Welded Metal Housing Assembly for Tolerance-Safe Electronics Carriers
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Solution Overview
Problem
Existing electronic devices, such as vehicle camera modules, face challenges in efficiently assembling housing parts without damaging electronics components due to manufacturing tolerances, leading to overpressure or loss of contact, and require complex and time-consuming screw-based assembly methods.
Innovation Solution
The use of a housing assembly with metal parts joined through overlap welding, where the electronics carrier is sandwiched between the housing parts, and optionally includes elastic means to prevent damage from overpressure, eliminating the need for screws and ensuring proper optical alignment and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screws are used to attach the electronics carrier to the housing assembly, then the connection is secure, but the assembly operation becomes complex and time-consuming
Solution Approach 1:
The patent removes the screws from the assembly process entirely. The electronics carrier is attached to the housing assembly through a snap-fit mechanism where protrusions on the carrier engage with corresponding recesses in the housing, eliminating the need for separate fastening elements and simplifying the assembly operation.
Solution Approach 2:
The attachment function is integrated into the housing assembly structure itself. The recesses formed by the housing parts inherently provide the attachment mechanism for the electronics carrier, combining the housing structure and attachment mechanism into a unified design that eliminates separate fasteners.
2Productivity
If the electronics carrier is sandwiched between housing parts, then screwless attachment is achieved, but overpressure may damage the electronics carrier due to manufacturing tolerances
Solution Approach 1:
The patent incorporates elastic elements (springs) between the housing parts and the electronics carrier. These elastic elements are pre-installed to provide cushioning and absorb excessive clamping force, preventing damage to the electronics carrier while maintaining secure attachment. The elastic elements compensate for manufacturing tolerances in the housing parts.
Solution Approach 2:
The patent changes the mechanical properties of the attachment system by introducing elastic elements that can deform under load. This allows the system to adapt to variations in manufacturing tolerances while maintaining consistent attachment force, preventing both overpressure damage and loss of contact.
3Temperature
If housing parts are made of metal, then heat dissipation is improved, but the assembly process becomes more complex
Solution Approach 1:
The metal housing assembly serves dual functions: it provides structural support and acts as a heat sink for dissipating heat from the electronics carrier. The inherent thermal conductivity of the metal material eliminates the need for separate cooling components, simplifying the overall assembly while improving heat dissipation.
Solution Approach 2:
The housing assembly combines multiple functions into a single structure: mechanical support, heat dissipation, and attachment mechanism. The metal housing parts with integrated recesses provide both structural integrity and thermal management, reducing the number of separate components needed.
4Manufacturing precision
If tight sandwiching is used to prevent movement, then optical alignment is maintained, but manufacturing tolerances cause contact loss or damage
Solution Approach 1:
The patent introduces dynamic elements (elastic springs) into the attachment system that can adapt to manufacturing tolerances. The elastic elements deform within acceptable ranges to maintain consistent contact force between the housing parts and the electronics carrier, ensuring both optical alignment and reliable contact despite variations in manufacturing precision.
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 method allows for quick and efficient assembly of electronic devices without adverse effects on performance, reduces the risk of damaging electronics components, and enhances heat dissipation and electromagnetic compatibility while minimizing costs.
Implementation Method 1
the first and second housing parts are joined to each other through an overlap welding
Implementation Method 2
an elastic means arranged in pressure contact with the electronics carrier for performing attachment through a sandwiching effect
Implementation Method 3
housing parts made of plastics have been more recently replaced with housing parts made of metal... In order to dissipate heat as quickly as possible to the outside of the housing assembly
Data Source
Figure 1~2
Figure 3~6
AI summary
The electronic device (100) comprises a housing assembly (110) extending along a longitudinal axis (O) and comprising a first housing part (120) and a second housing part (130) configured to be joined to each other through an overlap welding (210), and an electronics carrier (140) received within an inner space (115) of the housing assembly (110) defined when the first and second housing parts (120, 130) are joined to each other,