Installation method, replacement method and product of a concealed ultrasonic radar sensor

Abstract

The application discloses a mounting method, a replacement method and a product of a hidden ultrasonic radar sensor, wherein the mounting method comprises the following steps: S1, forming a local thinning area on the inner side of a specified mounting position of a covering member; S2, providing an ultrasonic radar sensor; S3, positioning the ultrasonic radar sensor relative to the covering member in such a way that the emission surface of the ultrasonic radar sensor is opposite to the local thinning area and is spaced apart from the local thinning area by a predetermined gap, and the emission surface of the ultrasonic radar sensor and the local thinning area are in a natural relaxed state without mutual extrusion; and S4, filling a solidifiable adhesive material in the predetermined gap to form a solid adhesive layer, and the adhesive layer connects the emission surface of the ultrasonic radar sensor and the local thinning area. The application can realize hidden installation and guarantee or even improve the emission efficiency and detection performance of the ultrasonic radar sensor.

Description

Technical Field

[0001] This invention relates to the field of automotive sensor technology, specifically to a method for installing and replacing a concealed ultrasonic radar sensor, as well as the product thereof. Background Technology

[0002] To meet specific requirements for use in vehicles, the ultrasonic radar sensor 10 for automobiles uses a ceramic plate 2 mounted inside an aluminum housing 1 to achieve both transmitting and receiving functions while remaining waterproof. Figure 1 As shown.

[0003] See Figure 1 As shown, the ultrasonic radar sensor 10, or simply the ultrasonic sensor, includes a ceramic plate 2, which is housed within an aluminum shell 1 and sealed with waterproof adhesive 3. The working principle of this ultrasonic sensor is as follows: an alternating pulse voltage (such as 51kHz, 58kHz, etc.) is applied to the ceramic plate 2. Under the action of the alternating voltage, the ceramic plate 2 undergoes mechanical deformation, causing the aluminum shell 1 in close contact to deform. The aluminum shell 1, in turn, causes the surrounding air to deform, transmitting signals into the air. When the deformed air encounters an obstacle 20, it is reflected back and acts on the surface of the aluminum shell 1, causing a slight deformation in the aluminum shell 1 and resulting in mechanical deformation of the ceramic plate, generating a small voltage signal. This voltage signal is amplified and processed by a DSP to identify the obstacle signal and its distance and orientation, thus realizing the ultrasonic sensor's detection function.

[0004] To achieve better transmission power and receiving sensitivity, a hole is typically made in the bumper (4) to expose the aluminum casing 1 of the ultrasonic sensor to the air. Figure 2 As shown, this results in the following shortcomings:

[0005] Disadvantage 1: The bumper needs to be drilled, and the bumper manufacturer needs to make a punching mold, which is not cheap and will also increase the labor cost of punching.

[0006] Disadvantage 2: Car bumpers are usually painted the same color as the car body. The bumper will be painted a different color depending on the color of the car body. Since the ultrasonic sensor is attached to the bumper, the surface of the ultrasonic sensor's aluminum shell must also be painted the same color as the bumper. In other words, the ultrasonic sensor also needs to be painted, which increases the cost of the ultrasonic sensor.

[0007] Disadvantage 3: Because the bumper needs to have holes, there will be some gap between the ultrasonic sensor and the bumper, which will make the bumper look less attractive than when there are no holes.

[0008] Current ultrasonic radar systems use only ultrasonic radar sensors as sensors. It is understandable that holes are made in the sensor to meet certain distance performance requirements. Future ultrasonic radar systems may adopt a combination of ultrasonic radar sensors and MEMS (silicon microscopy) sensors. Although this combination improves the detection distance performance, it also increases the cost of MEMS. How to ensure that the performance before adding MEMS remains close to the original while eliminating the need for holes in the ultrasonic radar sensor is a problem that the inventors have considered.

[0009] Of course, the inventors also considered the possibility of accepting a certain performance degradation over a distance while eliminating the need for drilling holes in a pure ultrasonic radar sensor system.

