Method of manufacturing vehicular camera with flexible connectors

• US 10,399,510 B2
• Filed: 01/15/2018
• Issued: 09/03/2019
• Est. Priority Date: 02/25/2011
• Status: Active Grant

• Current Assignee: Magna Electronics Incorporated (Magna International Incorporated)
• Original Assignee: Magna Electronics Incorporated (Magna International Incorporated)
• Inventors: Sesti, Matthew C., Byrne, Steven V.
• Primary Examiner(s): Aggarwal, Yogesh K
• Application Number:
  US15/871,174
• Publication Number:
  US 20180148001A1
• Time in Patent Office: 596 Days
• Field of Search: 348370-376
• CPC Class Codes: B60Q 9/008 for anti-collision purposes
• CPC Class Codes: B60R 11/04 Mounting of cameras operative during drive; Arrangement of controls thereof relative to the vehicle
• CPC Class Codes: H01R 12/716 Coupling device provided on the PCB
• CPC Class Codes: H01R 12/91 allowing relative movement between coupling parts, e.g. floating or self aligning for coupling devices not specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures, H01R13/6315 takes precedence
• CPC Class Codes: H01R 13/112 forked sockets having two legs
• CPC Class Codes: H04N 23/51 Housings

Abstract

A method of assembling a camera for mounting at a vehicle for a vehicle vision system includes providing front and rear housings and providing a set of first electrical connectors at a circuit board of the front housing and providing a set of second electrical connectors at the rear housing. One of the first and second electrical connectors includes male connectors and the other of the first and second electrical connectors includes female connectors. The rear housing is mated with the front housing to encase an imaging element and the circuit board. When mating the rear housing with the front housing, the male connectors are inserted into respective female connectors to electrically conductively connect the first and second electrical connectors. When inserting the male connectors into the respective female connectors, the female connectors flex to accommodate misalignment of the male and female connectors.

Claims

1. A method of assembling a camera for mounting at a vehicle for a vehicle vision system, said method comprising:

providing a front housing having a lens, an imaging element and a circuit board;

providing a rear housing;

providing a set of first electrical connectors at the circuit board;

providing a set of second electrical connectors at the rear housing, wherein the set of second electrical connectors is configured to electrically connect to an electrical connector of a vehicle wire harness when the assembled camera is mounted at the vehicle;

wherein one of the sets of first and second electrical connectors comprises a set of male connectors and the other of the sets of first and second electrical connectors comprises a set of female connectors;

providing a connector housing at the female connectors, wherein the connector housing includes a plurality of chambers, and wherein each chamber holds a respective one of the female connectors, and wherein each chamber is defined by a chamber wall that separates the respective chamber from the other chambers;

mating the rear housing with the front housing to encase the imaging element and the circuit board;

when mating the rear housing with the front housing, inserting the male connectors into respective female connectors and clamping the male connectors therein via jaw structure of the respective female connectors to electrically conductively connect the first and second electrical connectors;

when inserting the male connectors into the respective female connectors, the female connectors flex to accommodate misalignment of the male and female connectors;

wherein inserting the male connectors into the respective female connectors comprises inserting the male connectors until a stop element at at least one respective female connector limits movement of the male connector or the female connector;

wherein mating the rear housing with the front housing comprises moving one of the rear housing and the front housing in a first direction along a first axis; and

wherein, when inserting the male connectors into the respective female connectors, the female connectors flex in a second direction transverse to the first axis to accommodate misalignment of the male and female connectors.

2. A method of assembling a camera for mounting at a vehicle for a vehicle vision system, said method comprising:

providing a front housing having a lens, an imaging element and a circuit board;

providing a rear housing;

providing a set of first electrical connectors at the circuit board;

providing a set of second electrical connectors at the rear housing, wherein the set of second electrical connectors is configured to electrically connect to an electrical connector of a vehicle wire harness when the assembled camera is mounted at the vehicle;

wherein one of the sets of first and second electrical connectors comprises a set of male connectors and the other of the sets of first and second electrical connectors comprises a set of female connectors;

providing a connector housing at the female connectors, wherein the connector housing includes a plurality of chambers, and wherein each chamber holds a respective one of the female connectors, and wherein each chamber is defined by a chamber wall that separates the respective chamber from the other chambers;

mating the rear housing with the front housing to encase the imaging element and the circuit board;

when mating the rear housing with the front housing, inserting the male connectors into respective female connectors and clamping the male connectors therein via jaw structure of the respective female connectors to electrically conductively connect the first and second electrical connectors;

when inserting the male connectors into the respective female connectors, the female connectors flex to accommodate misalignment of the male and female connectors;

wherein inserting the male connectors into the respective female connectors comprises inserting the male connectors until a stop element at at least one respective female connector limits movement of the male connector or the female connector;

wherein mating the rear housing with the front housing comprises moving one of the rear housing and the front housing in a first direction along a first axis; and

wherein the male and female connectors are configured to accommodate misalignment along two axes that are orthogonal to each other and to the first axis.

