A high pressure resistant ultrasonic sensor structure

Abstract

The utility model relates to ultrasonic sensor technical field discloses a kind of high-pressure-resistant ultrasonic sensor structure, coaxially arranged briquetting, wire passing device, main structure and sensor shell are sequentially included;The main structure is columnar, and first cavity is arranged in, first cavity upper part is wider, and the peripheral dimension of wider place corresponds briquetting and wire passing device;The inner wall upper part of main structure is arranged with the first internal thread matched with the upper external thread of briquetting;The outer wall of main structure is sequentially formed from top to bottom six prism section, first external thread, first annular groove section and second external thread;First annular groove section outer wall forms the first annular groove that has first O ring;The wire passing device is inlaid at least two copper columns;Second cavity is arranged in the sensor shell, and sensor sealing layer is arranged in the bottom of second cavity, piezoelectric ceramic sheet is arranged in the inboard of sensor sealing layer, second internal thread is arranged in the inner wall upper part of sensor shell.

Description

Technical Field

[0001] This utility model relates to the field of ultrasonic sensor technology, and in particular to a high-pressure resistant ultrasonic sensor structure. Background Technology

[0002] Against the backdrop of continuous technological progress and industrial upgrading, ultrasonic sensors, with their unique technological advantages such as non-contact measurement, high precision, high sensitivity, and good directionality, play an irreplaceable and crucial role in numerous industries, becoming a core element driving technological innovation and industrial upgrading. However, in recent years, the structural problems of traditional ultrasonic sensors have become increasingly prominent in practical applications, becoming a key factor restricting their further development. Especially in working conditions requiring the withstand of high ultrasonic pressure, the pressure-bearing capacity and sealing performance of traditional sensors are significantly insufficient.

[0003] In terms of pressure resistance, the structural design of traditional ultrasonic sensors is often unable to effectively withstand the impact of external high-pressure environments. When faced with high-pressure conditions, the sensor housing is prone to deformation, leading to damage to the internal structure and affecting the normal operation of the sensor. Regarding sealing performance, the sealing structure design of traditional sensors is not perfect, and the selection of sealing materials and sealing processes also have certain defects. The external high-pressure environment acts like a powerful pressure source, constantly impacting the sensor's sealing defenses, making leakage at the sealing points prone to occur. Once the seal fails, the external high-pressure airflow will enter, interfering with the working environment of the internal piezoelectric ceramic sheet, resulting in unstable and inaccurate measurement data. More seriously, the high-pressure airflow may directly damage the precision components inside the sensor, causing the sensor to completely fail and cease normal operation.

[0004] From a cost perspective, pressure-resistant ultrasonic sensors, in order to achieve their pressure-resistant function, are often overly complex in structure, with numerous internal components and an unreasonable layout. Too many components not only increase the amount of raw materials used but also increase the difficulty of the manufacturing process. During manufacturing, more advanced materials and more precise processing techniques are required, along with more stringent quality inspection and control, which undoubtedly increases production costs. Furthermore, the complex structure leads to higher maintenance and repair costs, further increasing the user's operating costs. In the installation phase, the complex structure of pressure-resistant ultrasonic sensors presents a significant challenge to installers. Due to the numerous internal components and complex connections, installers need to spend considerable time and effort ensuring the correct installation and connection of each component. During installation, even a small mistake can lead to a decrease in sensor performance or even malfunction. Utility Model Content

[0005] To address the existing problems, this utility model provides a high-pressure resistant ultrasonic sensor structure, which aims to improve the pressure resistance and sealing performance of ordinary ultrasonic sensors, while also being easy to install and providing stable measurement.

[0006] To achieve the above objectives, the present invention provides the following technical solution.