[0010] A search revealed existing technologies for concealed ultrasonic sensor solutions, but these typically involve attaching the sensor to the inside of a covering component and transmitting and receiving ultrasonic waves by driving the covering component to vibrate. For example, Chinese patent document CN107850665A discloses an ultrasonic sensor device in which a pre-tightening force is applied to the sensor towards the covering component through a retaining device cover, pressing the sensor firmly against the covering component. US patent document US2017 / 0059697A1 also employs a pre-tightening structure, pressing the sensor against the inner surface of the panel. In these solutions, the sensor and the covering component have a tight, compressive contact, and the sensor's emitting surface is subjected to a certain pre-pressure after installation. This suppresses the sensor's mechanical vibration, thereby reducing transmission efficiency and receiving sensitivity, and affecting detection distance and performance.

[0011] Therefore, the technical problem to be solved by this invention is how to provide a solution that can achieve concealed installation while ensuring or even improving the transmission efficiency and detection performance of ultrasonic radar sensors. Summary of the Invention

[0012] In view of this, in order to solve the problems of vibration limitation and low transmission efficiency caused by pre-tightening force or compression installation of existing concealed ultrasonic sensors, the purpose of this invention is to provide an installation method, replacement method and product of a concealed ultrasonic radar sensor, which can achieve concealed installation and ensure or even improve the transmission efficiency and detection performance of the ultrasonic radar sensor.

[0013] The technical solution adopted is as follows:

[0014] The present invention discloses a method for installing a concealed ultrasonic radar sensor, which involves concealing the ultrasonic radar sensor on a vehicle's covering component, comprising the following steps:

[0015] S1. A locally thinned area is formed on the inner side of the designated installation position of the covering member;

[0016] S2. Provide an ultrasonic radar sensor;

[0017] S3. Position the ultrasonic radar sensor relative to the covering member such that its emitting surface is opposite to the locally thinned area and separated by a predetermined gap, and the emitting surface of the ultrasonic radar sensor and the locally thinned area are in a natural relaxed state without mutual compression.

[0018] S4. Fill the predetermined gap with a curable adhesive material, such that the adhesive material contacts the transmitting surface of the ultrasonic radar sensor and the locally thinned area respectively;

[0019] S5. The adhesive material is cured to form a solid adhesive layer that connects the emitting surface of the ultrasonic radar sensor to the locally thinned area.

[0020] Furthermore, the thickness of the locally thinned region is less than the thickness of other regions of the covering member, and the thickness of the locally thinned region is set to 0.4-1.0 mm.

[0021] Furthermore, the diameter of the locally thinned region is larger than the diameter of the emitting surface of the ultrasonic radar sensor.

[0022] Furthermore, the predetermined gap is 0.2-0.5 mm.

[0023] Furthermore, the adhesive layer formed after curing of the curable adhesive material is solid and non-elastic, and has a higher elastic modulus than that of elastomeric materials.

[0024] A concealed ultrasonic sensor assembly according to the above-described installation method of the present invention comprises:

[0025] A vehicle's cover component has a locally thinned area formed at a designated mounting location on its inner side;

[0026] An ultrasonic radar sensor, the emitting surface of which is disposed opposite to the locally thinned region; and

[0027] An adhesive layer is disposed between the emitting surface of the ultrasonic radar sensor and the locally thinned area, and the two are fixedly connected.

[0028] The adhesive layer is formed by curing a curable adhesive material, and before the adhesive material is cured, the emitting surface of the ultrasonic radar sensor and the locally thinned area maintain a predetermined gap and are in a natural relaxed state without mutual compression.

[0029] Furthermore, the thickness of the locally thinned region is 0.4-1.0 mm, and / or the diameter of the locally thinned region is larger than the diameter of the emitting surface of the ultrasonic radar sensor.

[0030] Furthermore, the thickness of the adhesive layer corresponds to the predetermined gap, which is 0.2-0.5 mm.

[0031] A vehicle according to the present invention includes the aforementioned concealed ultrasonic sensor assembly.