3. The method of claim 2, wherein the stop element at the at least one respective female connector is part of the connector housing.

4. The method of claim 2, wherein providing the connector housing at the female connectors comprises forming a female connector assembly that is provided as a unit at the circuit board or at the rear housing.

5. The method of claim 2, comprising, when mating the rear housing with the front housing, mating rear housing alignment structure of the rear housing with front housing alignment structure of the front housing to align the rear housing with respect to the front housing.

6. The method of claim 2, wherein the first electrical connectors comprise the female connectors and the second electrical connectors comprise the male connectors.

7. The method of claim 2, wherein the first electrical connectors comprise the male connectors and the second electrical connectors comprise the female connectors.

8. A method of assembling a camera for mounting at a vehicle for a vehicle vision system, said method comprising:

providing a front housing having a lens, an imaging element and a circuit board;

providing a rear housing;

providing a set of first electrical connectors at the circuit board;

providing a set of second electrical connectors at the rear housing, wherein the set of second electrical connectors is configured to electrically connect to an electrical connector of a vehicle wire harness when the assembled camera is mounted at the vehicle;

wherein one of the sets of first and second electrical connectors comprises a set of male connectors and the other of the sets of first and second electrical connectors comprises a set of female connectors;

providing a connector housing at the female connectors, wherein the connector housing includes a plurality of chambers, and wherein each chamber holds a respective one of the female connectors, and wherein each chamber is defined by a chamber wall that separates the respective chamber from the other chambers;

mating the rear housing with the front housing to encase the imaging element and the circuit board;

when mating the rear housing with the front housing, inserting the male connectors into respective female connectors and clamping the male connectors therein via jaw structure of the respective female connectors to electrically conductively connect the first and second electrical connectors;

when inserting the male connectors into the respective female connectors, the female connectors flex to accommodate misalignment of the male and female connectors;

wherein inserting the male connectors into the respective female connectors comprises inserting the male connectors until a stop element at at least one respective female connector limits movement of the male connector or the female connector;

wherein mating the rear housing with the front housing comprises moving one of the rear housing and the front housing in a first direction along a first axis; and

when mating of the front and rear housings, moving the male connectors in the first direction to enter the female connectors, wherein the stop element at the at least one respective female connector is positioned to limit movement of the female connectors in the first direction during entry of the male connectors into the female connectors.

9. A method of assembling a camera for mounting at a vehicle for a vehicle vision system, said method comprising:

providing a front housing having a lens, an imaging element and a circuit board;

providing a rear housing;

providing a set of first electrical connectors at the circuit board;

providing a set of second electrical connectors at the rear housing, wherein the set of second electrical connectors is configured to electrically connect to an electrical connector of a vehicle wire harness when the assembled camera is mounted at the vehicle;

wherein one of the sets of first and second electrical connectors comprises a set of male connectors and the other of the sets of first and second electrical connectors comprises a set of female connectors;

providing a connector housing at the female connectors, wherein the connector housing includes a plurality of chambers, and wherein each chamber holds a respective one of the female connectors, and wherein each chamber is defined by a chamber wall that separates the respective chamber from the other chambers;

mating the rear housing with the front housing to encase the imaging element and the circuit board;

when mating the rear housing with the front housing, inserting the male connectors into respective female connectors and clamping the male connectors therein via jaw structure of the respective female connectors to electrically conductively connect the first and second electrical connectors;

when inserting the male connectors into the respective female connectors, the female connectors flex to accommodate misalignment of the male and female connectors;

wherein inserting the male connectors into the respective female connectors comprises inserting the male connectors until a stop element at at least one respective female connector limits movement of the male connector or the female connector; and

providing retraction stop elements that limit movement of the female connectors when the male connectors are retracted from the female connectors.

10. The method of claim 9, wherein the retraction stop elements are part of the connector housing.

11. The method of claim 9, wherein mating the rear housing with the front housing comprises moving one of the rear housing and the front housing in a first direction along a first axis.

