An ultrasonic sensor housing and an ultrasonic sensor

Abstract

The application relates to the technical field of sensors, in particular to an ultrasonic sensor shell and an ultrasonic sensor. The inner side of one end of the shell is provided with an annular plate, the inner side of the annular plate is provided with a panel, the panel is used for connecting a piezoelectric ceramic sheet, the shell, the annular plate and the panel are integrally formed, and the outer side of the annular plate is provided with a first annular groove. The ultrasonic sensor shell adopts the panel as a matching layer for signal transmission of the piezoelectric ceramic sheet, so that the shell is coupled with the piezoelectric ceramic sheet, an additional matching layer is no longer needed, and the technological process is greatly simplified. Moreover, the first annular groove is arranged on the outer side of the annular plate, and the signal energy is regulated under the cooperation of a specific acoustic bucket structure, so that the detection range of the ultrasonic sensor is relatively increased, the acoustic wave propagation is restricted to a certain extent, and therefore the ultrasonic sensor can still meet the use requirements after the ultrasonic sensor shell is improved.

Description

Technical Field

[0001] This invention relates to the field of sensor technology, and in particular to an ultrasonic sensor housing and an ultrasonic sensor. Background Technology

[0002] Ultrasonic sensors have a wide range of applications in industrial automation, automotive safety, and smart homes. For example, they can be used to detect the movement of people or objects, measure distances, monitor video, and are widely used in smart offices and smart service robots for obstacle avoidance and material recognition.

[0003] With market development, there is a growing demand for ultrasonic sensors that are high-frequency, low-energy, high-precision, and small in size, and capable of identifying different types of floors, carpets, floor cracks, sliding door tracks, stair cliffs, and other obstacles under various working conditions.

[0004] Existing piezoelectric ceramic ultrasonic sensors generally use two types of housings. For example, Chinese patent application number CN221464641U discloses an air medium ultrasonic sensor, which is assembled by combining potting compound, piezoelectric ceramic, pin back cover and matching layer. However, its structure is complex, the process is complicated, there are many variables affecting the function, and the quality control is difficult. Summary of the Invention

[0005] The purpose of this invention is to address the problems of current piezoelectric ceramic ultrasonic sensors, which generally employ matching layers and two types of housings, resulting in complex structures, cumbersome processes, numerous variables affecting functionality, and difficulties in quality control. This invention provides an ultrasonic sensor housing and an ultrasonic sensor.

[0006] In a first aspect, this application provides an ultrasonic sensor housing, including an outer shell, an annular plate on the inner side of one end of the outer shell, a panel disposed on the inner side of the annular plate, the panel being used to connect a piezoelectric ceramic sheet, the outer shell, the annular plate and the panel being integrally formed, and a first annular groove being disposed on the outer side of the annular plate.

[0007] The ultrasonic sensor housing described in this application has an annular plate on the inner side of one end of the housing, and a panel is disposed on the inner side of the annular plate. The housing, the annular plate, and the panel are integrally formed, thus making the housing, the annular plate, and the panel a whole. Since the housing and matching layer of traditional ultrasonic sensors are manufactured separately, secondary assembly of the housing and matching layer is required during sensor production. This is not only structurally complex and cumbersome, but also easily affected by assembly tolerances during the assembly process, resulting in poor product consistency. However, the ultrasonic sensor housing of this application has an integral design of the housing, annular plate, and panel. During sensor production, the piezoelectric ceramic sheet is connected to the panel, and the panel is used as the matching layer for the piezoelectric ceramic sheet to transmit signals. This allows the housing to be coupled with the piezoelectric ceramic sheet, eliminating the need for an additional matching layer and greatly simplifying the process.

[0008] More preferably, a first annular groove is provided on the outer side of the annular plate. With the cooperation of a specific acoustic barrel structure, the signal energy level is adjusted, so that the detection range of the ultrasonic sensor after it is made is relatively increased. At the same time, it plays a certain role in constraining the propagation of sound waves, so that the ultrasonic sensor can still meet the usage requirements after the ultrasonic sensor housing is improved as described above.

[0009] Preferably, an ultrasonic sensor housing of this application further includes an inner shell, the outer shell being sleeved on the outside of the inner shell, and the inner shell being connected to at least one of the annular plate and the panel.

[0010] The inner shell is used to protect the inner structure of the outer shell and facilitates assembly.

[0011] Preferably, the inner shell, outer shell, annular plate, and panel are integrally formed.

[0012] The ultrasonic sensor housing described in this application is integrally formed from the inner shell, outer shell, annular plate, and panel. Traditional ultrasonic sensors require separate fabrication of the inner shell, outer shell, and matching layer, necessitating secondary assembly during sensor production. This process is not only structurally complex and cumbersome but also susceptible to assembly tolerances, leading to poor product consistency. In contrast, the ultrasonic sensor housing of this application integrates the inner shell, outer shell, annular plate, and panel. During ultrasonic sensor production, the piezoelectric ceramic sheet is connected to the panel, which serves as the matching layer for signal transmission. This allows coupling between the housing and the piezoelectric ceramic sheet, eliminating the need for an additional matching layer and significantly simplifying the process. Furthermore, the integral design of the inner shell and outer shell eliminates the need for an embedded small plastic shell for positioning the piezoelectric ceramic sheet, avoiding assembly tolerances that can occur when assembling two shells. The ultrasonic sensor housing of this application features a simple manufacturing process, effectively reduces variable factors, lowers the difficulty of production quality control, and significantly improves the production efficiency of traditional ultrasonic sensors.

[0013] Preferably, the inner shell and the outer shell are coaxially arranged to ensure the coaxiality of the inner shell and the outer shell, thereby ensuring the symmetry of the vibration of the ultrasonic sensor housing and the uniform transmission of ultrasonic waves.

[0014] Preferably, a first receiving cavity is formed between the inner shell and the panel, the first receiving cavity being used to place the piezoelectric ceramic sheet.

[0015] Preferably, a second receiving cavity is formed between the inner shell, the outer shell, and the annular plate. This second receiving cavity accommodates the damping layer, thereby improving the residual vibration of the piezoelectric ceramic sheet.

[0016] Preferably, the end of the inner shell away from the panel is located inside the outer shell.

[0017] Preferably, the inner shell has a first groove at the end away from the panel. This facilitates the installation of at least one of the positioning terminal wire and the lead wire.

[0018] Preferably, there are at least two first grooves, and all the first grooves are arranged along the circumference of the inner shell.

[0019] The first boss structure is used to protect the inner structure of the housing and facilitates the assembly of the piezoelectric ceramic sheet.

[0020] Preferably, the inner shell is cylindrical.

[0021] Preferably, the outer diameter of the inner shell is Φ8.2mm~Φ11mm.

[0022] Preferably, the inner shell includes at least two first boss structures, all of which are spaced apart circumferentially along the outer shell. One end of each first boss structure is connected to at least one of the front panel and the annular plate. The first boss structures are used to protect the inner structure of the outer shell and facilitate the assembly of piezoelectric ceramic sheets.

[0023] Preferably, the outer shell is cylindrical.

[0024] Preferably, the outer shell, the annular plate, and the panel form a closed cavity at one end. That is, there are no through holes in the outer shell, the annular plate, the panel, the connection between the annular plate and the outer shell, or the connection between the annular plate and the panel, to facilitate the assembly of the backing.

[0025] Preferably, the density of the panel is 0.35 g / cm³ to 0.9 g / cm³.

[0026] Preferably, the thickness of the panel is 1.6mm to 3.0mm.

[0027] This enables the panel to meet the requirements of serving as a matching layer.

[0028] Preferably, a second annular groove is provided on the inner side of the annular plate. The area of ​​the panel in contact with the piezoelectric ceramic sheet is adjusted by the second annular groove, thereby adjusting the residual vibration of the ultrasonic sensor. Furthermore, the third annular groove can be used to fill with elastic adhesive to suppress the vibration of the piezoelectric ceramic sheet towards the outer shell, or it can be filled with backing adhesive to form part of the backing layer for better vibration reduction.

