Rapidly formed ultrasonic sensor

Abstract

A rapidly-formed ultrasonic sensor comprises a probe core, the probe core is provided with a first probe core end face convenient for receiving ultrasonic signals, a second probe core end face convenient for packaging the internal structure of the probe core, and a shell which is embedded on the periphery of the probe core and is subjected to secondary injection molding. The end, close to the first probe core end face, of the shell is provided with an opening enabling the first probe core end face to be exposed, the ultrasonic sensor structure simplifies the manufacturing process, and the existing ultrasonic sensor manufacturing process includes the steps that the probe core is prepared, the probe core is installed in an injection mold to be subjected to injection molding, and finally testing is conducted; the subsequent processing steps are greatly reduced, the production speed and efficiency are improved, the application of the injection molding process reduces the manufacturing cost of the shell, the reasonable utilization of the damping glue also reduces the material waste, and the cost benefit is integrally improved.

Description

Technical Field

[0001] The utility model relates to the technical field of sensors, in particular to a rapid prototyping ultrasonic sensor.

Background Art

[0002] An ultrasonic sensor is a device that uses the characteristics of ultrasonic waves to detect distances, monitor object levels or liquid levels, identify objects, etc. Ultrasonic sensors are widely used, from simple distance measurement to complex medical imaging. The working principle of ultrasonic sensors is based on the reflection of ultrasonic waves. An ultrasonic sensor includes a transmitter and a receiver, and also includes using a single sensor to emit and receive by itself. The transmitter sends high-frequency sound waves, which propagate in the air and are reflected back to the receiver when they encounter the surface of an object. After the receiver receives the reflected signal, the circuit inside the sensor calculates the time it takes for the sound wave to travel from transmission to reception. In the prior art, the overall manufacturing time of ultrasonic sensors is relatively long, the process is relatively complex, and the time required for glue injection and curing is long, which is time-consuming and laborious, affecting the production capacity of products.

Content of the Utility Model

[0003] To overcome the technical defect of long glue injection and curing time in the manufacturing of ultrasonic sensors, the technical problem to be solved by the utility model is to provide a rapid prototyping ultrasonic sensor. The utility model is realized by the following technical solutions:

[0004] A rapid prototyping ultrasonic sensor includes a probe core. The probe core is provided with a first probe core end face convenient for receiving ultrasonic signals, and also provided with a second probe core end face convenient for encapsulating the internal structure of the probe core. An outer shell is formed by inlaid secondary injection molding on the outer periphery of the probe core, and an opening is provided at one end of the outer shell close to the first probe core end face to expose the first probe core end face.

[0005] For the rapid prototyping ultrasonic sensor as described above, an annular groove is provided between the outer shell and the probe core at the outer peripheral part close to the first probe core end face.

[0006] For the rapid prototyping ultrasonic sensor as described above, the outer shell is provided with a shell hole for inlaying with the protruding part of the probe core. The outer periphery of the shell hole is the upper end part of the outer shell formed by secondary injection molding and is airtight. The upper end part of the outer shell is provided with a flat upper end face of the outer shell at one end far from the second probe core end face.

[0007] For the rapid prototyping ultrasonic sensor as described above, a first groove is provided inside the outer shell close to the second probe core end face and having the same external surface structure as the probe core. The first groove includes a hollow inlaid plane inlaid with the second probe core end face, and the first groove also includes a first inlaid face inlaid with the outer periphery of the probe core.

[0008] A rapid prototyping ultrasonic sensor as described above, wherein the annular groove is filled with damping glue for vibration damping.

[0009] A rapid prototyping ultrasonic sensor as described above, wherein the annular groove includes an annular embedding plane inlaid with the top of the damping glue, and the annular groove further includes a second embedding surface inlaid with the outer periphery of the damping glue.

[0010] A rapid prototyping ultrasonic sensor as described above, wherein the probe core includes an inner shell inlaid with the outer shell. The inner shell is provided with a matching layer for receiving ultrasonic signals on the first probe core end face. The matching layer includes a matching sound-transmitting material. A ceramic strain gauge for generating an electrical signal is attached to the end face of the matching sound-transmitting material away from the first probe core end face. A wire for transmitting the electrical signal is connected to the end face of the ceramic strain gauge away from the matching sound-transmitting material.

