Method for installing an ultrasonic sensor on a body component in a covered manner
Patent Information
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2024-04-11
- Publication Date
- 2026-03-04
AI Technical Summary
Concealed mounting of ultrasonic sensors on vehicle body components is challenging due to the risk of air bubbles forming between the sensor membrane and the metal component, which can lead to malfunctions and aesthetic damage when excessive force is applied to ensure bubble-free contact.
A method involving the use of a damping material with an opening on the body component, pre-assembling the ultrasonic sensor, and applying a suction cup with negative pressure to ensure the sensor membrane lies flush against the component without bubbles, allowing for controlled forces exceeding 50 N without damaging the component.
This method achieves a stable, bubble-free coupling between the ultrasonic membrane and the body component, improving measurement precision, reducing reject rates, and allowing for precise, high-force application without risk of damage.
Smart Images
Figure EP2024059780_31102024_PF_FP_ABST
Abstract
Description
[0001] METHOD FOR CONCEALED MOUNTING OF AN ULTRASOUND SENSOR ON
[0002] A BODY COMPONENT
[0003] The present invention relates to the field of automotive ultrasonic sensors and, more particularly, to a method for concealed mounting of an ultrasonic sensor on a body component.
[0004] Motor vehicles are equipped with ultrasonic sensors that are used to measure the vehicle's surroundings by means of emitted and received reflected ultrasonic signals. The sensors use the measured information about possible reflection locations of the ultrasonic signals in the vehicle's surroundings, which represent potential obstacles, to provide assistance functions such as partially or fully autonomous parking, a blind spot assistance function, a door opening assistance function, and the like. The ultrasonic sensors can be mounted openly or covertly. In an open mounting, an ultrasonic membrane of the openly mounted ultrasonic sensor is exposed in an opening in a body component. In a covert mounting, the ultrasonic membrane is coupled to the body component, and a section of the body component coupled to the ultrasonic membrane oscillates together with the ultrasonic membrane.
[0005] Concealed mounting is preferred for aesthetic reasons, but also to better protect the ultrasonic sensor from environmental influences.
[0006] With a concealed ultrasonic sensor, it is important that the ultrasonic membrane sits flush against the body component without bubbles; otherwise, malfunctions of the concealed ultrasonic sensor are to be expected.
[0007] When an ultrasonic sensor is concealed on the inside of a metal body component, such as a vehicle door or bumper, warping and air bubbles can easily develop between the ultrasonic membrane and the body component. To achieve the necessary freedom from bubbles, the sensor can be pressed against the metal component by hand or with a tool. However, this risks creating a dent in the metal component if forces of more than 5 kg (50 N) are applied. If higher forces are to be applied, a suitable counterforce must be provided, which complicates installation and carries the risk of aesthetic damage to the exterior of the body component. Furthermore, with this type of installation, there is no certainty that the required force was applied long enough to achieve freedom from bubbles, so that rejects are inevitable.
[0008] Against this background, the object of the present invention is to improve the process of concealed mounting of ultrasonic sensors on body components.
[0009] Accordingly, a method for concealed mounting of an ultrasonic sensor on a body component is proposed, comprising: arranging a damping material with an opening on an inner side of the body component; pre-assembling the ultrasonic sensor such that an end face of a diaphragm cup of the ultrasonic sensor comes into surface contact with the inner side of the body component within the opening of the damping material; placing a suction cup onto the body component with the damping material arranged thereon and the pre-assembled ultrasonic sensor such that an outer peripheral wall of the suction cup rests on the damping material and an inner support element of the suction cup rests on the ultrasonic sensor; and creating a negative pressure in the suction cup, whereby the suction cup adheres to the body component by suction and the inner support element presses the ultrasonic sensor against the body component.
[0010] By creating a vacuum and pressing the ultrasonic sensor against the body component, it is advantageously possible to ensure that the ultrasonic membrane rests against the inside of the body component without any bubbles.