[0029] Preferably, the second annular groove is provided corresponding to the first annular groove, so as to jointly control the thickness of the annular plate and reduce the influence of the annular plate on the vibration of the panel.

[0030] Preferably, the inner surface of the annular plate and the inner surface of the panel are flush, to increase the reliability of the connection between the annular plate and the panel.

[0031] Preferably, the inner side of the annular plate is higher than the inner side of the panel, and the annular plate and the inner side of the panel form a placement groove for placing the piezoelectric ceramic sheet.

[0032] Preferably, reinforcing ribs are connected between the opposite sides of the first annular groove to adjust the strength of the residual vibration, which can be precisely controlled to a certain range.

[0033] Preferably, there are at least two reinforcing ribs, which are spaced apart from each other, and the reinforcing ribs divide the first annular groove into several arc-shaped grooves.

[0034] Multiple reinforcing ribs can further and more precisely control the strength of residual vibration to a certain range. Combined with a specific acoustic barrel structure, it can more precisely control the ultrasonic echo energy to a certain range.

[0035] Specifically, the reinforcing ribs are arranged such that the first annular groove is divided into several arc-shaped grooves, all of which are arranged along the annular shape, and adjacent arc-shaped grooves are spaced apart by reinforcing ribs.

[0036] Preferably, the reinforcing rib, outer shell, annular plate, and panel are integrally formed to facilitate installation, reduce installation steps, and lower costs.

[0037] Preferably, a third annular groove is provided at intervals on the inner side of the first annular groove.

[0038] Preferably, a third annular groove is provided at intervals on the outer side of the first annular groove.

[0039] Preferably, a third annular groove is provided at intervals on both the inner and outer sides of the first annular groove.

[0040] The residual vibration and ultrasonic echo energy are controlled by the cooperation of the first and third annular grooves.

[0041] Preferably, the bottom of the first annular groove is further provided with a bottom groove.

[0042] The residual vibration and ultrasonic echo energy are controlled by the cooperation of the first and third annular grooves.

[0043] Preferably, a portion of at least one side of the bottom groove and the first annular groove are coplanar.

[0044] Preferably, the bottom groove is located at the center of the bottom of the first annular groove along the radial direction of the first annular groove.

[0045] Preferably, at least a portion of the first annular groove extends laterally onto the panel.

[0046] Preferably, the outer side of the panel protrudes from the end face of the corresponding side of the outer shell. After passing through the convex interface, the sound waves diffuse outward along the central axis, resulting in a wider sound wave emission angle and a more uniform sound field in the near-field region, which is suitable for detecting large-area targets and also increases the detection angle.

[0047] Preferably, the outer surface of the panel has a curved surface that bulges outward toward the outer side of the panel. This increases the ultrasonic wave emission and reception angles, resulting in strong emission of sound waves, which is suitable for certain scenarios, such as those requiring a larger detection angle, achieving a wide near-field coverage effect.

[0048] Preferably, the outer surface of the panel has a curved surface, which is recessed towards the inner side of the panel. This forces the sound wave energy to propagate and converge along the normal direction of the concave surface, narrowing the directivity and reducing the beam angle. This addresses the needs of certain scenarios, such as significantly increasing local energy intensity, and with higher frequencies and shorter wavelengths, the focusing ability is stronger.

[0049] Preferably, the projection of the inner side of the panel along the radial direction of the outer casing is located on the side of the first annular groove.

[0050] Preferably, the outer shell is cylindrical.

[0051] In a second aspect, this application provides an ultrasonic sensor, including the ultrasonic sensor housing described in this application, with a panel connected to a piezoelectric ceramic sheet, the panel serving as a matching layer for the piezoelectric ceramic sheet to transmit vibrations.

[0052] This application provides an ultrasonic sensor, including the ultrasonic sensor housing described in this application. The ultrasonic sensor housing includes an outer shell, an annular plate on the inner side of one end of the outer shell, and a panel disposed on the inner side of the annular plate. The outer shell, the annular plate, and the panel are integrally formed, thus making the outer shell, the annular plate, and the panel a whole. Since the inner shell, outer shell, and matching layer of traditional ultrasonic sensors are manufactured separately, secondary assembly of the outer shell, the annular plate, and the panel is required during sensor production. This not only results in a complex structure and cumbersome process but is also easily affected by assembly tolerances, leading to poor product consistency. In contrast, the ultrasonic sensor housing of this application, with its integrally formed outer shell, annular plate, and panel, allows the piezoelectric ceramic sheet to be connected to the panel during sensor production. The panel serves as the matching layer for signal transmission by the piezoelectric ceramic sheet, thereby achieving coupling between the housing and the piezoelectric ceramic sheet. This eliminates the need for an additional matching layer, greatly simplifying the process. Furthermore, a first annular groove is provided on the outer side of the annular plate. With the cooperation of a specific acoustic barrel structure, the signal energy level is adjusted, which increases the detection range of the ultrasonic sensor after it is made. At the same time, it plays a certain role in constraining the propagation of sound waves. Thus, the ultrasonic sensor can still meet the usage requirements after the ultrasonic sensor housing is improved as described above.

[0053] In a third aspect, this application provides an ultrasonic sensor, including an ultrasonic sensor housing as described in this application, and further including a piezoelectric ceramic sheet, a damping layer, a backing layer, terminal wires and a potting layer, wherein the piezoelectric ceramic sheet and the backing layer are sequentially disposed inside the inner housing, and the piezoelectric ceramic sheet is connected to the panel. The vibration damping layer is also filled between the inner shell and the outer shell, and the potting layer is filled at the end of the outer shell away from the panel; The terminal wire passes through the potting layer and the backing layer and is connected to the lead wire of the piezoelectric ceramic sheet.

[0054] In the ultrasonic sensor described in this application, the piezoelectric ceramic sheet and the backing layer are sequentially arranged inside the inner shell during production, and the piezoelectric ceramic sheet is connected to the panel. The panel serves as a matching layer for the piezoelectric ceramic sheet to transmit signals, thereby enabling coupling between the shell and the piezoelectric ceramic sheet. This eliminates the need for an additional matching layer, greatly simplifying the process. Furthermore, due to the integrated design of the inner and outer shells, there is no need for an embedded small plastic shell for positioning the piezoelectric ceramic sheet, and assembly tolerances that are prone to occur when assembling the two shells are avoided, greatly improving the production efficiency of the ultrasonic sensor.

[0055] Preferably, the backing layer and the vibration damping layer are integrally cast.

[0056] In a fourth aspect, this application provides an ultrasonic sensor, including the ultrasonic sensor housing described in this application, and further including a piezoelectric ceramic sheet, a damping layer, a backing layer and terminal wires, wherein the piezoelectric ceramic sheet is connected to the inner side of the panel, the damping layer is located in the third annular groove, and the backing layer is disposed on the inner side of the housing; The inner side of the outer shell is also filled with a potting layer, which is located on the side of the backing layer away from the piezoelectric ceramic sheet; The terminal wire passes through the potting layer and enters the backing layer, where it connects to the lead wire of the piezoelectric ceramic sheet.

[0057] In the ultrasonic sensor described in this application, the piezoelectric ceramic sheet and the backing layer are sequentially arranged inside the housing during production, and the piezoelectric ceramic sheet is connected to the panel. The panel serves as a matching layer for the piezoelectric ceramic sheet to transmit signals, thereby enabling coupling between the housing and the piezoelectric ceramic sheet. This eliminates the need for an additional matching layer, greatly simplifying the process. Furthermore, since the housing, the annular plate, and the panel are integrally formed, there is no need for an embedded small plastic shell for positioning the piezoelectric ceramic sheet, and assembly tolerances that are prone to occur when assembling two housings are avoided, greatly improving the production efficiency of the ultrasonic sensor.

