Ultrasonic sensors for powered vehicles

Abstract

The invention relates to an ultrasonic sensor system (1) for a motor vehicle, comprising a sensor housing (2) and a pan-shaped membrane (5) connected to the sensor housing (2), the membrane (5) having a membrane bottom (6) for transmitting and / or receiving ultrasonic signals and a membrane wall (7) connected to the membrane bottom (6) and partly extending into the sensor housing (2). In the housing interior space of the housing segment (9) facing the membrane bottom (6) of the sensor housing (2) a first encapsulation material (10) is arranged, which fills the housing interior space. According to the invention, the first encapsulation material (10) at least partly extends into the membrane interior space of the membrane (5) surrounded by the membrane wall (7), the membrane (5) being geometrically connected to the sensor housing (2) by the first encapsulation material (10).

Description

Technical Field

[0001] The present invention relates to an ultrasonic sensor system for a motor vehicle, comprising a sensor housing and a bowl-shaped membrane connected to the sensor housing, wherein the membrane has a membrane bottom for transmitting and / or receiving ultrasonic signals and a membrane wall connected to the membrane bottom, and a part of the membrane wall extends into the sensor housing. A first encapsulant filling the housing interior space is disposed in the housing interior space on the side of the housing segment facing the membrane bottom of the sensor housing.

Background Art

[0002] Modern motor vehicles generally belong to driver assistance devices such as, for example, parking assistance systems and / or braking assistance systems, and have a plurality of ultrasonic sensors that provide information about the surroundings of the motor vehicle, particularly obstacles and objects in the surroundings and the distance from them to the motor vehicle. Such ultrasonic sensors are arranged around the motor vehicle, at least in the front and rear regions of the vehicle, and are usually incorporated into fairing components, particularly bumpers.

[0003] At this time, such an ultrasonic sensor is usually arranged in an opening or notch of a fairing component of the motor vehicle such that the tip side or front membrane bottom of the bowl-shaped membrane of the ultrasonic sensor is essentially flush with the surface of the fairing component, provided that during operation, ultrasonic waves can be transmitted from or received at the membrane bottom.

[0004] An ultrasonic sensor belonging to the species mentioned at the beginning is known, for example, from DE102006028214A1. This ultrasonic sensor has an essentially cylindrical sensor housing and a membrane formed in a pan shape, with a disc-shaped membrane bottom supported by the sensor housing, on the inside of the membrane bottom, a piezoelectric element is arranged which can vibrate the membrane so that it generates an ultrasonic signal. The membrane is surrounded on the circumferential outer side by an annular isolation element that separates the membrane from the sensor housing in terms of vibration, and on the housing side, it is supported by an annular housing segment of the sensor housing that surrounds the circumferential outer side of the isolation element facing the sensor housing side, the isolation element and the housing segment are connected to each other via snap means. In addition, a sealing material is arranged in the internal space of the sensor housing to protect the ultrasonic sensor and its electrical components from moisture and dirt.

[0005] This type of design has the disadvantage of having a large number of parts and assembly steps, resulting in a complex manufacturing process and an overall increase in manufacturing costs. [Prior art documents] [Patent Documents]

[0006] [Patent Document 1] DE102006028214A1 [Overview of the project] [Problems that the invention aims to solve]

[0007] Therefore, the problem that the present invention aims to solve is to disclose an improved form for ultrasonic sensors in which the structure is simplified and the number of parts and assembly steps in the manufacturing process are kept as low as possible. [Means for solving the problem]

[0008] The above problem is solved by the teaching described in claim 1. Embodiments and variations suitable for the purposes of the present invention are described in the dependent claims and the following specification.

[0009] According to the description, the sensor is an ultrasonic sensor for a powered vehicle comprising a sensor housing and a pan-shaped membrane connected to the sensor housing, wherein the membrane has a membrane bottom for transmitting and / or receiving ultrasonic signals, and a membrane wall connected to the membrane bottom, and a portion of the membrane wall extends into the sensor housing, and further, a first sealing material is arranged in the internal space of the housing segment on the side of the sensor housing facing the membrane bottom to fill the internal space of the housing.