[0011] Creating a negative pressure can also be referred to as creating a vacuum, whereby a vacuum does not necessarily mean an absolute vacuum, but a relative vacuum is sufficient as long as there is a negative pressure inside the suction cup compared to the atmospheric pressure outside the suction cup.
[0012] In particular, the vacuum can advantageously remove any air bubbles between the membrane surface and the body component. Furthermore, the negative pressure allows a contact force significantly higher than 50 N to be applied in a controlled and uniform manner without fear of damage. This advantageously achieves a flush, bubble-free coupling between a surface of the ultrasonic membrane and an inner surface of the body component.
[0013] As a result of the improved bubble-free coupling between the ultrasonic membrane and the body component, the operating characteristics of the measuring system formed by the ultrasonic sensor and the section of the body component coupled thereto are advantageously improved, and the measuring system can provide more precise, less error-prone measurement data.
[0014] It is also advantageous to reduce the scrap rate in the production of assemblies made of body components with ultrasonic sensors mounted on them in a concealed manner from the inside.
[0015] In particular, it is understood that the ultrasonic hood can be returned to normal pressure and removed after the ultrasonic sensor has been pressed against the body component. Accordingly, an assembly manufactured according to the proposed method can comprise, in particular, the body component, the damping material attached thereto, and the ultrasonic sensor finally assembled, particularly by the action of the vacuum, but not the suction cup, which is a tool for final assembly.
[0016] The body component can be, for example, a door for a motor vehicle, a side skirt for a motor vehicle, a bumper for a motor vehicle, or any other body component. Arranging the damping material can comprise attaching the damping material to the inside of the body component by gluing or the like. Arranging the damping material can also comprise preforming the damping material on the inside of the body component, for example, by applying a paste and subsequent curing or the like. The damping material can comprise butyl, purely by way of example.The damping material has the particularly advantageous function of damping vibrations of the undamped section of the body component coupled to the ultrasonic membrane against other sections of the body component during operation of the ultrasonic sensor, so that the assembly consisting of the undamped body component section and the ultrasonic membrane coupled to it can exhibit clearly defined vibration modes and natural frequencies. The opening can be arranged centrally in the damping material.
[0017] Pre-assembling the ultrasonic sensor may involve using a holding tool to hold the ultrasonic sensor in the position required for the pressing action that takes place in the subsequent steps. It is also conceivable to use a holding element, which is attached, for example, to the body component or the damping material, and in which the ultrasonic sensor is mounted and thus pre-assembled.
[0018] According to one embodiment, an adhesive and sound-conducting contact pad is arranged on the ultrasonic membrane of the ultrasonic sensor and, when the ultrasonic sensor is pre-assembled, is in surface contact with the inside of the body component.
[0019] The adhesive and sound-conducting contact pad can advantageously ensure a permanent, bubble-free acoustic coupling of the ultrasonic membrane with the interior of the body component. According to a further embodiment, when a vacuum is created, a pressure of 150 N or more, preferably 200 N or more, and most preferably 250 N or more, is exerted on the ultrasonic sensor.
[0020] Accordingly, a stable, bubble-free coupling between the ultrasonic membrane and the inner surface of the body component can be created with particularly high certainty and a rejection rate can be further reduced.
[0021] In particular, the proposed method can advantageously be used to exert forces in the said area without risking damage to the body component or the ultrasonic sensor.
[0022] According to a further embodiment, the suction cup has a cylinder which is movable in the axial direction and which, when the suction cup is attached, is aligned coaxially with the ultrasonic membrane of the ultrasonic sensor and whose end face facing the ultrasonic sensor forms the inner support element of the suction cup, which rests on an end face of the ultrasonic sensor axially opposite the ultrasonic membrane.
[0023] Accordingly, for a given negative pressure, the force exerted on the ultrasonic sensor when pressing can be clearly defined, in particular, the desired force can be appropriately controlled and selected by adjusting the diameter of the movable cylinder.
[0024] In particular, the suction cup may have an axial hollow cylindrical opening into which the movable cylinder is inserted and against which the movable cylinder closes hermetically.