[0007] A high-pressure resistant ultrasonic sensor structure comprises, in sequence, a pressure block, a wire guide device, a main structure, and a sensor housing. The main structure is columnar and has a through first cavity. The upper part of the first cavity is wider, corresponding to the outer dimensions of the pressure block and the wire guide device. The upper part of the inner wall of the main structure has a first internal thread that matches the external thread of the upper part of the pressure block. The outer wall of the main structure forms a hexagonal prism segment, a first external thread, a first annular groove segment, and a second external thread sequentially from top to bottom. The outer wall of the first annular groove segment forms a first annular groove that accommodates a first O-ring. The wire guide device has at least two embedded copper pillars. The sensor housing has a second cavity, a sensor sealing layer at the bottom of the second cavity, a piezoelectric ceramic sheet inside the sensor sealing layer, and a second internal thread on the upper part of the inner wall of the sensor housing.

[0008] As a further improvement of this utility model, the wire guiding device is columnar, and the outer wall forms a second annular groove that accommodates the second O-ring.

[0009] As a further improvement of this utility model, the lower part of the pressure block is formed into a cylindrical segment.

[0010] As a further improvement of this utility model, two cylindrical grooves are symmetrically arranged on the top of the pressure block.

[0011] As a further improvement of this utility model, the outer diameters of the hexagonal prism segment, the first external thread, the first annular groove segment, and the second external thread of the main structure decrease sequentially.

[0012] As a further improvement of this utility model, the bottom outer wall of the sensor housing is narrowed to form a slit.

[0013] As a further improvement of this utility model, the copper pillar and the wire guide device are sintered with Kovar alloy and hard glass.

[0014] As a further improvement of this utility model, the sensor sealing layer includes a first sensor matching layer and a second sensor matching layer.

[0015] As a further improvement of this utility model, cylindrical grooves are provided at the top and bottom of the wire guiding device.

[0016] As a further improvement of this utility model, epoxy resin is disposed inside the cylindrical groove.

[0017] This utility model has the following beneficial effects:

[0018] This coaxial arrangement of the pressure block, wire guide device, main structure, and sensor housing provides a stable overall architecture for the ultrasonic sensor, facilitating the installation and coordination of each component. The different sections of the main structure's outer wall also aid in sensor installation, sealing, and connection. Two O-rings reduce friction between the wire guide device and the main structure during installation, improve sealing of gaps, and enhance pressure resistance through their dual design. The pressure block stably presses the wire guide device into the first cavity of the main structure, and the pressure block is threaded into the first cavity to improve the pressing strength and gap sealing.

[0019] Preferably, the outer wall of the wire-passing device is provided with a second annular groove to accommodate the second O-ring. The second O-ring can play a sealing role, preventing external media (such as liquids, gases, etc.) from entering the sensor from the connection between the wire-passing device and surrounding components, thereby enhancing the sensor's sealing performance and helping to improve the stability and reliability of the sensor under high-pressure environments.

[0020] Preferably, the lower part of the pressure block forms a cylindrical segment. This structure can better fit with the first cavity of the main structure, making the pressure block more accurately positioned during installation, ensuring the connection stability and coaxiality between the pressure block and the main structure, and thus ensuring the stability and performance consistency of the entire sensor structure.

[0021] Preferably, two cylindrical grooves are symmetrically provided on the top of the pressure block, which facilitates the rotation of the pressure block using tools (such as screwdrivers), making it easier to install and disassemble the pressure block and improving the convenience of sensor assembly and maintenance.

[0022] Preferably, the outer diameters of the hexagonal prism segment, the first external thread, the first annular groove segment, and the second external thread of the main structure decrease sequentially. This design meets the actual needs of installation and connection. The hexagonal prism segment facilitates rotational operation using tools; the external thread segment with gradually decreasing outer diameter can be connected to components of different specifications, and the first annular groove segment is equipped with an O-ring to achieve a seal. The overall structure optimizes space utilization and sealing effect while satisfying installation and connection functions, which helps improve the performance of the sensor under high-pressure environments.

[0023] Preferably, the bottom outer wall of the sensor housing is narrowed to form a slit. This design may help reduce the weight of the bottom of the sensor housing, lower the overall center of gravity, and make the sensor more stable during installation and use. At the same time, the slit may change the stress distribution at the bottom of the housing to a certain extent, improve the compressive strength of the housing, and enhance the sensor's ability to withstand high-pressure environments.