[0058] Preferably, the backing layer and the vibration damping layer are integrally cast.

[0059] Preferably, it also includes a sound barrel, which is disposed on the outside of the panel and connected to at least one of the annular plate (3) and the panel.

[0060] Compared with the prior art, the beneficial effects of the present invention are as follows: The ultrasonic sensor housing described in this application has an annular plate on the inner side of one end of the outer shell, and a panel is disposed on the inner side of the annular plate. The outer shell, the annular plate, and the panel are integrally formed, thus making the outer shell, the annular plate, and the panel a whole. Since the outer shell and matching layer of traditional ultrasonic sensors are manufactured separately, secondary assembly of the outer shell and matching layer is required during sensor production. This is not only structurally complex and cumbersome, but also easily affected by assembly tolerances, resulting in poor product consistency. However, the ultrasonic sensor housing of this application, with its integral design of the outer shell, annular plate, and panel, allows the piezoelectric ceramic sheet to be connected to the panel during sensor production. The panel serves as the matching layer for signal transmission by the piezoelectric ceramic sheet, thereby achieving coupling between the housing and the piezoelectric ceramic sheet without the need for an additional matching layer, greatly simplifying the process. Further preferably, a first annular groove is provided on the outer side of the annular plate. With the cooperation of a specific acoustic barrel structure, the signal energy level is controlled, resulting in a relatively larger detection range of the ultrasonic sensor after fabrication. Simultaneously, it provides a certain constraint on sound wave propagation, ensuring that the ultrasonic sensor still meets the usage requirements after the above improvements to the ultrasonic sensor housing. Attached Figure Description

[0061] Figure 1 This is a three-dimensional schematic diagram of the ultrasonic sensor housing of this application. Figure 1 (Has an inner shell).

[0062] Figure 2 This is a three-dimensional schematic diagram of the ultrasonic sensor housing of this application. Figure 2 (Has an inner shell).

[0063] Figure 3 This is a cross-sectional view of the ultrasonic sensor housing of this application (with an inner shell and a first groove).

[0064] Figure 4 It is a dimensioned drawing of the inner shell, the annular plate, and the front panel (with the inner shell and the first groove).

[0065] Figure 5 This is a schematic diagram of the ultrasonic sensor of this application.

[0066] Figure 6 This is a cross-sectional view of an ultrasonic sensor (with an inner shell).

[0067] Figure 7 This is a cross-sectional view of the ultrasonic sensor housing of this application (with an inner shell, without the first groove).

[0068] Figure 8 This is a cross-sectional view of the ultrasonic sensor housing of this application (with an inner shell, which is shorter).

[0069] Figure 9This is a cross-sectional view of the ultrasonic sensor housing of this application (with a first boss structure).

[0070] Figure 10 This is a three-dimensional schematic diagram of the ultrasonic sensor housing of this application. Figure 1 (Has a first boss structure).

[0071] Figure 11 This is a bottom view of the ultrasonic sensor housing of this application (with a first annular groove).

[0072] Figure 12 This is a bottom view of the ultrasonic sensor housing of this application (with an arc-shaped groove).

[0073] Figure 13 This is a cross-sectional view of the ultrasonic sensor housing of this application (with a third annular groove).

[0074] Figure 14 This is a cross-sectional view (without inner shell) of the ultrasonic sensor of this application.

[0075] Figure 15 This is a cross-sectional view of the ultrasonic sensor housing of this application (with a shallow placement groove).

[0076] Figure 15-1 This is a cross-sectional view of the ultrasonic sensor housing of this application (with a deep placement groove).

[0077] Figure 16 This is a cross-sectional view of the ultrasonic sensor housing of this application (type one with a bottom groove).

[0078] Figure 17 This application Figure 16 Enlarged schematic diagram of section A in the middle.

[0079] Figure 18 This is a cross-sectional view of the ultrasonic sensor housing of this application (type two with a bottom groove).

[0080] Figure 19 This application Figure 18 Enlarged schematic diagram of section A in the middle.

[0081] Figure 20 This is a cross-sectional view of the ultrasonic sensor housing of this application (with a third annular groove).

[0082] Figure 21 This is a cross-sectional view of the ultrasonic sensor housing of this application (type three with a bottom groove).

[0083] Figure 22 This application Figure 21 Enlarged schematic diagram of section A in the middle.

[0084] Figure 23This is a cross-sectional view of the ultrasonic sensor housing of this application (the annular plate and the inner side of the panel are flush).

[0085] Figure 24 This is a cross-sectional view of the ultrasonic sensor housing of this application (the outer side of the panel protrudes from the corresponding side of the housing).

[0086] Figure 25 This is a cross-sectional view of the ultrasonic sensor housing of this application (curved surface protruding outwards).

[0087] Figure 26 This is a cross-sectional view (curved surface concave) of the ultrasonic sensor housing of this application.

[0088] Figure 27 This is a schematic diagram of the fit between the ultrasonic sensor housing and the acoustic barrel of this application. Detailed Implementation

[0089] The present invention will now be described in further detail with reference to specific embodiments. However, this should not be construed as limiting the scope of the present invention to the following embodiments; all technologies implemented based on the content of the present invention fall within the scope of the present invention.

[0090] Unless otherwise specified, the use of terms such as "upper," "lower," "left," "right," "center," "inner," and "outer" to indicate orientation or positional relationships in the description of specific embodiments of the present invention is based on the orientation or positional relationships shown in the accompanying drawings, or the orientation or positional relationship in which the product / equipment / device is typically placed during use. These terms are merely for the purpose of facilitating the description of the present invention or simplifying the description in specific embodiments, enabling those skilled in the art to quickly understand the solution, and do not indicate or imply that a particular device / component / element must have a specific orientation, or be constructed and operated in a specific positional relationship. Therefore, they should not be construed as limitations on the present invention.

[0091] Furthermore, the use of terms such as "horizontal," "vertical," "suspended," and "parallel" does not imply that the corresponding device / component / element must be absolutely horizontal, vertical, suspended, or parallel, but rather that it can be slightly tilted or have a deviation. For example, "horizontal" simply means that its direction is more horizontal relative to "vertical," not that the structure must be completely horizontal, but that it can be slightly tilted. Alternatively, it can be simplified to mean that the corresponding device / component / element, when set in a "horizontal," "vertical," "suspended," or "parallel" direction, can have an error / deviation of ±10% relative to the corresponding direction, more preferably within ±8%, more preferably within ±6%, more preferably within ±5%, and more preferably within ±4%. As long as the corresponding device / component / element is within the error / deviation range, it can still achieve its function in the present invention. In addition, the use of terms such as "first," "second," and "third" in the terminology is merely used to distinguish the description of the same or similar components, and should not be construed as emphasizing or implying the relative importance of a specific component.

[0092] Furthermore, in the description of the embodiments of the present invention, "several", "more than", and "a number of" represent at least two. The number can be any number, such as two, three, four, five, six, seven, eight, nine, or even more than nine.

[0093] Furthermore, in the description of the technical solution of this invention, unless otherwise explicitly specified / limited / restricted, the terms "set up," "install," "connect," "link," "provided with," "laid out," and "arranged" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to common connection methods in the art, such as welding, riveting, bolting, and threaded connections. Such connections can be mechanical, electrical, or communication connections; they can be direct connections or indirect connections through an intermediate medium; and they can refer to the internal communication between two components.

[0094] Example 1 like Figures 1-3 As shown, the ultrasonic sensor housing described in this embodiment includes an inner shell 1, an outer shell 2 coaxially arranged on the outside of the inner shell 1, an annular plate 3 between the top of the inner shell 1 and the outer shell 2, and a panel 4 arranged at one end of the inner shell 1 near the annular plate 3. The panel 4 is used to connect a piezoelectric ceramic sheet 5. The inner shell 1, the outer shell 2, the annular plate 3 and the panel 4 are integrally formed.