[0011] A rapid prototyping ultrasonic sensor as described above, wherein the inner shell is provided with a PCB board for transferring electrical signals below the second probe core end face, and potting glue is filled between the PCB board and the matching layer.

[0012] A rapid prototyping ultrasonic sensor as described above, wherein a shielded wire for transmitting electrical signals is connected to the second probe core end face.

[0013] A rapid prototyping ultrasonic sensor as described above, wherein the inner shell is a hollow cylindrical structure in the middle.

[0014] Compared with the prior art, the present utility model has the following advantages:

[0015] 1. The structure of this ultrasonic sensor simplifies the manufacturing process. The original manufacturing process of the ultrasonic sensor is: preparing the probe core, installing the probe core into the outer shell, then adding fixing glue to fix the outer shell and the probe core. After fixing, damping glue is filled before potting, cured for 24 hours after potting, then potting glue for the rear part is filled and cured for 12 hours, and finally testing is carried out. Now, the manufacturing process of the ultrasonic sensor is optimized as: preparing the probe core, installing the probe core in an injection mold for injection molding, and finally testing, which greatly reduces the manufacturing process and the processing production cycle.

[0016] 2. The structure of this probe core is suitable for quickly forming the outer shell of the ultrasonic sensor by clamping the probe core in an injection mold after the probe core is manufactured. The upper end of the outer shell is made of the same injection material, which is different from the prior art that requires re-sealing glue after installing the outer shell. The outer shell of this structure has excellent sealing performance and shortens the time for manufacturing the outer shell of the ultrasonic sensor.

[0017] 3. Due to the simplified process of this ultrasonic sensor structure, the processing cost is greatly reduced, the labor cost and the material consumption are reduced, and the processing cost is reduced to 1 / 4 of the original.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings required for description in the embodiments will be briefly introduced below.

[0019] Figure 1 Cross-sectional schematic view of a rapid prototyping ultrasonic sensor of the present invention Figure 1 ;

[0020] Figure 2 Cross-sectional schematic view of the housing of a rapid prototyping ultrasonic sensor of the present invention Figure 2 ;

[0021] Figure 3 Cross-sectional and enlarged view A schematic of the probe core of a rapid prototyping ultrasonic sensor of the present invention Figure 3 .

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0022] In order to make the technical problems, technical solutions and beneficial effects solved by the present application more clearly understood, the present application will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present application and are not used to limit the present application.

[0023] Please refer to Figures 1 to 3 , a rapid prototyping ultrasonic sensor, including a probe core 2. The probe core 2 is provided with a first probe core end face 201 for conveniently receiving ultrasonic signals, and a second probe core end face 202 for facilitating the encapsulation of the internal structure of the probe core 2. The housing 1 is formed by inlaid two-shot injection molding around the probe core 2. An opening 101 for exposing the first probe core end face 201 is provided at one end of the housing 1 close to the first probe core end face 201. The structural design of the probe core 2 is highly matched with the injection molding process of the housing 1, making the mass production of the sensor faster and more economical. Injection molding can be formed in one step, greatly reducing subsequent processing steps, improving production speed and efficiency. The housing 1 not only protects the probe core 2 from external physical damage, reduces performance fluctuations caused by mechanical vibration, and improves the reliability and lifespan of the device. The application of the injection molding process reduces the manufacturing cost of the housing 1, and the structural design of the ultrasonic sensor simplifies the mold making and material use, further controlling the production cost, and overall improving the cost-effectiveness.

[0024] Furthermore, as a preferred implementation mode of the present scheme but not a limitation, an annular groove 301 is provided between the outer shell 1 and the probe core 2 near the outer peripheral part of the first probe core end face 201, and the annular groove 301 is filled with damping glue 3 for vibration reduction. The setting of the damping glue 3 effectively reduces the residual vibration generated by the probe core 2 after receiving the ultrasonic signal, reduces the clutter interference of the signal, and improves the clarity and detection accuracy of the signal, which is particularly important for ultrasonic applications requiring high resolution and accuracy. The cooperation between the outer shell 1 and the damping glue 3 enhances the structural stability of the entire sensor, and it can also be determined whether the damping glue 3 needs to be packaged according to actual needs.