[0025] According to a further embodiment, the outer peripheral wall of the suction cup has a door. With the door open, the suction cup is pushed from the side over the damping material and the pre-assembled ultrasonic sensor, and the door is then closed. This means that the suction cup, with the damping material and the pre-assembled ultrasonic sensor arranged thereon, can be placed on the body component by pushing the suction cup from the side over the damping material and the ultrasonic sensor.
[0026] Accordingly, the space required for placing the suction cup on the assembly consisting of the body component, damping material and pre-assembled ultrasonic sensor is reduced and the ultrasonic sensor can also be mounted in confined spaces, for example, in particular when the body component is already installed in a motor vehicle.
[0027] The door can, for example, be a sliding door.
[0028] According to a further embodiment, the pre-assembly of the ultrasonic sensor comprises: attaching a holding element for the ultrasonic sensor to the damping material and inserting the ultrasonic sensor into the holding element such that the ultrasonic membrane within the opening of the damping material comes into planar contact with an inner side of the body component.
[0029] The holding element is in particular an element that remains after the assembly of the ultrasonic sensor in the assembly thus produced consisting of the body component, damping material, holding element and ultrasonic sensor.
[0030] The holding element advantageously enables easy pre-assembly of the ultrasonic sensor and also enables easy later replacement of the ultrasonic sensor, for example, in the event of a defect. For this purpose, the defective ultrasonic sensor can be removed from the holding element and a new ultrasonic sensor inserted into the holding element. The suction cup can then be used again to couple the new ultrasonic sensor to the body component without bubbles. According to a further embodiment, the suction cup has a further internal support element that rests on the holding element when the suction cup is in place and presses on the holding element when a vacuum is created.
[0031] Accordingly, in embodiments that use the holding element, a separate operation for pressing the holding element against the damping material, such as rolling, is advantageously eliminated, and the holding element can be pressed against the damping material and the body element together with the ultrasonic sensor in a single operation.
[0032] According to a further embodiment, the further inner support element is formed from a plurality of columns which rest on the holding element at a plurality of points, or the further inner support element is formed by a stamp which rests on the holding element over its entire surface.
[0033] "Fully covering" means that the stamp covers a surface of the retaining element running parallel to the body component, such as a flange section of the retaining element, not just at specific points, but across the entire surface, in particular by more than 50%, preferably more than 75%. However, it is not necessary for the surface of the retaining element running parallel to the body component to be completely covered.
[0034] With a fully supported ram, more even pressure can be exerted on the retaining element than with multiple columns resting at specific points. In contrast, the multiple columns offer the advantage of leaving more space within the suction cup and simplifying the placement of the suction cup on the assembly consisting of the body component, damping material, retaining element, and ultrasonic sensor.
[0035] According to a further embodiment, the ultrasonic sensor comprises a cylindrical housing component and a cylindrical diaphragm cup inserted into a front opening of the cylindrical housing component, the front surface of which forms the ultrasonic diaphragm; the holding element comprises a first hollow cylindrical section, the inner contour of which corresponds to an outer contour of the cylindrical housing component, a second hollow cylindrical section, the inner contour of which corresponds to an outer contour of the cylindrical diaphragm cup and the outer contour of which corresponds to an inner contour of the opening, and a flange section; the holding element is attached to the damping material in such a way that the flange section rests on the damping material and the second hollow cylindrical section is inserted into the opening of the damping material.and the ultrasonic sensor is inserted into the holding element in such a way that the diaphragm cup lies flush with the second hollow cylindrical section of the holding element and the cylindrical housing section lies flush with the first hollow cylindrical section of the holding element.;
[0036] Accordingly, the ultrasonic sensor is advantageously seated firmly in the holding element without any gaps, and the holding element is preferably seated firmly in the opening of the sealing material without any gaps.
[0037] The first hollow cylindrical section, the second hollow cylindrical section and the flange section can be formed in one piece, in particular in one piece.
[0038] According to a further development, during the pre-assembly, after the ultrasonic sensor has been inserted into the holding element, a holding clip can be placed on the assembly consisting of the holding element and the ultrasonic sensor, which holds the ultrasonic sensor in the holding element.