[0095] The inner shell 1 and the outer shell 2 are connected by an annular plate 3, and a panel 4 is provided at one end of the inner shell 1 near the annular plate 3. The inner shell 1, outer shell 2, annular plate 3, and panel 4 are integrally formed, thus making the inner shell 1, outer shell 2, and panel 4 a whole. Since the two shells and matching layer of traditional ultrasonic sensors are made separately, secondary assembly of the two shells and matching layer is required during the production of the sensor. This is not only complex in structure and cumbersome in process, but also easy to be affected by the assembly tolerance during the assembly process, resulting in poor product consistency. However, the ultrasonic sensor shell of this application has an integral setting of the inner shell 1, outer shell 2, and panel 4. During sensor production, the piezoelectric ceramic sheet 5 is connected to the panel 4, and the panel 4 is used as a matching layer for the piezoelectric ceramic sheet 5 to transmit signals. This allows the housing to be coupled with the piezoelectric ceramic sheet 5, eliminating the need for an additional matching layer and greatly simplifying the process. Furthermore, since the inner shell 1 and the outer shell 2 are integrated, there is no need for an embedded small plastic shell to position the piezoelectric ceramic sheet 5, and it also avoids the assembly tolerances that are easy to occur when assembling the two types of housings. The ultrasonic sensor housing of this application has a simple process, effectively reduces variable factors, lowers the difficulty of production quality control, and effectively improves the production efficiency of traditional ultrasonic sensors.

[0096] In this application, the inner shell 1, outer shell 2, annular plate 3, and panel 4 are preferably integrally molded using injection molding or machining. Taking injection molding as an example, a convex and concave mold is made in advance to design the shape of the shell. The main component of the shell material is preferably epoxy resin, and fillers are added to the epoxy resin to reduce its density to a range of 0.35 g / cm³ to 0.9 g / cm³, thereby ensuring the uniformity of the shell material. During integral molding, the shell material, which is in a semi-fluid state at room temperature, is first poured into the concave mold, and then the convex and concave mold is locked and baked to cure, forming the ultrasonic sensor shell described in this application.

[0097] The ultrasonic sensor housing of this application eliminates the traditional outer shell and embedded plastic shell, reducing material costs and solving the problem of difficult quality control caused by the complex structure and many variables of traditional housings.

[0098] In one or more embodiments, the density of panel 4 is 0.35 g / cm³ to 0.9 g / cm³, such as... Figure 4 As shown, the thickness of panel 4 is 'a', and the dimension of 'a' is 1.6mm to 3.0mm. The thickness of panel 4 directly affects the coupling frequency and impedance parameters after the piezoelectric ceramic sheet 5 is bonded to the shell, and its control range is 1.6mm to 3.0mm.

[0099] In optional implementations, such as Figure 4As shown, the outer diameter of the inner shell 1 is b. The outer diameter of the inner shell 1 affects the vibration and ultrasonic energy of the product, and its control range is Φ8.2mm~Φ11mm.

[0100] Preferably, such as Figure 4 As shown, the thickness of the annular plate 3 is c. Different thicknesses of the annular plate 3 will cause residual vibration interference. Furthermore, the thickness of the annular plate 3 is directly related to the connection strength between the inner shell 1 and the outer shell 2. Its control range is 1mm to 1.5mm.

[0101] In one or more implementations, such as Figure 3 As shown, a first receiving cavity 10 is formed between the inner shell 1 and the panel 4. The first receiving cavity 10 is used to place the piezoelectric ceramic sheet 5, such as... Figure 6 .

[0102] The piezoelectric ceramic sheet 5 is placed in the first receiving cavity 10 and is bonded to the panel 4. The first receiving cavity 10 accommodates the piezoelectric ceramic sheet 5, and the panel 4 serves as a matching layer for the piezoelectric ceramic sheet 5. There is no need to embed a small plastic shell for positioning the piezoelectric ceramic sheet 5, nor is there a need to set a matching layer. The shell structure is simplified while ensuring that the piezoelectric ceramic sheet 5 can be used normally.

[0103] In optional implementations, such as Figure 3 As shown, a second receiving cavity 20 is formed between the inner shell 1, the outer shell 2, and the annular plate 3.

[0104] By filling the second receiving cavity 20 with a damping layer 6, the residual vibration of the piezoelectric ceramic sheet 5 is buffered. Figure 6 .

[0105] In optional implementations, such as Figure 3 As shown, the end of the inner shell 1 furthest from the panel 4 is located inside the outer shell 2, preventing the inner shell 1 from protruding from the outer shell 2. This facilitates the filling of the potting layer 9 at the end of the outer shell 2 during subsequent ultrasonic sensor assembly, thereby sealing the inner shell 1. Figure 6 .

[0106] In optional implementations, such as Figure 1 As shown, the inner shell 1 also has a first groove 11 at the end away from the panel 4. By providing a first groove 11 at the end of the inner shell 1 away from the panel 4, it is convenient to snap the terminal wire 8 into the first groove 11 for fixation during subsequent installation of the terminal wire 8. This eliminates the need for a pin cover as an intermediate connection between the piezoelectric ceramic sheet 5's lead wire 30 and the terminal wire 8, allowing for direct connection between the terminal wire 8 and the lead wire 30. This simplifies the ultrasonic sensor's structure without affecting its function. Figure 6 .

[0107] In an optional embodiment, the annular plate 3 is flush with the panel 4. In an optional embodiment, the inner shell 1 is cylindrical.

[0108] In an optional embodiment, the inner shell 1 and the outer shell 2 are cylindrical structures, with the inner shell 1 located inside the cavity of the outer shell 2, and the annular plate 3 connecting the inner shell 1 and the outer shell 2 into a whole.

[0109] In an optional embodiment, the inner shell 1 includes at least two first boss structures 40, all of which are arranged circumferentially around the outer shell 2, and one end of each first boss structure 40 is connected to the panel 4 or the annular plate 3.

[0110] Example 2 like Figures 1-24 As shown, the ultrasonic sensor housing described in this embodiment includes an outer shell 2, an annular plate 3 on the inner side of one end of the outer shell 2, a panel 4 on the inner side of the annular plate 3, and the panel 4 for connecting a piezoelectric ceramic sheet 5. The outer shell 2, the annular plate 3 and the panel 4 are integrally formed, and a first annular groove 50 is provided on the outer side of the annular plate 3.

[0111] The ultrasonic sensor housing described in this application includes an outer shell 2, an annular plate 3 on the inner side of one end of the outer shell 2, and a panel 4 disposed on the inner side of the annular plate 3. The outer shell 2, the annular plate 3, and the panel 4 are integrally formed, thereby making the outer shell 2, the annular plate 3, and the panel 4 a whole. Since the outer shell and the matching layer of traditional ultrasonic sensors are manufactured separately, secondary assembly of the outer shell and the matching layer is required during sensor production. This is not only structurally complex and cumbersome, but also easily affected by assembly tolerances during the assembly process, resulting in poor product consistency. However, the ultrasonic sensor housing of this application, with the outer shell 2, the annular plate 3, and the panel 4 being integrally set, allows the piezoelectric ceramic sheet to be connected to the panel during sensor production. The panel 4 is used as the matching layer for the piezoelectric ceramic sheet to transmit signals, thereby realizing the coupling between the housing and the piezoelectric ceramic sheet. This eliminates the need for an additional matching layer and greatly simplifies the process.

[0112] Furthermore, a first annular groove 50 is provided on the outer side of the annular plate 3. With the cooperation of a specific acoustic barrel structure, the signal energy level is adjusted, which increases the detection range of the ultrasonic sensor after it is made, and at the same time, it plays a certain role in constraining the propagation of sound waves. Thus, the ultrasonic sensor can still meet the usage requirements after the ultrasonic sensor housing is improved as described above.