[0032] The present invention provides a method for replacing a concealed ultrasonic radar sensor, which includes the following steps:

[0033] 1) Apply a debonding agent to the cured adhesive layer to soften or dissolve it;

[0034] 2) Remove the existing ultrasonic radar sensor;

[0035] 3) Provide a new ultrasonic radar sensor and install it on the locally thinned area of ​​the covering member according to the installation method described above.

[0036] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0037] 1. No need to drill holes in the cover components, maintaining the integrity and aesthetics of the vehicle body appearance, saving on drilling mold and punching costs, and eliminating the need to paint the sensors, thus reducing manufacturing costs.

[0038] 2. By setting a locally thinned area, the attenuation of ultrasonic signals by the covering component is reduced, enabling the sensor to effectively drive the vibration of the covering component and ensuring detection distance and sensitivity.

[0039] 3. An innovative approach using a pre-reserved gap-filling curing adhesive layer ensures that the sensor's emitting surface is in a naturally relaxed state with the covering component before curing, without any compression or pre-tightening force. Compared to existing technologies that use a pre-tightening structure to press the sensor onto the covering component, the sensor of this invention can achieve maximum mechanical amplitude during emission, thereby maximizing emission energy and improving detection performance.

[0040] 4. After curing, the adhesive layer forms a solid, non-elastic bonding layer with a higher elastic modulus than elastomeric materials. Therefore, it can efficiently transmit vibrations and avoid the absorption of vibration energy by elastomeric materials. Furthermore, a debonding agent can be used to enable sensor replacement and maintenance, balancing reliability and maintainability. Attached Figure Description

[0041] Figure 1 This is a schematic diagram of the structure of a traditional ultrasonic radar sensor;

[0042] Figure 2 This is a schematic diagram of a traditional perforated installation.

[0043] Figure 3 This is a schematic diagram of the structure of the locally thinned area of ​​the covering component in this invention;

[0044] Figure 4 This is a side view of the locally thinned area of ​​the covering component in this invention.

[0045] Figure 5 This is a schematic diagram showing the gap between the sensor and the cover component in this invention, which is filled with adhesive material.

[0046] The serial numbers and corresponding features in the attached diagram are as follows:

[0047] 1-Aluminum shell (sensor emitting surface); 2-Ceramic sheet; 3-Waterproof adhesive; 4-Protective rod (covering component); 5-Locally thinned area; 6-Gap; 7-Liquid adhesive (bonding material); 10-Ultrasonic radar sensor; 20-Obstacle. Detailed Implementation

[0048] The invention will be further described below.

[0049] When the original ultrasonic radar sensor was installed on the bumper with the opening, its emitting surface would undergo mechanical deformation and vibrate when it was working. This vibration would cause the surrounding air to vibrate, and the signal would propagate in the air. At this time, the emitting surface of the ultrasonic radar sensor was in direct contact with the air, thus realizing the transmission of ultrasonic radar signals. Based on this principle, we can also theoretically realize the transmission of ultrasonic signals by placing the emitting surface of the ultrasonic radar sensor tightly against the inside of the bumper and using the vibration of the emitting surface of the ultrasonic radar sensor to drive the vibration of the bumper, which in turn would drive the vibration of the surrounding air.

[0050] While the above principle makes sense, the actual performance in practical use will not be good. This is because the thickness of car bumpers is generally between 2.2 and 3 mm, with a common thickness of around 2.5 mm. Ultrasonic radar sensors have difficulty deforming such a thick bumper to emit ultrasonic signals. In other words, the poor performance is due to the excessive thickness of the bumper. Therefore, we can reduce the thickness of the bumper at the location where it needs to emit ultrasonic signals. For example, the thickness can be reduced from 2.5 mm to 1 mm or even lower (such as 0.6 mm). The diameter of the ultrasonic radar sensor's emitting surface is about 15.5 mm. We can make the diameter of the thinned area greater than 15.5 mm. According to test data, selecting a thinned area in the range of 20 to 40 mm can balance the emission performance without affecting the bumper's own toughness. Since the thinning is only about 20 to 40 mm in diameter, it has virtually no impact on the original bumper's performance compared to the overall bumper size of about 1900 mm in length and 600 mm in height. Meanwhile, since the locally thinned area is only about 20-40mm in diameter, although the thickness has decreased, as long as the high-pressure water jet doesn't break through this area, the smaller the thickness in this area, the better. A smaller thickness results in a larger emission amplitude, thus greater emission energy and enabling detection at a greater distance. According to actual measurements, as long as the thickness is not less than 0.4mm, it can basically ensure that the high-pressure water jet during a car wash does not affect the local bumper area, while still maintaining the emission energy effect. The effect of locally thinning the bumper is as follows: Figure 3 and Figure 4 As shown.