12. A method of assembling a camera for mounting at a vehicle for a vehicle vision system, said method comprising:

providing a front housing having a lens, an imaging element and a circuit board;

providing a rear housing;

providing a set of first electrical connectors at the circuit board;

providing a set of second electrical connectors at the rear housing, wherein the set of second electrical connectors is configured to electrically connect to an electrical connector of a vehicle wire harness when the assembled camera is mounted at the vehicle;

wherein one of the sets of first and second electrical connectors comprises a set of male connectors and the other of the sets of first and second electrical connectors comprises a set of female connectors;

providing a connector housing at the female connectors, wherein the connector housing includes a plurality of chambers, and wherein each chamber holds a respective one of the female connectors, and wherein each chamber is defined by a chamber wall that separates the respective chamber from the other chambers;

mating the rear housing with the front housing to encase the imaging element and the circuit board;

when mating the rear housing with the front housing, inserting the male connectors into respective female connectors and clamping the male connectors therein via jaw structure of the respective female connectors to electrically conductively connect the first and second electrical connectors;

when inserting the male connectors into the respective female connectors, the female connectors flex to accommodate misalignment of the male and female connectors;

wherein inserting the male connectors into the respective female connectors comprises inserting the male connectors until a stop element at at least one respective female connector limits movement of the male connector or the female connector;

wherein providing the connector housing at the female connectors comprises forming a female connector assembly that is provided as a unit at the circuit board or at the rear housing; and

wherein the connector housing comprises base structure that snugly engages a base portion of each of the female connectors to retain the female connectors at the connector housing.

13. A method of assembling a camera for mounting at a vehicle for a vehicle vision system, said method comprising:

providing a front housing having a lens, an imaging element and a circuit board;

providing a rear housing;

providing a set of first electrical connectors at the circuit board;

providing a set of second electrical connectors at the rear housing, wherein the set of second electrical connectors is configured to electrically connect to an electrical connector of a vehicle wire harness when the assembled camera is mounted at the vehicle;

wherein one of the sets of first and second electrical connectors comprises a set of male connectors and the other of the sets of first and second electrical connectors comprises a set of female connectors;

providing a connector housing at the female connectors, wherein the connector housing includes a plurality of chambers, and wherein each chamber holds a respective one of the female connectors, and wherein each chamber is defined by a chamber wall that separates the respective chamber from the other chambers;

mating the rear housing with the front housing to encase the imaging element and the circuit board;

when mating the rear housing with the front housing, inserting the male connectors into respective female connectors and clamping the male connectors therein via jaw structure of the respective female connectors to electrically conductively connect the first and second electrical connectors;

when inserting the male connectors into the respective female connectors, the female connectors flex to accommodate misalignment of the male and female connectors;

wherein inserting the male connectors into the respective female connectors comprises inserting the male connectors until a stop element at at least one respective female connector limits movement of the male connector or the female connector; and

wherein the jaw structure of each female connector has a width that is sized so that a male connector is insertable therein over a range of positions.

14. A method of assembling a camera for mounting at a vehicle for a vehicle vision system, said method comprising:

providing a front housing having a lens, an imaging element and a circuit board;

providing a rear housing;

providing a set of first electrical connectors at the circuit board;

providing a set of second electrical connectors at the rear housing, wherein the set of second electrical connectors is configured to electrically connect to an electrical connector of a vehicle wire harness when the assembled camera is mounted at the vehicle;

wherein one of the sets of first and second electrical connectors comprises a set of male connectors and the other of the sets of first and second electrical connectors comprises a set of female connectors;

providing a connector housing at the female connectors, wherein the connector housing includes a plurality of chambers, and wherein each chamber holds a respective one of the female connectors, and wherein each chamber is defined by a chamber wall that separates the respective chamber from the other chambers;

mating the rear housing with the front housing to encase the imaging element and the circuit board;

when mating the rear housing with the front housing, inserting the male connectors into respective female connectors and clamping the male connectors therein via jaw structure of the respective female connectors to electrically conductively connect the first and second electrical connectors;

when inserting the male connectors into the respective female connectors, the female connectors flex to accommodate misalignment of the male and female connectors;

wherein inserting the male connectors into the respective female connectors comprises inserting the male connectors until a stop element at at least one respective female connector limits movement of the male connector or the female connector; and

wherein the female connectors have biasing structure that bias the jaw structure towards a home position.