[0113] like Figure 27 As shown, in a preferred embodiment, the specific sound barrel structure is preferably, for example, a horn-shaped sound barrel 80 or a hollow cone-shaped structure.

[0114] In one preferred embodiment, a piezoelectric ceramic sheet 5 is adhered to one side of the panel 4.

[0115] In this application, the integral molding process of the outer shell 2, the annular plate 3, and the panel 4 is preferably injection molding. Taking injection molding as an example, a convex and concave mold is made in advance, and the shape of the shell is designed by the convex and concave mold. The main component of the shell material is preferably epoxy resin, and fillers are added to the epoxy resin to reduce its density to a range of 0.35 g / cm³ to 0.9 g / cm³, thereby ensuring the uniformity of the shell material. During integral molding, the shell material, which is in a semi-fluid state at room temperature, is first poured into the concave mold, and then the convex and concave mold is locked and baked to cure, forming the ultrasonic sensor shell described in this application.

[0116] The ultrasonic sensor housing of this application eliminates the traditional outer shell and embedded plastic shell, reducing material costs and solving the problem of difficult quality control caused by the complex structure and many variables of traditional housings.

[0117] like Figure 4 As shown, in one or more embodiments, the preferred density of panel 4 is 0.35 g / cm³ to 0.9 g / cm³, and the thickness of panel 4 is a, with the preferred size of a being 1.6 mm to 3.0 mm.

[0118] The thickness of panel 4 directly affects the coupling frequency and impedance parameters after the piezoelectric ceramic sheet 5 is bonded to panel 4, and its control range is preferably 1.6mm to 3.0mm.

[0119] In a preferred embodiment, the ultrasonic sensor housing of this application further includes an inner shell 1, with an outer shell 2 fitted over the outer side of the inner shell 1. The inner shell 1 is connected to at least one of the annular plate 3 and the panel 4. The inner shell 1 serves to protect the inner structure of the outer shell 2 and facilitates assembly.

[0120] Preferably, the inner shell 1, outer shell 2, annular plate 3, and panel 4 are integrally formed.

[0121] The inner shell 1, outer shell 2, annular plate 3, and panel 4 are integrally formed, thus making the inner shell 1, outer shell 2, and panel 4 a whole. Since traditional ultrasonic sensors have two shells and matching layers manufactured separately, secondary assembly of the two shells and matching layers is required during sensor production. This not only results in complex structure and cumbersome processes, but also makes the two shells susceptible to assembly tolerances during assembly, leading to poor product consistency. In contrast, the ultrasonic sensor shell of this application, with its integral design of the inner shell 1, outer shell 2, and panel 4, allows the piezoelectric ceramic sheet 5 to be connected to the panel 4 during sensor production. The panel 4 serves as the matching layer for the piezoelectric ceramic sheet 5 to transmit signals, thereby achieving coupling between the shell and the piezoelectric ceramic sheet 5. This eliminates the need for an additional matching layer, greatly simplifying the process. Furthermore, due to the integral design of the inner shell 1 and outer shell 2, there is no need for an embedded small plastic shell for positioning the piezoelectric ceramic sheet 5, avoiding assembly tolerances that are prone to occur during the assembly of the two shells. The ultrasonic sensor shell of this application has a simple process, effectively reduces variable factors, lowers the difficulty of production quality control, and effectively improves the production efficiency of traditional ultrasonic sensors.

[0122] In this application, the inner shell 1, outer shell 2, annular plate 3, and panel 4 are integrally molded using injection molding. A convex and concave mold is prefabricated to design the shape of the shell. The main component of the shell material is epoxy resin, and fillers are added to the epoxy resin to reduce its density to a range of 0.35 g / cm³ to 0.9 g / cm³, thereby ensuring the uniformity of the shell material. During integral molding, the shell material, which is in a semi-fluid state at room temperature, is first poured into the concave mold, and then the convex and concave mold is locked and baked to cure, forming the ultrasonic sensor shell described in this application.

[0123] In a preferred embodiment, the inner shell 1 and the outer shell 2 are coaxially arranged to ensure the coaxiality of the inner shell and the outer shell, thereby ensuring the symmetry of the vibration of the ultrasonic sensor housing and the uniform transmission of ultrasonic waves.

[0124] A preferred embodiment, such as Figure 4 As shown, the outer diameter of the inner shell 1 is b. The outer diameter of the inner shell 1 affects the vibration and ultrasonic energy of the product, and its control range is Φ8.2mm~Φ11mm.

[0125] A preferred embodiment, such as Figure 4 As shown, the thickness of the annular plate 3 is c. Different thicknesses of the annular plate 3 will cause residual vibration interference. The thickness of the annular plate 3 is also related to the connection strength between the inner shell 1 and the outer shell 2. Its control range is 1mm to 1.5mm.

[0126] like Figure 3As shown, in one or more embodiments, a first receiving cavity 10 is formed between the inner shell 1 and the panel 4, such as... Figure 6 As shown, the first receiving cavity 10 is used to place the piezoelectric ceramic sheet 5.

[0127] The piezoelectric ceramic sheet 5 is placed in the first receiving cavity 10 and is bonded to the panel 4. The first receiving cavity 10 accommodates the piezoelectric ceramic sheet 5, and the panel 4 serves as a matching layer for the piezoelectric ceramic sheet 5. There is no need to embed a small plastic shell for positioning the piezoelectric ceramic sheet 5, nor is there a need to set a matching layer. The shell structure is simplified while ensuring that the piezoelectric ceramic sheet 5 can be used normally.

[0128] A preferred embodiment, such as Figure 3 and 6 As shown, a second receiving cavity 20 is formed between the inner shell 1, the outer shell 2 and the annular plate 3. The second receiving cavity 20 is used to accommodate the damping layer, which can improve the magnitude of the residual vibration of the piezoelectric ceramic sheet 5.

[0129] A preferred embodiment, such as Figure 3 and 6 As shown, the end of the inner shell 1 away from the panel 4 is located inside the outer shell 2, so that the inner shell 1 does not protrude from the outer shell 2. During the subsequent assembly of the ultrasonic sensor, it is convenient to fill the end of the outer shell 2 with the potting layer 9 to seal the inner shell 1.

[0130] A preferred embodiment, such as Figure 1 As shown, the inner shell 1 also has a first groove 11 at the end away from the panel 4. By providing a first groove 11 at the end of the inner shell 1 away from the panel 4, it is convenient to snap the terminal wire 8 into the first groove 11 for fixation during subsequent installation of the terminal wire 8. This eliminates the need for a pin cover as an intermediate connection between the piezoelectric ceramic sheet 5's lead wire 30 and the terminal wire 8, allowing for direct connection between the terminal wire 8 and the lead wire 30. This simplifies the ultrasonic sensor's structure without affecting its function. Figure 6 .

[0131] Preferably, there are at least two first grooves 11, and all first grooves 11 are arranged circumferentially along the inner shell 1.

[0132] In a preferred embodiment, the inner shell 1 is cylindrical. If it does not have the first groove 11, the Z-axis vibration is small, the vibration of the product end face is relatively weak, and more energy is concentrated at the rear end, resulting in greater vibration at the rear end. If the first groove 11 is present, the ultrasonic sensor after manufacturing will vibrate more along the Z-axis, the vibration of the product end face will be stronger, it will be more capable of energy transfer, and the residual vibration will be smaller.

[0133] The outer diameter of the inner shell is preferably Φ8.2mm~Φ11mm.

[0134] like Figure 9 and 10 As shown, in a preferred embodiment, the inner shell 1 includes at least two first boss structures 40, all of which are arranged circumferentially around the outer shell 2, and one end of each first boss structure 40 is connected to at least one of the panel 4 and the annular plate 3.