[0039] The retaining clip can have an opening through which, in the subsequent assembly step, the inner support element of the suction cup presses against the ultrasonic sensor under the effect of the negative pressure. Alternatively, during the assembly step, the inner support element of the suction cup can press against the retaining clip and, via the retaining clip, against the ultrasonic sensor. According to a further aspect, a motor vehicle with a body component is proposed, on which an ultrasonic sensor is concealedly mounted according to the proposed method.
[0040] The embodiments and features described for the proposed method apply accordingly to the proposed motor vehicle.
[0041] Further possible implementations of the invention also include combinations of features or embodiments described above or below with respect to the exemplary embodiments not explicitly mentioned. In this case, the person skilled in the art will also add individual aspects as improvements or additions to the respective basic form of the invention.
[0042] Further advantageous embodiments and aspects of the invention are the subject of the dependent claims and the exemplary embodiments of the invention described below. The invention will be explained in more detail below using preferred embodiments with reference to the accompanying figures.
[0043] Fig. 1 illustrates steps of a proposed manufacturing method according to embodiments;
[0044] Fig. 2 shows an assembly comprising a body component, damping material, holding element and pre-assembled ultrasonic sensor according to embodiments;
[0045] Fig. 3 shows a sectional view of a suction cup mounted on the assembly of Fig. 2 according to a first embodiment;
[0046] Fig. 4 shows a sectional view of a suction cup mounted on the assembly of Fig. 2 according to a second embodiment; and Fig. 5 shows a sectional view of a suction cup mounted on the assembly of Fig. 2 according to a further development of the second embodiment.
[0047] Fig. 6 shows a suction cup according to a further development of the second embodiment; and
[0048] Fig. 7 shows a motor vehicle with a concealed ultrasonic sensor.
[0049] In the figures, identical or functionally equivalent elements have been given the same reference numerals unless otherwise stated.
[0050] Fig. 1 illustrates steps of a proposed manufacturing method according to exemplary embodiments. Fig. 2 shows an assembly comprising a body component, damping material, retaining element, and pre-assembled ultrasonic sensor according to exemplary embodiments. Fig. 3 shows a sectional view of a suction cup mounted on the assembly of Fig. 2 according to a first exemplary embodiment. Reference is made to Figs. 1 to 3.
[0051] The body component 1 is a sheet-metal body component, such as a door panel or a bumper of a motor vehicle, such as an automobile. In step S1 of the proposed method, a damping material 2 is arranged in a substantially circular region of the body component 1. The damping material 2 can be, for example, butyl, which adheres to the body component by adhesion. The damping material 2 has a substantially circular, central opening 7 (Fig. 3).
[0052] Then, in step S2, a holding element 3 having a first hollow-cylindrical section 4, a flange section 5, and a second hollow-cylindrical section 6 (Fig. 3) is attached to the damping material 2. Specifically, the holding element 3 can be glued to the damping material, and by rolling the flange section 5, a firm connection between the holding element 3 and the damping material 2 can be established. It should be noted that, according to the first exemplary embodiment, the holding element 3 is arranged such that an inner circumference of the second hollow-cylindrical section 6 is aligned flush with an inner circumference of the central opening 7 of the damping material 2.
[0053] Furthermore, in step S2, an ultrasonic sensor 8 is inserted into the holding element 3. The ultrasonic sensor 8 has a cylindrical housing component 9 and a diaphragm cup 10 inserted into a front opening of the cylindrical housing component 9. An inner contour of the first hollow-cylindrical section 4 of the holding element 3 corresponds to an outer contour of the cylindrical housing component 9 of the ultrasonic sensor 8, so that they lie flush against one another.
[0054] An adhesive and sound-conducting contact pad 13 is attached, for example glued, to an end face 12 of the diaphragm cup 10 of the ultrasonic sensor 8, which forms an ultrasonic membrane 12 of the ultrasonic sensor 8.