[0051] To maximize the energy emitted by the locally thinned bumper driven by the ultrasonic radar sensor, both the sensor's emitting surface and the bumper must be in a naturally relaxed state before emission, meaning there should be no compression or tension between them. This ensures maximum mechanical amplitude of the ultrasonic radar sensor during emission, which in turn maximizes the amplitude of the locally thinned bumper, resulting in maximum emitted energy. To achieve this, a certain gap must be maintained between the emitting surface of the ultrasonic radar sensor and the locally thinned bumper after installation at the factory (e.g., ...). Figure 5As shown in the diagram, the thickness is approximately 0.3mm. Therefore, when designing the installation parameters, it is crucial to ensure that the emitting surface of the ultrasonic radar sensor and the locally thinned support rod do not come into contact. Contact could cause deformation of both the ultrasonic radar sensor and the locally thinned support rod before launch, preventing the actual amplitude from reaching its maximum and thus affecting the launch energy. To ensure that the ultrasonic radar sensor and the locally thinned support rod are in a naturally relaxed state before launch, a drop of liquid adhesive can be placed between them during installation. This adhesive, once placed between the ultrasonic radar sensor and the locally thinned support rod (i.e., exposed to air), will harden within a certain time (e.g., a few minutes to tens of minutes) without detaching from them. This liquid adhesive acts as a connector between the ultrasonic radar sensor's emitting surface and the locally thinned support rod, ensuring that the mechanical waves are effectively transmitted to the locally thinned support rod during launch, while also ensuring that there is almost no compression or pulling between them before launch (i.e., in a naturally relaxed state), thereby maximizing the launch energy.

[0052] The liquid adhesive should harden after a certain period of time without easily detaching from the adhesive. This includes, but is not limited to, AB glue, as long as it achieves the aforementioned effect. If the ultrasonic radar sensor requires replacement, a solvent that can remove the liquid adhesive or soft glue (such as AB glue remover) can be applied around it. After the adhesive or soft glue detaches, the ultrasonic radar sensor can be replaced.

[0053] There are two main methods to reduce the thickness of a bumper in certain areas:

[0054] Method 1: When designing the bumper mold, reserve space for thinning in areas where localized areas need to be thinned during injection molding;

[0055] Method 2: Use a machine tool insert to thin out certain areas of the injection-molded bumper;

[0056] Method 1 only requires considering the required thickness and diameter of specific areas during the initial design of the bumper mold, without increasing mold costs or subsequent bumper processing costs. Method 2, on the other hand, requires further processing of the bumper. Therefore, Method 1 is the preferred choice, unless the bumper mold is already finalized and cannot be modified, in which case Method 2 should be used.

[0057] The above-mentioned method of locally thinning the guardrail and bonding with liquid glue or soft glue can eliminate the need for guardrail drilling when installing radar sensors. This solves the problems of time required for guardrail drilling, the need for punching molds, the need for painting ultrasonic radar sensors, and poor guardrail appearance.

[0058] The invention will be further illustrated below with examples and comparative examples.

[0059] Example 1

[0060] This embodiment provides a method for concealing an ultrasonic radar sensor on a car's rear bumper (covering component), which includes the following steps:

[0061] First, during the bumper mold design phase, a circular, locally thinned area is pre-formed on the inner side of the location where the sensor will be installed. This area is designed to be 0.6mm thick (compared to 2.5mm for other areas of the bumper) and 25mm in diameter (the sensor's emitting surface diameter is 15.5mm). For example... Figure 3 and Figure 4 As shown, the locally thinned area 5 is located inside the bumper 4, and its thickness is significantly less than that of the surrounding area.