[0024] Preferably, the copper pillar and the wire guide device are sintered with Kovar alloy and hard glass. Kovar alloy has good sintering performance and a matching coefficient of thermal expansion with copper and other metals. When hard glass is sintered and sealed together, its reliability is higher, which can ensure that the copper pillar and the wire guide device are firmly sealed, forming a reliable electrical and mechanical connection, ensuring the stability of signal transmission. At the same time, the sintering of Kovar alloy and glass can also adapt to temperature and pressure changes under high pressure environment to a certain extent, improving the reliability and durability of the sensor.

[0025] Preferably, the sensor sealing layer includes a first sensor matching layer and a second sensor matching layer. This double-layer sealing structure provides a more reliable sealing effect. Even if one sealing layer is slightly damaged or leaks, the other sealing layer can still function as a seal, effectively preventing external media from entering the sensor and greatly improving the sensor's sealing performance and reliability under high-pressure environments.

[0026] Preferably, cylindrical grooves are provided at the top and bottom of the wire guiding device. These cylindrical grooves can provide better fixing and protection space for internal circuits such as copper pillars, preventing the circuits from being damaged by external force pulling or vibration during sensor use, and ensuring the stability of signal transmission. At the same time, the cylindrical grooves also help with the installation and cooperation of the wire guiding device with other components.

[0027] Optionally, epoxy resin can be placed inside the cylindrical groove. Epoxy resin has excellent insulation, sealing, and bonding properties. It can fill the gaps inside the cylindrical groove, further fixing the copper pillars and other wiring, and preventing the wiring from loosening. At the same time, the sealing effect of epoxy resin can prevent external media from entering the cylindrical groove and corroding the wiring, improving the insulation and corrosion resistance of the wiring, thereby enhancing the stability and reliability of the sensor under high-voltage environments. Attached Figure Description

[0028] The accompanying drawings described herein are for illustrative purposes only and do not limit the scope of this invention in any way. Furthermore, the shapes and proportions of the components in the drawings are merely schematic to aid in understanding the invention and do not specifically limit the shapes and proportions of the components. In the drawings:

[0029] Figure 1 This is an overall diagram of a high-pressure resistant ultrasonic sensor structure as described in Example 1;

[0030] Figure 2 This is a schematic diagram of the pressure block of a high-pressure resistant ultrasonic sensor structure as described in Example 1;

[0031] Figure 3 This is a schematic diagram of the wire-passing device for a high-voltage resistant ultrasonic sensor structure as described in Example 1;

[0032] Figure 4 This is a schematic diagram of the main structure of a high-pressure resistant ultrasonic sensor structure as described in Example 1;

[0033] Figure 5 This is a schematic diagram of the sensor housing of a high-pressure resistant ultrasonic sensor structure as described in Example 1;

[0034] Figure 6 This is a diagram showing the lead wires and external wiring connections for a high-voltage resistant ultrasonic sensor structure as described in Example 1.

[0035] The components are as follows: 1. Pressure block; 2. Wire guide device; 3. Main structure; 4. Sensor housing; 5. Top cylindrical groove; 6. Upper external thread of pressure block; 7. Second cavity; 8. Cylindrical section; 9. Copper pillar; 10. Second annular groove; 11. Second O-ring; 12. Cylindrical groove; 13. First internal thread; 14. Hexagonal prism section; 15. First external thread; 16. First cavity; 17. First annular groove; 18. First O-ring; 19. First annular groove section; 20. Second external thread; 21. Second internal thread; 22. Lead wire; 23. Piezoelectric ceramic sheet; 24. Cutout; 25. First sensor matching layer; 26. Second sensor matching layer; 27. External connection wire. Detailed Implementation

[0036] To enable those skilled in the art to better understand the technical solutions of this utility model, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort should fall within the protection scope of this utility model.

[0037] It should be noted that when an element is referred to as being "set on" another element, it can be directly on the other element or there may be an intervening element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only embodiments.