[0055] With the insertion of the thus configured ultrasonic sensor 8 into the holding element 3, a process of preassembling the ultrasonic sensor 8 is completed. The ultrasonic membrane 12 of the ultrasonic sensor 8 is in planar contact with the inside of the body component 1 within the central opening 7 of the damping material, and the cylindrical housing section 9 of the ultrasonic sensor 9 is held in the first hollow cylindrical section 4 of the holding element 3.
[0056] In this preassembled state, the ultrasonic membrane 12, the contact pad 13, and a section of the body component 1 contacted therewith and not covered by the damping material 2 form a vibrating membrane that can be set into vibration, for example, with a piezo element (not shown) that can be attached to an inner side of the ultrasonic membrane 12, in order to emit ultrasonic waves, or can receive incoming ultrasonic waves and be set into vibration by them, whereby the incoming ultrasonic waves can be registered by the piezo element. The damping material 2 ensures that vibrations of the section of the body component 1 contacted by the contact pad 13 do not propagate into other sections of the body component 1, thus ensuring defined natural frequencies and vibration modes of the vibrating membrane.
[0057] However, in the pre-assembled state, air bubbles may still be present between the ultrasonic membrane 12 and the contact pad 13 and / or between the contact pad 13 and the inside of the body component 1, which may impair the operating properties of the ultrasonic sensor 8 and the oscillatory membrane.
[0058] Accordingly, in step S3, a suction cup 14 is placed on the assembly shown in Fig. 2 and Fig. 3, comprising the body component 1 with the damping material 2 arranged thereon and the pre-assembled ultrasonic sensor 8, such that an outer peripheral wall 15 of the suction cup 14 rests on the damping material 2 and several internal support elements 17 of the suction cup 14 rest on the ultrasonic sensor 8. In particular, the support elements 17 rest on an end face 18 of the ultrasonic sensor 8 axially opposite the ultrasonic membrane 12.
[0059] The suction cup 14 further comprises an intake port 16 which is connected to a vacuum pump (not shown) via a hose (not shown).
[0060] In step S4, a negative pressure (for example a vacuum) is created in the suction cup 14 by pumping out the air from an interior of the suction cup 14 through the suction nozzle 16 and the hose using the vacuum pump.
[0061] As a result, the suction cup adheres to the body component 1, the vacuum sucks away any air bubbles between the ultrasonic sensor 8 and the body component 1, and the internal support elements 17 of the suction cup press the ultrasonic sensor 18 against the body component 1. This advantageously creates a firm, bubble-free coupling between the ultrasonic membrane 12, the contact pad 13, and the body component 1.
[0062] The pressure force to be exerted can be controlled by regulating the negative pressure or the pumping power of the vacuum pump, and the pressure force to be exerted is applied evenly to the entire ultrasonic sensor 8.
[0063] Advantageously, by creating a suitable negative pressure or vacuum in the suction cup 14, a compressive force of 150 N, 200 N, 250 N or more can be achieved without causing deformation of the body component 1.
[0064] It should be noted that preferably the first hollow cylindrical section 4 and the second hollow cylindrical section 6 of the holding element 3 are not formed in a ring shape around the entire circumference of the cylindrical housing component 9 or the membrane top 10, but have at least one vertically extending slot in at least one sectional plane not shown in Fig. 3, so that the slot allows air to pass between the interior of the suction bell 14 and the membrane cup 10, the contact pad 19 and the body component 1 within the hollow cylindrical sections 4 and 6. In this way, the vacuum created inside the suction bell 14 can advantageously suck out air bubbles between the membrane cup 10, the contact pad 19 and the body component 1.
[0065] Fig. 4 shows a sectional view of a suction cup mounted on the assembly of Fig. 2 according to a second embodiment. The following description focuses on the differences between the second embodiment and the first embodiment. Identical or functionally equivalent elements and / or steps will not be described again. Reference is made to Fig. 4 and Fig. 1.
[0066] According to the second embodiment, the configurations of the holding element 3 and the suction cup 14 differ from those of the corresponding elements according to the first embodiment. First, the suction cup 14 of the second embodiment will be described.