[0135] Since all the first boss structures 40 are arranged at intervals along the circumference of the outer shell 2, the manufactured ultrasonic sensor vibrates greatly along the Z-axis, the vibration of the product end face is stronger, it can generate more energy transfer, and the residual vibration is smaller.

[0136] In a preferred embodiment, the outer shell 2 is cylindrical.

[0137] In a preferred embodiment, the outer shell 2, the annular plate 3, and the panel 4 form an inner cavity 21 that is closed at one end. That is, there are no through holes in the outer shell 2, the annular plate 3, the panel 4, the connection between the annular plate 3 and the outer shell 2, or the connection between the annular plate 3 and the panel 4.

[0138] In a preferred embodiment, a solder joint receiving groove 41 is provided on the inner side of the panel 4 to receive solder joints on the piezoelectric ceramic sheet 5, and at the same time, it can be used for positioning the piezoelectric ceramic sheet 5.

[0139] In a preferred embodiment, the weld joint receiving groove 41 extends partially onto the annular plate 3.

[0140] like Figure 13 As shown, in a preferred embodiment, a second annular groove 60 is provided on the inner side of the annular plate 3. The area of ​​the panel in contact with the piezoelectric ceramic sheet is adjusted by the second annular groove 60, thereby adjusting the residual vibration of the ultrasonic sensor. Furthermore, the third annular groove can be used to fill with elastic adhesive to suppress the vibration of the piezoelectric ceramic sheet towards the outer shell, or it can be filled with backing adhesive to form part of the backing layer for better vibration reduction.

[0141] like Figure 13 As shown, in a preferred embodiment, the second annular groove 60 is provided correspondingly to the first annular groove 50, thereby jointly controlling the thickness of the annular plate 3 to reduce the influence of the annular plate 3 on the vibration of the panel 4.

[0142] like Figure 23 As shown, in a preferred embodiment, the annular plate 3 is flush with the inner side of the panel 4.

[0143] In a preferred embodiment, the inner shell 1 and the outer shell 2 are cylindrical structures, with the inner shell 1 located inside the cavity of the outer shell 2, and the annular plate 3 connecting the inner shell 1 and the outer shell 2 into a whole.

[0144] like Figure 15 and 15-1 As shown, in a preferred embodiment, the inner side of the annular plate 3 is higher than the inner side of the panel 4, and the annular plate 3 and the inner side of the panel 4 form a placement groove 42 for placing the piezoelectric ceramic sheet 5. The placement groove 42 is used to place the piezoelectric ceramic sheet 5.

[0145] like Figure 12 As shown, preferably, a reinforcing rib 54 is connected between the opposite sides of the first annular groove 50.

[0146] like Figure 12 As shown, in a preferred embodiment, there are at least two reinforcing ribs 54, which are spaced apart from each other, and the reinforcing ribs 54 divide the first annular groove 50 into several arc-shaped grooves 51.

[0147] Preferably, the reinforcing ribs 54 are arranged such that the first annular groove 50 is divided into several arc-shaped grooves 51, all of which are arranged in a ring, and adjacent arc-shaped grooves 51 are spaced apart by the reinforcing ribs 54.

[0148] In a preferred embodiment, the reinforcing rib 54, the outer shell 2, the annular plate 3, and the panel 4 are integrally formed.

[0149] In a preferred embodiment, a third annular groove 52 is provided at intervals on the inner side of the first annular groove 50.

[0150] In a preferred embodiment, a third annular groove 52 is provided at intervals on the outer side of the first annular groove 50.

[0151] In a preferred embodiment, a third annular groove 52 is provided at intervals on both the inner and outer sides of the first annular groove 50.

[0152] The residual vibration and ultrasonic echo energy are controlled by the cooperation of the first annular groove 50 and the third annular groove 52.

[0153] In a preferred embodiment, the bottom of the first annular groove 50 is further provided with a bottom groove 53.

[0154] Preferably, a portion of at least one side of the bottom groove 53 and the first annular groove 50 are coplanar.

[0155] In a preferred embodiment, the bottom groove 53 is disposed in the middle of the bottom of the first annular groove 50 along the radial direction of the first annular groove 50.

[0156] In a preferred embodiment, at least a portion of the first annular groove 50 extends laterally onto the panel 4.

[0157] In a preferred embodiment, the outer surface of the panel 4 protrudes from the end face of the corresponding side of the outer shell 2. After passing through the convex interface, the sound waves diffuse outwards along the central axis, resulting in a wider sound wave emission angle, a more uniform sound field in the near-field region, and suitability for detecting large-area targets, while also increasing the detection angle.

[0158] In a preferred embodiment, the outer surface of the panel 4 has an arcuate portion 43, which convex outwards toward the outer side of the panel 4. This convex surface increases the ultrasonic wave emission and reception angles, resulting in strong emission of sound waves. This addresses the needs of certain scenarios, such as those requiring a larger detection angle, achieving wide near-field coverage.

[0159] In a preferred embodiment, the outer surface of the panel 4 has an arcuate portion 43, which is recessed towards the inner side of the panel 4. This concave design forces sound wave energy to propagate and converge along the normal direction of the concave surface, resulting in narrower directivity and a smaller beam angle. To meet certain user needs, this can significantly improve local energy intensity, and the higher the frequency, the shorter the wavelength, and the stronger the focusing ability.

[0160] In one preferred embodiment, the projection of the inner side surface of the panel 4 along the radial direction of the outer casing 2 lies on the side surface of the first annular groove 50. In another preferred embodiment, the outer casing 2 is cylindrical. In yet another preferred embodiment, at least a portion of the first annular groove 50 extends laterally onto the panel 4.

[0161] Example 3 Based on Example 1, such as Figures 5-6 As shown, the ultrasonic sensor described in this embodiment includes a piezoelectric ceramic sheet 5, a damping layer 6, a backing layer 7, a terminal wire 8, a potting layer 9, and a housing structure as described in Embodiment 1. The piezoelectric ceramic sheet 5 and the backing layer 7 are sequentially disposed inside the inner housing 1, and the piezoelectric ceramic sheet 5 is connected to the panel 4. A damping layer 6 is also filled between the inner shell 1 and the outer shell 2, and a potting layer 9 is filled at the end of the outer shell 2 away from the panel 4; Terminal wire 8 passes through potting layer 9 and backing layer 7 and is connected to lead wire 30 of piezoelectric ceramic sheet 5.

[0162] During production, the piezoelectric ceramic sheet 5 and the backing layer 7 are sequentially placed inside the inner shell 1, and the piezoelectric ceramic sheet 5 is connected to the panel 4. The panel 4 serves as a matching layer for the piezoelectric ceramic sheet 5 to transmit signals, thereby enabling coupling between the shell and the piezoelectric ceramic sheet 5. This eliminates the need for an additional matching layer, greatly simplifying the process. Furthermore, since the inner shell 1 and the outer shell 2 are integrated, there is no need to embed a small plastic shell for positioning the piezoelectric ceramic sheet 5, which also avoids assembly tolerances that are prone to occur when assembling the two shells, greatly improving the production efficiency of ultrasonic sensors.

[0163] Preferably, such as Figure 6 As shown, the backing layer 7 and the vibration damping layer 6 are cast in one piece, which reduces the number of processes and increases efficiency.

[0164] This embodiment also discloses a method for producing an ultrasonic sensor, the specific steps of which are: (1) preparing the housing material; (2) injecting the housing material into the cavity mold using a precision dispensing machine, the amount of adhesive being controlled by the dispensing air pressure and dispensing time; (3) welding the lead wires 30 of the piezoelectric ceramic sheet 5, the welding using professional laser welding equipment, the lead wires 30 being silver-plated copper wires; (4) pre-installing the piezoelectric ceramic sheet 5 with the welded lead wires 30 on the punch platform and adsorbing it under negative pressure; (5) then locking the punch and cavity molds together. Baking one end for a time to cure, then demolding, (6) demolding, using a mechanical gripper to separate the convex and concave molds, and taking out the sensor housing; (7) welding the external terminal wire 8 to the lead wire 30 of the piezoelectric ceramic sheet 5; (8) using a precision dispensing machine to inject backing adhesive into the inner shell 1 to form a backing layer 7, the amount of adhesive is controlled by dispensing air pressure and dispensing time; (9) using a precision dispensing machine to inject potting adhesive into the outer shell 2 to form a potting layer 9, the amount of adhesive is controlled by dispensing air pressure and dispensing time, and the ultrasonic sensor fabrication is completed. The lead wire 30 includes a positive electrode wire 81 and a negative electrode wire 82.