[0038] Unless otherwise defined below, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0039] Example 1

[0040] like Figure 1 As shown, a high-pressure resistant ultrasonic sensor structure includes, from top to bottom, a pressure block 1, a wire guide device 2, a main structure 3, and a sensor housing 4.

[0041] Press 1 is ring-shaped and hollow inside, as shown Figure 2 As shown, two cylindrical grooves 5 are drilled at the top, which can be inserted into the grooves to facilitate connection with the main structure 3; the upper end of the pressure block 1 is machined with an external thread 6, which mates with the first internal thread 13 of the main structure 3; the middle of the pressure block 1 is hollow, which facilitates the passage of the external connection wire 27 of the sensor; the lower end of the pressure block 1 is cylindrical, with an outer diameter smaller than the external thread 6, which facilitates connection with the main structure 3.

[0042] The wire guide device 2 is cylindrical, such as Figure 3 As shown, two copper pillars 9 pass through the wire-passing device 2 at the center, connecting the sensor lead 22 and the external connection 27 via the copper pillars 9. This provides good sealing, isolating the inside and outside of the sensor and increasing its pressure resistance. The outer wall of the wire-passing device 2 is provided with two annular grooves, which are the second annular grooves 10, through which two second O-rings 11 can be installed. The two second O-rings 11 can reduce the dynamic friction between the wire-passing device 2 and the main structure 3 during installation, and after installation, the elasticity will increase the static friction and sealing performance. The top and bottom of the wire-passing device 2 are provided with cylindrical grooves 12, and epoxy resin is poured into the cylindrical grooves 12 to prevent the connection between the wire-passing device 2 and the sensor lead 22 from breaking or short-circuiting.

[0043] like Figure 4As shown, the main structure 3 is a hollow hexagonal bolt. The upper part of the main structure 3 is a hexagonal prism section 14, and the outer wall of the hexagonal prism facilitates connection to the flow meter using a wrench. The top inner wall of the main structure 3 is machined with a first internal thread 13, which can mate with the external thread 6 on the upper part of the pressure block. The middle part of the main structure 3 is provided with a first external thread 15 that matches the flow meter, which matches the internal thread of the flow meter, allowing the sensor and the flow meter to be connected. The hollow inner cavity of the main structure 3 is a first cavity 16, used to house the wire guide device 2. After connecting to the external connection 27, rotate two times and insert into the first cavity 16; the lower middle part of the main structure 3 is the first annular groove section 19, which is provided with a first annular groove 17, and two first O-rings 18 can be installed; the two first O-rings 18 can reduce dynamic friction when the main structure 3 is installed into the flow meter cavity, and after installation, the elasticity will increase static friction and sealing performance, and enhance its pressure bearing capacity; the lower part of the main structure 3 is provided with a second external thread 20, which can match the second internal thread 21 in the sensor housing 4.

[0044] The sensor housing 4 is a hollow cylinder, such as... Figure 5 As shown, a second cavity 7 is provided inside the sensor housing 4, and the second cavity 7 has an internal thread to facilitate mating and connection with the second external thread 20 of the main structure 3; the cylindrical bottom of the sensor housing 4 is sealed by a first sensor matching layer 25 and a second sensor matching layer 26. A piezoelectric ceramic sheet 23 is disposed on the innermost first sensor matching layer 25, and the piezoelectric ceramic sheet 23 is the main component of the sensor; cutouts 24 are provided on both sides of the bottom of the sensor housing 4 to reduce the weight of the sensor matching layer and facilitate the connection between the sensor and the flow meter. The lead wire 22 of the piezoelectric ceramic sheet 23 is connected to the bottom of the copper pillar 9 of the wire guide device 2.

[0045] Example 2

[0046] The difference between this embodiment and Embodiment 1 is that:

[0047] 1) The lower part of the pressing block 1 forms a cylindrical segment 8.

[0048] The lower part of the pressure block 1 forms a cylindrical segment 8. This structure can better fit with the first cavity 16 of the main structure 3, making the positioning of the pressure block 1 more accurate during installation, ensuring the connection stability and coaxiality between the pressure block 1 and the main structure 3, and thus ensuring the stability and performance consistency of the entire sensor structure.