[0010] According to the present invention, the first encapsulating material is at least partially embedded in the internal space of the membrane surrounded by the membrane walls, and the membrane is shaped by the first encapsulating material relative to the sensor housing. join It is being done.

[0011] As a result, the membrane is bonded to the sensor housing by the first encapsulating material and fixed relative to the sensor housing. In other words, here the first encapsulating material has the role of sealing and mechanically separating the membrane from the sensor housing, as well as the corresponding shape join It also plays a role in forming [something].

[0012] Therefore, the embodiment of the present invention has the advantage of providing an improved form of ultrasonic sensor with a simplified structure and assembly.

[0013] To allow the membrane wall to enter the sensor housing, the outer diameter of the membrane wall is smaller than the inner diameter of the sensor housing.

[0014] It is advantageous for the membrane to be formed integrally with its bottom and membrane walls, and it is preferable that it be made of aluminum.

[0015] In one preferred embodiment, shape condition The force acts at least in the axial and circumferential directions. That is, the shape condition The joining is carried out at least in the axial and circumferential directions.

[0016] In one further preferred embodiment, a gap is formed in the internal housing space between the outside of the membrane wall that extends into the sensor housing and the inside of the housing wall of the housing segment, and the first encapsulant is at least partially contained within this gap. In this case, the first encapsulant is supported by the outside of the membrane wall and the inside of the housing wall. Preferably, the first encapsulant is fully contained within the gap, i.e., the first encapsulant completely fills the gap. This results in a reliable shape in this region, at least in the circumferential direction. Conclusion This contributes to achieving a consensus.

[0017] In one further preferred embodiment, the axial end of the membrane wall opposite the membrane bottom is provided with a ring-band-shaped projection that extends circumferentially outward, particularly around the entire circumference of the axial end of the membrane wall. This results in a particularly preferred shape. join This becomes possible. In this case, it is preferable that the projection extends circumferentially outward at a right angle to the membrane wall.

[0018] In a further preferred embodiment, the protrusions of the membrane wall are located within the first encapsulating material. department A corresponding notch is provided, and the projection is positioned within the notch, thereby shaping at least in the axial and circumferential directions. The bond It is working. In short, the first encapsulant here corresponds to the surrounding projection and has a notch for receiving the projection, but in the assembled state, the first filler material completely surrounds the projection.

[0019] In a further preferred embodiment, a ring-shaped flexible molded body is disposed within the axial segment of the gap on the side facing the bottom side of the membrane, and the protrusion is placed on the molded body, and its shape Conclusion engagement acts axially. In short, in this case, the shape Conclusion engagement acts through the first encapsulant and the flexible molded body.

[0020] In a further preferred embodiment, the first encapsulant extends circumferentially to the inner side of the housing wall of the housing segment within the internal space of the housing, and the first encapsulant extends circumferentially to the inner side of the membrane wall within the internal space of the membrane.

[0021] In a further preferred embodiment, the first encapsulant extends circumferentially to the inner side of the bottom of the membrane within the internal space of the membrane. At this time, it is preferable that the first encapsulant completely fills the internal space of the membrane. At this time, the first encapsulant Conclusion not only forms an engagement, but particularly preferably also plays a role in vibration damping in the membrane bottom and / or the membrane wall.

[0022] In a further preferred embodiment, the first encapsulant is integrally formed from a first material. It is advantageous that the first material is made of an elastomer, a thermoplastic resin, a thermosetting resin, or a silicon material.

[0023] In a further preferred embodiment, the first encapsulant extends only along one segment of the membrane wall facing away from the membrane bottom in the axial direction within the internal space of the membrane. However, a second encapsulant is disposed in direct contact with the first encapsulant, extending axially from the first encapsulant to the inside of the membrane bottom and circumferentially to the inside of the membrane wall within the internal space of the membrane. At this time, it is advantageous that the first encapsulant is made of a first material and the second encapsulant is made of a second material different from the first material. In addition, it is particularly preferable that the second encapsulant serves as a vibration damper in the region of the membrane bottom and / or the membrane wall facing the membrane bottom side at this time.