[0062] Then, a standard ultrasonic radar sensor is provided, with its emitting surface being an aluminum shell 1. The sensor contains a ceramic sheet 2 and a potting waterproof adhesive 3, its structure being identical to existing technologies. The sensor is positioned inside the bumper, with its emitting surface directly facing the locally thinned area 5, maintaining a uniform gap of approximately 0.3 mm 6 between them. At this point, there is no contact or compression between the sensor and the bumper; it is in a completely relaxed, natural state, such as... Figure 5 As shown.

[0063] Next, using a syringe, an appropriate amount of AB glue (epoxy resin-based two-component adhesive) is dripped into the aforementioned gap 6, allowing the glue to occupy the gap and wet the sensor's emitting surface and the surface of the locally thinned area. Because the gap is uniform, the glue fills naturally through capillary action. Before curing, the AB glue is a flowable liquid; after curing, it hardens, forming a solid, non-elastic layer.

[0064] Finally, allow the AB adhesive to cure completely at room temperature, forming a solid adhesive layer approximately 0.3 mm thick. This cured adhesive layer exhibits a high elastic modulus, significantly greater than that of elastomers such as silicone rubber. This adhesive layer firmly connects the sensor to the retaining rod; however, because no shrinkage stress is generated during curing, and there was no compression between the sensor and retaining rod before curing, the sensor and retaining rod remain in a relaxed state without pre-tightening after curing. After installation, the sensor functions normally: vibrations from the sensor's emitting surface are transmitted through the adhesive layer to the locally thinned retaining rod area, driving that area to vibrate and radiate ultrasonic waves outwards. Since the adhesive layer is solid and non-elastic, vibration energy is almost not absorbed, resulting in high transmission efficiency.

[0065] Example 2

[0066] This embodiment provides a concealed ultrasonic sensor assembly, the structure of which is as follows: Figure 5As shown. The component includes: a car bumper 4 as a cover member, with a locally thinned area 5 at a designated location on the inner side of the bumper 4; an ultrasonic radar sensor 10, which has an aluminum shell 1 as a transmitting surface; and an adhesive layer 7 disposed between the aluminum shell 1 and the locally thinned area 5. The adhesive layer 7 is formed by curing AB glue and has a thickness of 0.3 mm. Before the adhesive layer 7 cures, a 0.3 mm gap is maintained between the aluminum shell 1 and the locally thinned area 5, and there is no mutual compression. After curing, the adhesive layer 7 is a solid, non-elastic material with a Shore D hardness typically above 70 and an elastic modulus significantly higher than that of elastomers such as silicone. Other parts of the component, such as the ceramic sheet 2 and the potting waterproof adhesive 3, are the same as in the prior art and will not be described in detail.

[0067] Actual testing showed that the sensor assembly in this embodiment, without requiring openings, has a significantly improved effective detection distance compared to the pre-tightening installation method, and the sensor's emitted waveform is cleaner.

[0068] Example 3

[0069] When the ultrasonic radar sensor in the sensor assembly of the present invention malfunctions and needs to be replaced, this embodiment provides a method for replacing a concealed ultrasonic radar sensor, which includes the following steps:

[0070] First, apply a special AB adhesive release agent to the edge of the cured adhesive layer 7 on the inside of the bumper. Wait several minutes for the adhesive layer 7 to soften and lose its stickiness.

[0071] Then, gently pry the sensor with a tool to separate it from the bumper and remove the old sensor.

[0072] Next, clean the residual adhesive from the surface of the locally thinned area 5, and reinstall the new sensor by leaving a gap, filling it with new adhesive material, and allowing it to relax and cure naturally, as described in Example 1.

[0073] Finally, test the new sensor's functionality, and once it is confirmed to be working properly, the replacement is complete.