[0165] The ultrasonic sensor described in this embodiment is preferably used for material identification and distance measurement.

[0166] Example 4 like Figures 5-6 As shown, this embodiment of an ultrasonic sensor includes the ultrasonic sensor housing described in Embodiment 1 or 2. The ultrasonic sensor housing includes an outer shell, an annular plate on the inner side of one end of the outer shell, and a panel on the inner side of the annular plate. The outer shell, the annular plate, and the panel are integrally formed, thus creating a single unit. Traditional ultrasonic sensors, where the inner shell, outer shell, and matching layer are manufactured separately, require secondary assembly of these components during sensor production. This process is not only complex and cumbersome but also susceptible to assembly tolerances, leading to poor product consistency. In contrast, the ultrasonic sensor housing of this application, with its integrally formed outer shell, annular plate, and panel, allows the piezoelectric ceramic sheet to be connected to the panel during sensor production. The panel serves as the matching layer for signal transmission by the piezoelectric ceramic sheet, enabling coupling between the housing and the piezoelectric ceramic sheet. This eliminates the need for an additional matching layer, significantly simplifying the manufacturing process. Furthermore, a first annular groove is provided on the outer side of the annular plate to increase the signal transmission angle and reception angle, thereby increasing the detection range of the ultrasonic sensor after it is made, and at the same time, it plays a certain focusing role on the sound waves. Thus, the ultrasonic sensor can still meet the usage requirements after the ultrasonic sensor housing is improved as described above.

[0167] Furthermore, since the outer shell 2, the annular plate 3, and the panel 4 are integrated, there is no longer a need for an embedded small plastic shell to position the piezoelectric ceramic sheet 5, and the assembly tolerances that are easy to occur when assembling the two shells are also avoided. The ultrasonic sensor shell of this application has a simple process, effectively reduces variable factors, reduces the difficulty of production quality control, and effectively improves the production efficiency of traditional ultrasonic sensors.

[0168] In this application, the shell 2, the annular plate 3, and the panel 4 are integrally molded using injection molding. A convex and concave mold is made in advance to design the shape of the shell. The main component of the shell material is epoxy resin, and fillers are added to the epoxy resin to reduce its density to a range of 0.35 g / cm³ to 0.9 g / cm³, thereby ensuring the uniformity of the shell material. During the integral molding process, the shell material, which is in a semi-fluid state at room temperature, is first poured into the concave mold, and then the convex and concave mold is locked and baked to cure, forming the ultrasonic sensor shell described in this application.

[0169] The ultrasonic sensor housing of this application eliminates the traditional outer shell and embedded plastic shell, reducing material costs and solving the problem of difficult quality control caused by the complex structure and many variables of traditional housings.

[0170] In one or more embodiments, the density of panel 4 is 0.35 g / cm³ to 0.9 g / cm³, such as... Figure 4 As shown, the thickness of panel 4 is 'a', and the dimension of 'a' is 1.6mm to 3.0mm. The thickness of panel 4 directly affects the coupling frequency and impedance parameters after the piezoelectric ceramic sheet 5 is bonded to the shell, and its control range is 1.6mm to 3.0mm.

[0171] In optional implementations, such as Figure 4 As shown, the thickness of the annular plate 3 is c. Different thicknesses of the annular plate 3 will cause residual vibration interference. The thickness of the annular plate 3 is also related to the connection strength between the inner shell 1 and the outer shell 2. Its control range is 1mm to 1.5mm.

[0172] The piezoelectric ceramic sheet 5 is bonded to the panel 4 and accommodated by the first receiving cavity 10. The panel 4 serves as a matching layer for the piezoelectric ceramic sheet 5. There is no need for an embedded small plastic shell to position the piezoelectric ceramic sheet 5, nor is there a need to set up a matching layer. The shell structure is simplified while ensuring that the piezoelectric ceramic sheet 5 can be used normally.

[0173] The ultrasonic sensor described in this embodiment is preferably used for material identification and distance measurement.

[0174] Example 5 like Figures 5-6 As shown, the ultrasonic sensor described in this embodiment includes the ultrasonic sensor housing described in embodiment 2, and also includes a piezoelectric ceramic sheet 5, a damping layer 6, a backing layer 7, and a terminal wire 8. The difference between this embodiment and embodiment 3 or 4 is that the piezoelectric ceramic sheet 5 is connected to the inner side of the panel 4, the damping layer 6 is located in the second annular groove 60, and the backing layer 7 is disposed on the inner side of the outer shell 2. The inner side of the outer shell 2 is also filled with a potting layer 9, which is located on the side of the backing layer 7 away from the piezoelectric ceramic sheet 5; Terminal wire 8 passes through potting layer 9 and enters backing layer 7, and is connected to lead wire 30 of piezoelectric ceramic sheet 5.

[0175] A second annular groove 60 is provided on the inner side of the annular plate 3. The area of ​​the panel in contact with the piezoelectric ceramic sheet is adjusted by the second annular groove 60, thereby adjusting the residual vibration of the ultrasonic sensor. Furthermore, the second annular groove 60 is used to fill elastic adhesive to suppress the vibration of the piezoelectric ceramic sheet toward the outer shell. It can also be filled with backing adhesive to form part of the backing layer for better vibration reduction.

[0176] In the production of the ultrasonic sensor described in this application, the piezoelectric ceramic sheet 5 and the backing layer 7 are sequentially arranged inside the housing 2, and the piezoelectric ceramic sheet 5 is connected to the panel 4. The panel 4 serves as a matching layer for the transmission of signals by the piezoelectric ceramic sheet 5, thereby achieving coupling between the housing and the piezoelectric ceramic sheet 5. This eliminates the need for an additional matching layer, greatly simplifying the process. Furthermore, since the housing 2, the annular plate 3, and the panel 4 are integrally formed, there is no need for an embedded small plastic shell for positioning the piezoelectric ceramic sheet, and assembly tolerances that are prone to occur when assembling two housings are avoided, greatly improving the production efficiency of the ultrasonic sensor. Alternatively, during production, the piezoelectric ceramic sheet 5 and the backing layer 7 can be sequentially placed inside the inner shell 1, with the piezoelectric ceramic sheet 5 connected to the panel 4. The panel 4 serves as a matching layer for the piezoelectric ceramic sheet 5 to transmit signals, thereby enabling coupling between the shell and the piezoelectric ceramic sheet 5. This eliminates the need for an additional matching layer, greatly simplifying the process. Furthermore, since the outer shell 2, the annular plate 3, and the panel 4 are integrally formed, there is no need for an embedded small plastic shell to position the piezoelectric ceramic sheet 5. This also avoids assembly tolerances that are prone to occur when assembling two shells, greatly improving the production efficiency of ultrasonic sensors.

[0177] In optional implementations, such as Figure 6 As shown, the backing layer 7 and the vibration damping layer 6 are cast in one piece, which reduces the number of processes and increases efficiency.