[0049] Advantages of this utility model:

[0050] The pressure resistance of ordinary ultrasonic sensors can be increased to over 10 MPa by using the solution of this patent.

[0051] Ordinary ultrasonic sensors are connected by threads and do not have sealing properties. However, this patent uses a wire-passing device 2 to separate the inner cavity of the ultrasonic sensor containing the piezoelectric ceramic sheet 23 from the outside world, and uses copper pillars 9 to connect the external connection wire 27 and lead wire 22. The wire-passing device 2 improves the sensor's ability to withstand external pressure.

[0052] Kovar alloy and hard glass are sintered together to seal the copper pillar 9 to the wire guide device 2. The copper pillar 9 leads out the sensor lead 22, which can both protect the transmission needs of the cable and increase the pressure resistance.

[0053] The pressure block 1 and the wire guide device 2 are designed as coaxial components to achieve a sealing function. With this coaxial structure, the second O-ring 11 in the wire guide device will function as a seal. This not only effectively prevents the lead wire 22 from getting stuck in the gap and being pulled off, as is common in traditional methods, but also allows the epoxy resin to flow smoothly into the cylindrical groove 12 of the wire guide device 2 during injection, further enhancing the sealing effect.

[0054] The above embodiments are merely one of the implementation methods for achieving the technical solution of this utility model. The scope of protection claimed by this utility model is not limited to this embodiment, but also includes any variations, substitutions, and other implementation methods that are easily conceived by those skilled in the art within the scope of the technology disclosed in this utility model. Although embodiments of this utility model have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of this utility model. The scope of this utility model is defined by the appended claims and their equivalents.

Claims

1. A high-pressure resistant ultrasonic sensor structure, characterized in that, The device comprises, in sequence, a pressure block, a wire guide device, a main structure, and a sensor housing arranged coaxially. The main structure is columnar and has a through first cavity. The upper part of the first cavity is wider, corresponding to the outer dimensions of the pressure block and the wire guide device. The upper part of the inner wall of the main structure has a first internal thread that matches the external thread on the upper part of the pressure block. The outer wall of the main structure forms a hexagonal prism segment, a first external thread, a first annular groove segment, and a second external thread from top to bottom. The outer wall of the first annular groove segment forms a first annular groove that accommodates a first O-ring. The wire guide device has at least two embedded copper pillars. The sensor housing has a second cavity, a sensor sealing layer at the bottom of the second cavity, a piezoelectric ceramic sheet inside the sensor sealing layer, and a second internal thread on the upper part of the inner wall of the sensor housing.

2. The high-pressure resistant ultrasonic sensor structure according to claim 1, characterized in that, The wire guiding device is columnar, and its outer wall forms a second annular groove that accommodates a second O-ring.

3. The high-pressure resistant ultrasonic sensor structure according to claim 1, characterized in that, The lower part of the pressing block forms a cylindrical section.

4. The high-pressure resistant ultrasonic sensor structure according to claim 1, characterized in that, The top of the pressure block is symmetrically provided with two top cylindrical grooves.

5. The high-pressure resistant ultrasonic sensor structure according to claim 1, characterized in that, The outer diameters of the hexagonal prism segment, the first external thread, the first annular groove segment, and the second external thread of the main structure decrease sequentially.

6. The high-pressure resistant ultrasonic sensor structure according to claim 1, characterized in that, The bottom outer wall of the sensor housing narrows to form a cut.

7. The high-pressure resistant ultrasonic sensor structure according to claim 1, characterized in that, The copper pillars and wire guides are sintered with hard glass using Kovar alloy.

8. The high-pressure resistant ultrasonic sensor structure according to claim 1, characterized in that, The sensor sealing layer includes a first sensor matching layer and a second sensor matching layer.

9. The high-pressure resistant ultrasonic sensor structure according to claim 1, characterized in that, The top and bottom of the wire guiding device are provided with cylindrical grooves.

10. The high-pressure resistant ultrasonic sensor structure according to claim 9, characterized in that, Epoxy resin is placed inside the cylindrical groove.

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