[0025] Further, as a preferred embodiment of the present solution but not a limitation, the housing 1 is provided with a first groove 12 which is close to the second probe core end face 202 and has the same structure as the outer surface of the probe core 2. The first groove 12 includes a hollow inlay plane 121 inlaid with the second probe core end face 202, and the first groove 12 also includes a first inlay surface 122 inlaid with the outer periphery of the probe core 2. The annular groove 301 includes an annular inlay plane 131 inlaid with the top of the damping glue 3, and the annular groove 301 also includes a second inlay surface 132 inlaid with the outer periphery of the damping glue 3. The cooperation of the hollow inlay plane 121 and the first inlay surface 122 ensures the precise alignment and firm fixation of the probe core 2, reduces the error caused by displacement, and through the design of the first groove 12, the probe core 2 can remain stable when subjected to external interference, reducing the influence of vibration or shaking. The damping glue 3 is located in the annular groove 301, and its top contacts the annular inlay plane 131, and the outer periphery contacts the second inlay surface 132, which can effectively absorb and disperse external impact force and protect the probe core from damage.

[0026] Further, as a preferred embodiment of the present solution but not a limitation, the outer surface of the housing 1 is a cylindrical structure, the first end face 201 is flush with the end face of the housing 1 near the damping glue 3, the housing 1 is also provided with a housing hole 11 for inlaying with the extended part of the core probe, the outer periphery of the housing hole 11 is a housing upper end 16 which is twice injection molded and sealed, and the housing upper end 16 is provided with a straight housing upper end face 15 at one end away from the second core probe end face 202. The cylindrical structure provides uniform mechanical properties, can better resist external pressure and distortion, and maintain the overall structural stability of the device, and the first end face 201 is flush with the housing end face near the damping glue 3, which can ensure the integrity and sealing of the damping glue 3, prevent dust, moisture, etc. from entering the interior of the device, and the sealed housing upper end 16 and the straight housing upper end face 15 ensure the sealing of the upper part of the housing.

[0027] Furthermore, as a preferred embodiment of the present invention but not a limitation, the probe core 2 includes an inner shell 21 inlaid with the outer shell 1, and the inner shell 21 is provided with a matching layer 22 for receiving ultrasonic signals on the first probe core end face 201, and the matching layer 22 includes a matching sound-transmitting material 221, and the matching sound-transmitting material 221 is bonded with a ceramic strain gauge 222 for generating an electrical signal on the end face away from the first probe core end face 201, and the ceramic strain gauge 222 is connected with a wire 223 for transmitting electrical signals on the end face away from the matching sound-transmitting material 221. The design of the matching sound-transmitting material 221 can effectively improve the transmission efficiency of ultrasonic signals from air to the sensor, reduce the reflection loss of the signal at the interface, and thus enhance the strength of the received signal. The ceramic strain gauge 222 is tightly attached to the matching sound-transmitting material 221 to ensure the acoustic signal. The high precision and low distortion in the conversion process from signal to electrical signal improves the overall performance of the ultrasonic detection or communication system. The special design of the matching layer enables it to maintain a good working state under different environmental conditions, whether it is high temperature, low temperature or humidity change, it can ensure the effective transmission and reception of ultrasonic signals and improve the overall environmental adaptability. The design of the inner shell 21 not only provides physical protection for the internal components of the probe core to prevent the influence of the external environment on the sensitive components, but also its design of direct contact with the outer shell 1 contributes to the structural stability and sealing of the entire device, ensuring that the internal components can work normally in various environments. The structural design of the probe core fully considers the process requirements of the injection molding shell, making the production process of the ultrasonic sensor more convenient and lower cost, which is conducive to large-scale rapid manufacturing, shortening the product launch cycle, and meeting market demand.

[0028] Furthermore, as a preferred implementation mode of the present invention but not a limitation, the inner shell 21 is provided with a PCB board 25 for transferring electrical signals below the second core probe end face 202, and a potting glue 23 is filled between the PCB board 25 and the matching layer 22. A shielding wire 26 for transmitting electrical signals is connected to the second core probe end face 202. The inner shell 21 is a hollow cylindrical structure in the middle, and a conductor 223 is connected under the PCB board 25. The end face of the matching layer 22 for receiving ultrasonic signals is flush with the end face of the inner shell 1 close to the matching layer 22, which can reduce damage to the matching layer 22 when colliding with an object.