[0074] Comparative Example 1

[0075] To further illustrate the technical effects of the present invention, the following comparative example is provided: Following the method described in CN107850665A or US2017 / 0059697A1, an ultrasonic radar sensor of the same model was pressed into the inner side of a retainer rod (without gaps and filled with a flexible coupling agent such as silicone grease) using a pre-tightening structure. Test results show that the transmitting power of the sensor in this comparative example is significantly lower than that of Embodiment 1 of the present invention, and the signal strength of the received echo is significantly reduced, resulting in a significantly reduced effective detection distance. This is because the pre-tightening force suppresses the free vibration of the sensor's transmitting surface, while the flexible coupling agent absorbs some of the vibration energy. The present invention, through a naturally relaxed state and a hardened adhesive layer after curing, achieves higher vibration transmission efficiency.

[0076] The detailed descriptions listed above are merely specific illustrations of feasible embodiments of the present invention and are not intended to limit the scope of protection of the present invention. All equivalent embodiments or modifications made without departing from the spirit of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for installing a concealed ultrasonic radar sensor, characterized in that the ultrasonic radar sensor is concealedly installed on a vehicle's covering component, wherein... Includes the following steps: S1. A locally thinned area is formed on the inner side of the designated installation position of the covering member; S2. Provide an ultrasonic radar sensor; S3. Position the ultrasonic radar sensor relative to the covering member such that its emitting surface is opposite to the locally thinned area and separated by a predetermined gap, and the emitting surface of the ultrasonic radar sensor and the locally thinned area are in a natural relaxed state without mutual compression. S4. Fill the predetermined gap with a curable adhesive material, such that the adhesive material contacts the transmitting surface of the ultrasonic radar sensor and the locally thinned area respectively; S5. The adhesive material is cured to form a solid adhesive layer that connects the emitting surface of the ultrasonic radar sensor to the locally thinned area.

2. The installation method according to claim 1, characterized in that, The thickness of the locally thinned region is less than the thickness of other regions of the covering member, and the thickness of the locally thinned region is set to 0.4-1.0 mm.

3. The installation method according to claim 1 or 2, characterized in that, The diameter of the locally thinned region is larger than the diameter of the transmitting surface of the ultrasonic radar sensor.

4. The installation method according to claim 1, characterized in that, The predetermined gap is 0.2-0.5 mm.

5. The installation method according to claim 1, characterized in that, The adhesive layer formed after curing of the curable adhesive material is solid and non-elastic, and has a higher elastic modulus than that of elastomeric materials.

6. A concealed ultrasonic sensor assembly implemented according to the installation method of claim 1, characterized in that, include: A vehicle's cover component has a locally thinned area formed at a designated mounting location on its inner side; An ultrasonic radar sensor, the emitting surface of which is disposed opposite to the locally thinned region; and An adhesive layer is disposed between the emitting surface of the ultrasonic radar sensor and the locally thinned area, and the two are fixedly connected. The adhesive layer is formed by curing a curable adhesive material, and before the adhesive material is cured, the emitting surface of the ultrasonic radar sensor and the locally thinned area maintain a predetermined gap and are in a natural relaxed state without mutual compression.

7. The concealed ultrasonic sensor assembly according to claim 6, characterized in that, The thickness of the locally thinned region is 0.4-1.0 mm, and / or the diameter of the locally thinned region is larger than the diameter of the transmitting surface of the ultrasonic radar sensor.

8. The concealed ultrasonic sensor assembly according to claim 6, characterized in that, The thickness of the adhesive layer corresponds to the predetermined gap, which is 0.2-0.5 mm.

9. A vehicle, characterized in that, Includes the concealed ultrasonic sensor assembly as described in any one of claims 6-8.

10. A method for replacing a concealed ultrasonic radar sensor, characterized in that, Includes the following steps: 1) Apply a debonding agent to the cured adhesive layer to soften or dissolve it; 2) Remove the existing ultrasonic radar sensor; 3) Provide a new ultrasonic radar sensor and mount it on a locally thinned area of ​​the covering member according to the mounting method of any one of claims 1-5.

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