Brief Description of the Drawings

[0024] Hereinafter, embodiments of the present invention will be described in more detail based on the drawings. Explanation of the figures: [Figure 1a] The ultrasonic sensor is shown as an exploded perspective view, [Figure 1b] The ultrasonic sensor according to FIG. 1a is shown as a cross-sectional view, [Figure 2a] The ultrasonic sensor in an alternative embodiment is shown as an exploded perspective view, [Figure 2b] The ultrasonic sensor according to FIG. 2a is shown as a cross-sectional view, [Figure 3a] The ultrasonic sensor of a further alternative embodiment is shown as an exploded perspective view, [Figure 3b] The ultrasonic sensor according to FIG. 3a is shown as a cross-sectional view, [Figure 4a] The ultrasonic sensor of a further alternative embodiment is shown as an exploded perspective view, [Figure 4b] The ultrasonic sensor according to FIG. 4a is shown as a cross-sectional view, [Figure 5a] The ultrasonic sensor of a further alternative embodiment is shown as an exploded perspective view, and [Figure 5b] shows the ultrasonic sensor according to FIG. 5a as a cross-sectional view.

Modes for Carrying Out the Invention

[0025] In all diagrams, corresponding parts are always given the same symbol.

[0026] Figures 1a and 1b depict one embodiment of the ultrasonic sensor 1 from different angles. Figure 1a shows the ultrasonic sensor 1 as an exploded view, while Figure 1b shows it as a cross-sectional view.

[0027] The ultrasonic sensor 1 includes a integrally formed sensor housing 2 with a plurality of connection pins 3, and a wiring board 4 disposed within the sensor housing 2 and connected to the connection pins 3. The ultrasonic sensor 1 also includes a pan-shaped membrane 5 connected to the sensor housing 2, the membrane 5 having a membrane bottom 6 for transmitting and / or receiving ultrasonic signals, and a membrane wall 7 connected to the membrane bottom 6, with a portion of the membrane wall 7 extending into the sensor housing 2. Inside the membrane bottom 6 is a disc-shaped piezoceramic, electrically connected to the wiring board 4. At the axial end of the sensor housing 4 opposite to the membrane 5, the sensor housing 2 is closed by a cover 8.

[0028] Within the housing internal space of the housing segment 9 on the side of the sensor housing 2 facing the membrane bottom 6, a first encapsulating material 10 is placed to completely fill this internal space. This first encapsulating material 10 is integrally formed from a first material, particularly preferably an elastomer, thermoplastic, thermosetting material, or silicon material.

[0029] The first encapsulating material 10 extends circumferentially R within the internal space of the sensor housing 2, reaching the inside of the housing wall of the housing segment 9 of the sensor housing 2. At this time, the first encapsulating material 10 completely fills the gap formed between the outside of the membrane wall 7 that extends into the sensor housing 2 and the inside of the housing wall of the housing segment 9.

[0030] In addition, the first encapsulating material 10 extends into the internal space of the membrane 5, which is surrounded by the membrane walls 7. The first encapsulating material 10 extends circumferentially R to the inside of the membrane walls 7, and axially Z to the inside of the membrane bottom 6. That is, the first encapsulating material 10 completely encloses the internal space of the membrane. to This is met, and the membrane base 6 and membrane wall 7 play a role in vibration damping.

[0031] Furthermore, a ring-band shaped projection 11 is provided at the axial end of the membrane wall 7 opposite to the membrane bottom 6, perpendicular to the membrane wall 7 and extending circumferentially outward, surrounding the entire circumference of the axial end of the membrane wall 7. This projection 11 is positioned within the first encapsulating material 10 and engages with a notch corresponding to the projection 11, and the first encapsulating material 10 is configured to completely surround the projection 11.