[0029] The working principle of this embodiment is as follows:

[0030] A manufacturing process of a rapid prototyping ultrasonic sensor includes preparing a probe core. First, a matching sound-transmitting material 221 and a ceramic strain gauge 222 are pressed and bonded. After the bonding is completed, a connecting wire 223 is welded above the ceramic strain gauge 222. The inner shell 21 and the welded ceramic strain gauge 222 are assembled, and then potting glue 23 is poured in and cured. After curing, it is assembled with a PCB. The PCB board 25 is connected to a shielded wire 26 to form the probe core 2. The probe core 2 is fixed in an injection mold. After raw material preparation, the raw material is put into the machine to heat it into a melt, and the melt is injected into the mold. After pressure holding, followed by cooling and curing, an outer shell 1 is formed. Then, it is judged whether damping glue 3 needs to be encapsulated according to actual requirements, so as to finally form a rapid prototyping ultrasonic sensor. This structure greatly shortens the processing time and improves economic benefits.

[0031] The above are the implementation manners provided in combination with specific contents, and it is not determined that the specific implementation of this application is only limited to these descriptions. Any structure similar to the method of this application, or several technical deductions or replacements made under the premise of the concept of this application, should be regarded as the protection scope of this application.

Claims

1. A rapid prototyping ultrasonic sensor, characterized in that: The invention comprises a probe core (2), wherein the probe core (2) is provided with a first probe core end face (201) for conveniently receiving ultrasonic signals, and is also provided with a second probe core end face (202) for conveniently encapsulating the internal structure of the probe core (2); a shell (1) formed by secondary injection molding inlaid on the periphery of the probe core (2); and an opening (101) for exposing the first probe core end face (201) is provided at one end of the shell (1) close to the first probe core end face (201).

2. A rapid prototyping ultrasonic sensor according to claim 1, characterized in that An annular groove (301) is provided between the outer shell (1) and the probe core (2) at the outer peripheral portion close to the first probe core end surface (201).

3. The rapid prototyping ultrasonic sensor according to claim 1, characterized in that The housing (1) is provided with a housing hole (11) for being embedded with the protruding part of the probe core, the outer periphery of the housing hole (11) is a housing upper end portion (16) which is twice injection molded and sealed, and the housing upper end portion (16) is provided with a straight housing upper end surface (15) at one end away from the second probe core end surface (202).

4. The rapid prototyping ultrasonic sensor according to claim 1, characterized in that The housing (1) is provided with a first groove (12) which is close to the second probe core end face (202) and has the same structure as the outer surface of the probe core (2). The first groove (12) includes a hollow inlay plane (121) inlaid with the second probe core end face (202). The first groove (12) also includes a first inlay surface (122) inlaid with the outer periphery of the probe core (2).

5. A rapid prototyping ultrasonic sensor according to claim 2, characterized in that : The annular groove (301) is filled with damping glue (3) for vibration reduction.

6. A rapid prototyping ultrasonic sensor according to claim 5, characterized in that The annular groove (301) includes an annular inlay plane (131) inlaid with the top of the damping glue (3), and the annular groove (301) also includes a second inlay surface (132) inlaid with the outer periphery of the damping glue (3).

7. The rapid prototyping ultrasonic sensor according to claim 1, characterized in that The probe core (2) comprises an inner shell (21) embedded with the outer shell (1); the inner shell (21) is provided with a matching layer (22) for receiving ultrasonic signals on a first probe core end face (201); the matching layer (22) comprises a matching sound-transmitting material (221); a ceramic strain gauge (222) for generating an electrical signal is attached to the end face of the matching sound-transmitting material (221) away from the first probe core end face (201); and a wire (223) for transmitting an electrical signal is connected to the end face of the ceramic strain gauge (222) away from the matching sound-transmitting material (221) 8. The rapid prototyping ultrasonic sensor according to claim 7, characterized in that The inner shell (21) is provided with a PCB board (25) for transferring electrical signals below the second probe core end surface (202), and a potting glue (23) is filled between the PCB board (25) and the matching layer (22).

9. A rapid prototyping ultrasonic sensor according to claim 8, characterized in that The second probe core end surface (202) is connected to a shielded wire (26) for transmitting electrical signals.

10. The rapid prototyping ultrasonic sensor according to claim 7, characterized in that The inner shell (21) is a cylindrical structure with a hollow center.

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