[0067] The suction cup 14 has an axial, hollow-cylindrical opening 20 into which a movable cylinder 19 is inserted. An end face 17 of the movable cylinder 19 facing the ultrasonic sensor 8 forms an internal support element 17 of the suction cup 14. When air is sucked out of the interior of the suction cup 14 through the intake port 16 using the vacuum pump (not shown), the movable cylinder 19 is pulled downward in Fig. 4 and presses against the end face 18 of the ultrasonic sensor 8.
[0068] Accordingly, the pressure exerted on the ultrasonic sensor 8 in step S4 is advantageously distributed evenly across the entire end face 18 of the ultrasonic sensor 8. In addition, the force exerted upon pressing on the ultrasonic sensor 8 can advantageously be regulated more precisely. This force depends on the diameter of the movable cylinder 19. Thus, for a given pumping power of the vacuum pump, the desired pressure force can be clearly defined by selecting a suitable diameter of the movable cylinder 19.
[0069] The suction cup 14 also has further internal support elements 21, which are designed as respective columns 21 that rest at several points on the flange section 5 of the holding element 3. Accordingly, in step S4, when the air is pumped out of the suction cup 14, not only is the cylinder 19 pressed against the ultrasonic sensor 8, but the suction cup 14 also additionally presses on the holding element 8 via the columns 21. According to the second exemplary embodiment, a work step of pressing or rolling the holding element 3 against the sealing material 2 can therefore advantageously be omitted in step S2, and the adhesive connection of the holding element 3 to the sealing material 2 can be established in the same work step in which the ultrasonic membrane 12 is coupled to the body component 1, namely by creating the negative pressure inside the suction cup 14.The holding element 3 of the second embodiment differs from the holding element 3 of the first embodiment in that the second hollow-cylindrical section 6 of the holding element 3 of the second embodiment is not arranged flush with the central opening 7 of the damping material, but rather that the second hollow-cylindrical section 6 is inserted into the central opening 7 of the damping material 2. An outer contour of the second hollow-cylindrical section 6 corresponds to an inner contour of the central opening 7, so that they lie flush against one another. An inner contour of the second hollow-cylindrical section 6 corresponds to an outer contour of the cylindrical diaphragm cup 10 of the ultrasonic sensor 8, so that they lie flush against one another.This advantageously ensures an even tighter fit of the ultrasonic sensor 8 in the holding element 3, since the diaphragm cup 10 of the ultrasonic sensor 8 is now held even better in the second hollow-cylindrical section 6 of the holding element 3.
[0070] Fig. 5 shows a sectional view of a suction cup placed on the assembly from Fig. 2 according to a further development of the second exemplary embodiment. Reference is made to Fig. 5 and Fig. 1. After pre-assembly in step S2 or after the vacuum has been created following completion of step S4, a holding clip 11 is placed from above onto the hollow cylindrical section 6 of the holding element 3, which holds and fixes the ultrasonic sensor 8 in the hollow cylindrical section 6 of the holding element 3 after the suction cup 14 has been removed again. If the holding clip is attached before the suction cup 14 is placed on, the inner support element 17 of the suction cup can rest on the holding clip (not shown in Fig. 5) and exert pressure on the end face 18 of the ultrasonic sensor 8 via the holding clip in step S4, or the inner support element 17 can, as in Fig.5, through an opening of the retaining clip 11, for example a circular opening, they rest directly on a central portion of the end face 18 of the ultrasonic sensor 8 and exert pressure thereon, whereas an outer peripheral edge of the end face 18 is held by the retaining clip 11.
[0071] Fig. 6 shows a suction cup 14 according to a further development of the second exemplary embodiment. The suction cup 14 of the further development is similar to the suction cup 14 of the second exemplary embodiment or its development and likewise has the movable cylinder 19. In addition, however, the outer wall 15 of the suction cup 14 of the development has a sliding door 22. This offers the advantage that, in step S3, with the sliding door 22 open, the suction cup 14 can be pushed from the side over the assembly shown in Fig. 2 with the pre-assembled ultrasonic sensor 8 and can thus be placed onto it and does not need to be placed onto it from above. Thus, the concealed installation of the ultrasonic sensor 8 is simplified with the proposed method, even in confined spaces, for example when installation takes place in a state in which the body component 1 is already installed in a motor vehicle.