15. A method of assembling a camera for mounting at a vehicle for a vehicle vision system, said method comprising:

providing a front housing having a lens, an imaging element and a circuit board;

providing a rear housing;

providing a set of first electrical connectors at the circuit board;

providing a set of second electrical connectors at the rear housing, wherein the set of second electrical connectors is configured to electrically connect to an electrical connector of a vehicle wire harness when the assembled camera is mounted at the vehicle;

wherein one of the sets of first and second electrical connectors comprises a set of male connectors and the other of the sets of first and second electrical connectors comprises a set of female connectors;

providing a connector housing at the female connectors, wherein the connector housing includes a plurality of chambers, and wherein each chamber holds a respective one of the female connectors, and wherein each chamber is defined by a chamber wall that separates the respective chamber from the other chambers;

mating the rear housing with the front housing to encase the imaging element and the circuit board;

when mating the rear housing with the front housing, inserting the male connectors into respective female connectors and clamping the male connectors therein via jaw structure of the respective female connectors to electrically conductively connect the first and second electrical connectors;

when inserting the male connectors into the respective female connectors, the female connectors flex to accommodate misalignment of the male and female connectors;

wherein inserting the male connectors into the respective female connectors comprises inserting the male connectors until a stop element at at least one respective female connector limits movement of the male connector or the female connector; and

wherein the female connectors include a flexible base portion, and wherein the connector housing comprises a flex-limiting structure that limits flexing of the flexible base portion when the male connectors are inserted into the female connectors.

16. A method of assembling a camera for mounting at a vehicle for a vehicle vision system, said method comprising:

providing a front housing having a lens, an imaging element and a circuit board;

providing a rear housing;

providing a set of first electrical connectors at the circuit board;

providing a set of second electrical connectors at the rear housing, wherein the set of second electrical connectors is configured to electrically connect to an electrical connector of a vehicle wire harness when the assembled camera is mounted at the vehicle;

wherein the set of first electrical connectors comprises a set of female connectors and the set of second electrical connectors comprises a set of male connectors;

providing a connector housing at the female connectors, wherein the connector housing includes a plurality of chambers, and wherein each chamber holds a respective one of the female connectors, and wherein each chamber is defined by a chamber wall that separates the respective chamber from the other chambers;

mating the rear housing with the front housing to encase the imaging element and the circuit board;

wherein mating the rear housing with the front housing comprises moving one of the rear housing and the front housing in a first direction along a first axis;

when mating the rear housing with the front housing, inserting the male connectors into respective female connectors and clamping the male connectors therein via jaw structure of the respective female connectors to electrically conductively connect the first and second electrical connectors;

wherein each female connector has a width along a second axis orthogonal to the first axis that is sized so that a male connector is insertable therein over a range of positions; and

when inserting the male connectors into the respective female connectors, the female connectors flex in a direction orthogonal to the first and second axes to accommodate misalignment of the male and female connectors.

17. The method of claim 16, comprising, when mating of the front and rear housings, moving the male connectors in the first direction to enter the female connectors, wherein stop elements are positioned to limit movement of the female connectors in the first direction during entry of the male connectors into the female connectors.

18. A method of assembling a camera for mounting at a vehicle for a vehicle vision system, said method comprising:

providing a front housing having a lens, an imaging element and a circuit board;

providing a rear housing;

providing a set of first electrical connectors at the circuit board;

providing a set of second electrical connectors at the rear housing, wherein the set of second electrical connectors is configured to electrically connect to an electrical connector of a vehicle wire harness when the assembled camera is mounted at the vehicle;

wherein one of the sets of first and second electrical connectors comprises a set of male connectors and the other of the sets of first and second electrical connectors comprises a set of female connectors;

providing a connector housing at the female connectors, wherein the connector housing includes a plurality of chambers, and wherein each chamber holds a respective one of the female connectors, and wherein each chamber is defined by a chamber wall that separates the respective chamber from the other chambers;

mating the rear housing with the front housing to encase the imaging element and the circuit board;

when mating the rear housing with the front housing, inserting the male connectors into respective female connectors and clamping the male connectors therein via jaw structure of the respective female connectors to electrically conductively connect the first and second electrical connectors;

when inserting the male connectors into the respective female connectors, the female connectors flex to accommodate misalignment of the male and female connectors;

wherein inserting the male connectors into the respective female connectors comprises inserting the male connectors until stop elements at respective female connectors limit flexing of the respective female connector;

wherein the stop elements are part of the connector housing;

when mating of the front and rear housings, moving the male connectors in a first direction to enter the female connectors, wherein the stop elements are positioned to limit flexing of the female connectors during entry of the male connectors into the female connectors;

providing retraction stop elements that limit movement of the female connectors when the male connectors are retracted from the female connectors; and

wherein the retraction stop elements are part of the connector housing.

19. The method of claim 18, wherein providing the connector housing at the female connectors comprises forming a female connector assembly that is provided as a unit at the circuit board or at the rear housing, and wherein the connector housing comprises base structure that snugly engages a base portion of each of the female connectors to retain the female connectors at the connector housing.