing assembly complexity while maintaining precise field of view alignment through built-in positioning features molded directly into the single piece.
Solution Approach 2:
The integrally molded polymeric mounting structure serves multiple functions simultaneously: it provides mechanical support for both the camera and lens, establishes precise spatial relationships between components, enables mounting to the windshield, and incorporates electrical connector positioning. This multi-functional design replaces what would traditionally require multiple separate parts.
2Ease of manufacture
If the camera and lens are provided as a fixed unit, then assembly is simplified, but flexibility in adjusting the field of view is reduced
Solution Approach 1:
The patent creates a modular assembly where the camera and lens are mounted on separate attachable structures rather than being permanently fixed together. The lens can be independently positioned and angled relative to the camera through the integrally molded mounting structure, allowing field of view adjustment while maintaining ease of assembly through the unified design.
Solution Approach 2:
The mounting structure is segmented into distinct functional zones: a camera mounting portion, a lens mounting portion with angular adjustment capability, and an electrical connector portion. This segmentation allows the lens to be independently positioned relative to the camera while both remain part of the same integrally molded component, providing flexibility without complicating assembly.
3Measurement precision
If separate mounting elements are used for the camera and lens, then individual positioning is possible, but the number of parts increases making assembly more complex
Solution Approach 1:
The patent merges multiple mounting functions into a single integrally molded polymeric component that simultaneously positions the camera, lens, and electrical connector. This eliminates the need for assembling multiple separate mounting brackets and fixtures, improving assembly efficiency while maintaining precise component positioning through built-in molded features.
Data Source
AI summary
An accessory module is mountable to an interior surface of a vehicle windshield and includes a mounting element securable to an interior surface of a windshield of a vehicle, and an accessory support having a base portion attachable to the mounting element. The accessory support includes an accessory holding element configured to hold an accessory, at least one circuitry holding element configured to hold a printed circuit board at the accessory support, and an electrical connector for electrically connecting the printed circuit board and the accessory to an electrical source of the vehicle. The base portion, the accessory holding element and the circuitry holding element are integrally molded together so that the accessory support comprises a unitarily molded accessory support. The accessory module includes a cover portion attachable to the accessory support to substantially encompass the accessory and the printed circuit board within the accessory module.