[0072] Fig. 7 shows a motor vehicle 100 with an ultrasonic sensor 8 mounted in a concealed manner, for example, behind a bumper 101 (example of a body component 1 in Fig. 2) of the motor vehicle 100. The assembly took place according to the proposed method according to one of the exemplary embodiments or its modifications. While the embodiment from Fig. 6 does not differ from a motor vehicle with an ultrasonic sensor mounted in a conventional manner upon visual inspection, it can be expected that the ultrasonic sensor 8 mounted in a concealed manner according to the proposed method will operate with fewer errors, deliver more precise measured values, and / or that a lower reject rate will result when manufacturing a plurality of motor vehicles 100 or a plurality of bumpers 101 with concealed ultrasonic sensors 8.
[0073] Although the present invention has been described using exemplary embodiments, it can be modified in many ways.
[0074] Both embodiments show that the ultrasonic sensor 8 is pre-assembled using a holding element 3 attached to the damping material 2. However, this configuration is not required. The holding element 3 can also be attached to the body component 1, or the ultrasonic sensor 8 can also be held in position with a tool (not shown) that is not attached to the body component 1 or the damping material 2; in the latter case, the suction cup 14 can have a sealed passage for inserting the tool.
[0075] The sliding door 22 shown in the further development of the second embodiment can also be a folding door or another type of door. Furthermore, a modification of the suction cup 14 of the first embodiment with a door is also conceivable.
[0076] In the second exemplary embodiment, additional internal support elements 21 of the suction cup 14, which rest on the holding element 3, were described as a plurality of columns 21 that press on the flange section 5 of the holding element 3 at a plurality of points. However, it is conceivable to form a stamp (round stamp with a hollow cylindrical central opening) instead of the plurality of columns 21, which rests over substantially the entire exposed section of the flange section 5. Accordingly, the pressure can be exerted even more evenly on the holding element 3.
[0077] In the second exemplary embodiment, the second cylindrical section 6 of the holding element 3 does not necessarily need to be inserted into the central opening 7 of the damping material 2, but can be designed analogously to the first exemplary embodiment and only touch a section of the diaphragm cup 10 above the sealing material 2. Conversely, in the first exemplary embodiment, the second cylindrical section 6 of the holding element 3 can also be inserted into the central opening 7 of the damping material 2, as in the second exemplary embodiment, and touch the diaphragm cup 10 over its entire length protruding from the cylindrical housing component 9.
[0078] The retaining clip 11 of the further development of the second embodiment can also be used in a further development of the first embodiment. LIST OF REFERENCE SYMBOLS
[0079] 1 body component
[0080] 2 Damping material
[0081] 3 Holding element
[0082] 4 first hollow cylindrical section
[0083] 5 Flange section
[0084] 6 second hollow cylindrical section
[0085] 7 central opening in the damping material
[0086] 8 Ultrasonic sensor
[0087] 9 cylindrical housing section
[0088] 10 diaphragm pot
[0089] 11 Retaining clip
[0090] 12 Ultrasonic membrane, front side of the membrane cup
[0091] 13 Contact pad
[0092] 14 Suction cup
[0093] 15 Outer wall of the suction cup
[0094] 16 intake manifolds
[0095] 17 internal support element
[0096] 18 End face of the ultrasonic sensor, which is axially opposite the ultrasonic membrane
[0097] 19 movable cylinder
[0098] 20 hollow cylindrical opening
[0099] 21 additional internal support element
[0100] 22 sliding door
[0101] 100 motor vehicles
[0102] 101 bumpers
Claims
PATENT CLAIMS 1. A method for concealed mounting of an ultrasonic sensor (8) on a body component (1), comprising: Arranging (S1) a damping material (2) with an opening (7) on an inner side of the body component (1), Pre-assembling (S2) the ultrasonic sensor (8) in such a way that an ultrasonic membrane (12) of the ultrasonic sensor (8) within the opening (7) of the damping material (2) comes into surface contact with the inside of the body component (1), Placing (S3) a suction cup (14) on the body component (1) with the damping material (2) arranged thereon and the pre-assembled ultrasonic sensor (8) such that an outer peripheral wall (15) of the suction cup (14) rests on the damping material (2) and an inner support element (17) of the suction cup (14) rests on the ultrasonic sensor (8), and Creating (S4) a negative pressure in the suction cup (14), whereby the suction cup (14) sucks itself onto the body component (1) and the internal support element (17) presses the ultrasonic sensor (8) against the body component (1).