[0178] This embodiment also discloses a method for producing an ultrasonic sensor, the specific steps of which are: a. preparing the housing material; b. injecting the housing material into the cavity mold using a precision dispensing machine, the amount of adhesive being controlled by dispensing air pressure and dispensing time; c. welding the lead wires 30 of the piezoelectric ceramic sheet 5 using professional laser welding equipment, the lead wires 30 being made of silver-plated copper wire; d. pre-installing the piezoelectric ceramic sheet 5 with the welded lead wires 30 on the punch platform and adsorbing it under negative pressure; e. then assembling and locking the punch and cavity molds together, and baking. f. Demolding: Use a robotic gripper to separate the convex and concave molds and remove the ultrasonic sensor housing; g. Solder the external terminal wires 8 to the lead wires 30 of the piezoelectric ceramic sheet 5; h. Use a precision dispensing machine to inject backing adhesive into the inner shell 1 to form a backing layer 7. The amount of adhesive is controlled by dispensing air pressure and dispensing time; i. Use a precision dispensing machine to inject potting compound into the outer shell 2 to form a potting layer 9. The amount of adhesive is controlled by dispensing air pressure and dispensing time, thus completing the fabrication of the ultrasonic sensor.

[0179] The ultrasonic sensor described in this embodiment is preferably used for material identification and distance measurement.

[0180] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An ultrasonic sensor housing, characterized in that, Includes a housing (2), an annular plate (3) on the inner side of one end of the housing (2), a panel (4) on the inner side of the annular plate (3), the panel (4) for connecting a piezoelectric ceramic sheet (5), the housing (2), the annular plate (3) and the panel (4) are integrally formed, and a first annular groove is provided on the outer side of the annular plate (3).

2. The ultrasonic sensor housing according to claim 1, characterized in that, It also includes an inner shell (1), the outer shell (2) being fitted over the outer side of the inner shell (1), and the inner shell (1) being connected to at least one of the annular plate (3) and the panel (4).

3. The ultrasonic sensor housing according to claim 2, characterized in that, The inner shell (1), outer shell (2), annular plate (3) and panel (4) are integrally formed.

4. The ultrasonic sensor housing according to claim 3, characterized in that, The inner shell (1) and the outer shell (2) are coaxially arranged.

5. An ultrasonic sensor housing according to claim 2, characterized in that, A first receiving cavity is formed between the inner shell (1) and the panel (4), and the first receiving cavity is used to place the piezoelectric ceramic sheet (5). and / or A second receiving cavity is formed between the inner shell (1), the outer shell (2), and the annular plate (3).

6. The ultrasonic sensor housing according to claim 2, characterized in that, The end of the inner shell (1) away from the panel (4) is located inside the outer shell (2).

7. An ultrasonic sensor housing according to claim 2, characterized in that, The inner shell (1) is further provided with a first groove at the end away from the panel (4).

8. The ultrasonic sensor housing according to claim 2, characterized in that, The inner shell (1) is cylindrical; And / or, The outer shell (2) is cylindrical.

9. An ultrasonic sensor housing according to claim 2, characterized in that, The inner shell (1) includes at least two first boss structures, all of which are arranged circumferentially around the outer shell (2), and one end of each first boss structure is connected to at least one of the panel (4) and the annular plate (3).

10. An ultrasonic sensor housing according to claim 1, characterized in that, The outer shell (2), the annular plate (3), and the panel (4) form an inner cavity that is closed at one end.

11. An ultrasonic sensor housing according to claim 1, characterized in that, The density of the panel (4) is 0.35 g / cm³ to 0.9 g / cm³; And / or, The thickness of the panel (4) is 1.6mm to 3.0mm.

12. The ultrasonic sensor housing according to claim 1, characterized in that, A second annular groove is provided on the inner side of the annular plate (3).

13. An ultrasonic sensor housing according to claim 12, characterized in that, The second annular groove is provided corresponding to the first annular groove.

14. The ultrasonic sensor housing according to claim 1, characterized in that, The inner side of the annular plate (3) and the inner side of the panel (4) are flush.

15. An ultrasonic sensor housing according to claim 1, characterized in that, The inner side of the annular plate (3) is higher than the inner side of the panel (4). The annular plate (3) and the inner side of the panel (4) form a placement groove for placing the piezoelectric ceramic sheet (5). The placement groove is used to place the piezoelectric ceramic sheet (5).

16. An ultrasonic sensor housing according to claim 1, characterized in that, A reinforcing rib is connected between the opposite sides of the first annular groove.

17. An ultrasonic sensor housing according to claim 16, characterized in that, There are at least two reinforcing ribs, which are spaced apart from each other, and the reinforcing ribs divide the first annular groove into several arc-shaped grooves.

18. An ultrasonic sensor housing according to claim 16, characterized in that, The reinforcing rib, outer shell (2), annular plate (3) and panel (4) are integrally formed.

19. An ultrasonic sensor housing according to claim 1, characterized in that, A third annular groove is provided at intervals on the inner and / or outer sides of the first annular groove.

20. An ultrasonic sensor housing according to claim 1, characterized in that, The bottom of the first annular groove is also provided with a bottom groove.

21. An ultrasonic sensor housing according to claim 20, characterized in that, The bottom groove and the first annular groove are partially coplanar on at least one side.

22. An ultrasonic sensor housing according to claim 20, characterized in that, Along the radial direction of the first annular groove, the bottom groove is disposed in the middle of the bottom of the first annular groove.

23. The ultrasonic sensor housing according to claim 1, characterized in that, At least a portion of the first annular groove extends laterally onto the panel (4).

24. The ultrasonic sensor housing according to claim 1, characterized in that, The outer side of the panel (4) protrudes from the end face of the corresponding side of the outer shell (2).

25. An ultrasonic sensor housing according to claim 1, characterized in that, The outer side of the panel (4) has an arc-shaped surface, which is convex outward toward the outer side of the panel (4); or, The outer side of the panel (4) has an arc-shaped surface, which is recessed towards the inner side of the panel (4).

26. The ultrasonic sensor housing according to claim 1, characterized in that, Along the radial direction of the outer shell (2), the projection of the inner side of the panel (4) is located on the side of the first annular groove.

27. An ultrasonic sensor, characterized in that, The device includes a piezoelectric ceramic sheet (5) and an ultrasonic sensor housing as described in any one of claims 1-26, wherein the panel (4) is connected to the piezoelectric ceramic sheet (5) and the panel (4) serves as a matching layer for transmitting vibrations of the piezoelectric ceramic sheet (5).

28. An ultrasonic sensor, characterized in that, The ultrasonic sensor housing as described in any one of claims 2-9 further includes a piezoelectric ceramic sheet (5), a damping layer (6), a backing layer (7), a terminal wire (8), and a potting layer (9). The piezoelectric ceramic sheet (5) and the backing layer (7) are sequentially disposed inside the inner shell (1), and the piezoelectric ceramic sheet (5) is connected to the panel (4). The vibration damping layer (6) is also filled between the inner shell (1) and the outer shell (2), and the potting layer (9) is filled at the end of the outer shell (2) away from the panel (4). The terminal wire (8) passes through the potting layer (9) and the backing layer (7) and is connected to the lead wire of the piezoelectric ceramic sheet (5).

29. An ultrasonic sensor, characterized in that, The ultrasonic sensor housing as described in claim 12 or 13 further includes a piezoelectric ceramic sheet (5), a damping layer (6), a backing layer (7), and a terminal wire (8). The piezoelectric ceramic sheet (5) is connected to the inner side of the panel (4), the damping layer (6) is located in the second annular groove, and the backing layer (7) is disposed on the inner side of the outer shell (2). The inner side of the outer shell (2) is also filled with a potting layer (9), which is located on the side of the backing layer (7) away from the piezoelectric ceramic sheet (5); The terminal wire (8) passes through the potting layer (9) and enters the backing layer (7), and is connected to the lead wire of the piezoelectric ceramic sheet (5).

30. An ultrasonic sensor according to claim 28 or 29, characterized in that, The backing layer (7) and the vibration damping layer (6) are integrally cast; And / or, It also includes a sound barrel, which is disposed on the outside of the panel (4) and is connected to at least one of the annular plate (3) and the panel (4).

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