2. Method according to claim 1, characterized in that an adhesive and sound-conducting contact pad (13) is arranged on the ultrasonic membrane (12) of the ultrasonic sensor (8) and, when the ultrasonic sensor (8) is pre-assembled, is in planar contact with the inside of the body component (1).
3. Method according to one of the preceding claims, characterized in that when the negative pressure is established, a pressure of 150 N or more, preferably of 200 N or more, most preferably of 250 N or more, is exerted on the ultrasonic sensor (8).
4. Method according to one of the preceding claims, characterized in that the suction cup (14) has a cylinder (19) which is movable in the axial direction and which, when the suction cup (14) is in place, is aligned coaxially with the ultrasonic membrane (12) of the ultrasonic sensor (8) and whose end face facing the ultrasonic sensor (8) forms the inner support element (17) of the suction cup (14), which rests on an end face (18) of the ultrasonic sensor (8) which is axially opposite the ultrasonic membrane.
5. Method according to one of the preceding claims, characterized in that the outer peripheral wall (15) of the suction cup (14) has a door (22) and the suction cup (14) is pushed from the side over the damping material (2) and the pre-assembled ultrasonic sensor (8) with the door (22) open and then the door (22) is closed.
6. Method according to claim one of the preceding claims, characterized in that the pre-assembly (S2) of the ultrasonic sensor (8) comprises: Attaching a holding element (3) for the ultrasonic sensor (8) to the damping material (2) and Inserting the ultrasonic sensor (8) into the holding element (3) in such a way that the ultrasonic membrane (12) within the opening (7) of the damping material (2) comes into planar contact with an inner side of the body component (1).
7. Method according to claim 6, characterized in that the suction cup (14) has a further internal support element (21) which, when the suction cup (14) is in place, rests on the holding element (3) and presses on the holding element (3) when negative pressure is established.
8. Method according to claim 7, characterized in that the further inner support element is formed from (21) several columns which rest on the holding element (3) at several points, or the further inner support element (21) is formed by a stamp which rests over its entire surface on the holding element (3).
9. Method according to one of claims 6 to 8, characterized in that the ultrasonic sensor (8) has a cylindrical housing component (9) and a cylindrical diaphragm cup (10) inserted into a front opening of the cylindrical housing component (9), the front surface of which forms the ultrasonic membrane (12), the holding element (3) is a hollow cylindrical holding element which has a first hollow cylindrical section (4), the inner contour of which corresponds to an outer contour of the cylindrical housing component (9), a second hollow cylindrical section (6), the inner contour of which corresponds to an outer contour of the cylindrical diaphragm cup (10) and the outer contour of which corresponds to an inner contour of the opening (7), and a flange section (5), the holding element (3) is attached to the damping material (2) in such a way,that the flange section (5) rests on the damping material (2) and the second hollow cylindrical section (6) is inserted into the opening (7) of the damping material (2), the ultrasonic sensor (8) is inserted into the holding element (3) in such a way that the diaphragm cup (10) lies flush against the second hollow cylindrical section (6) of the holding element (3) and the cylindrical housing section (9) lies flush against the first hollow cylindrical section (4) of the holding element (3).
10. Motor vehicle (100) with a body component (101) on which an ultrasonic sensor (8) is mounted concealed according to a method according to one of claims 1 to 9.