[0032] This form and arrangement of the first encapsulating material 10 provides a reliable configuration for the sensor housing 2 and the inside of the membrane 5, as well as for the membrane 5, particularly its protrusions 11, acting in the axial Z and circumferential R directions. condition A suitable configuration has been achieved, that is, the first encapsulating material 10 provides not only a sealing function, vibration damping between the membrane bottom 6 and the membrane wall 7, and mechanical separation between the membrane 5 and the sensor housing 2, but also appropriate shape condition It also plays a role in forming a bond and, consequently, in reliably fixing the membrane 5 to the sensor housing 2.

[0033] Figures 2a and 2b depict an alternative embodiment of the ultrasonic sensor 1 from different angles. Figure 2a shows the ultrasonic sensor 1 as an exploded view, while Figure 2b shows it as a cross-sectional view.

[0034] This ultrasonic sensor 1 is essentially the same as the ultrasonic sensor 1 shown in Figures 1a to 1b, but here the ultrasonic sensor 1 also has a second encapsulation material 12 in addition to the first encapsulation material 10.

[0035] Here, the first encapsulating material 10 extends within the internal space of the membrane in the axial direction Z, along only one segment of the membrane wall 7 opposite to the membrane bottom 6, but the second encapsulating material 12 is positioned in direct contact with the first encapsulating material 10. The second encapsulating material 12 is 、 Within the internal space of the membrane, the second encapsulating material 12 extends axially Z from the first encapsulating material 10 to the inside of the membrane bottom 6, and circumferentially R to the inside of the membrane wall 7. In this case, the second encapsulating material 12 is formed from a second material different from the first material of the first encapsulating material 10. Here, the second encapsulating material 12 plays a particularly important role in vibration damping in the region of the membrane bottom 6 and the membrane wall 7 facing the membrane bottom 6. In this case, a material particularly suitable for vibration damping can be used as the second material.

[0036] Figures 3a and 3b depict another alternative embodiment of the ultrasonic sensor 1 from different angles. Figure 3a shows the ultrasonic sensor 1 as an exploded view, and Figure 3b shows it as a cross-sectional view.

[0037] This ultrasonic sensor 1 is essentially the same as the ultrasonic sensor 1 shown in Figures 1a to 1b, but here, in addition to the first encapsulating material 10, the ultrasonic sensor 1 also has a ring-shaped flexible molded body 13.

[0038] The flexible molded body 13 is positioned in the axial region facing the membrane bottom 6 within the gap between the outside of the membrane wall 7 that extends into the sensor housing 2 and the inside of the housing wall of the housing segment 9 of the sensor housing 2. At this time, the projection 11 formed on the membrane wall 7 contacts the molded body 13, and the shape in the axial direction Z Conclusion It acts as a combination. In short, here, shape Conclusion The bonding is acted upon via the first encapsulating material 10 and the flexible molded body 13.

[0039] Figures 4a and 4b depict another alternative embodiment of the ultrasonic sensor 1 from different angles. Figure 4a shows the ultrasonic sensor 1 as an exploded view, and Figure 4b shows it as a cross-sectional view.

[0040] This ultrasonic sensor 1 is essentially the same as the ultrasonic sensor 1 shown in Figures 2a to 2b, but here, in addition to the first encapsulation material 10, the ultrasonic sensor 1 also has a ring-shaped flexible molded body 13.

[0041] The flexible molded body 13 itself is positioned in the axial region facing the membrane bottom 6, between the outside of the membrane wall 7 that extends into the sensor housing 2 and the inside of the housing wall of the housing segment 9 of the sensor housing 2, but the protrusions 11 formed on the membrane wall 7 rest on the molded body 13, and as a result, condition The force acts in the axial direction Z. In short, here in particular, shape condition The bonding is acted upon via the first encapsulating material 10 and the flexible molded body 13.

[0042] Figures 5a and 5b depict another alternative embodiment of the ultrasonic sensor 1 from different angles. Figure 5a shows the ultrasonic sensor 1 as an exploded view, and Figure 5b shows it as a cross-sectional view.

[0043] The ultrasonic sensor 1 is essentially the same as the ultrasonic sensor 1 shown in Figures 1a to 1b, but here the sensor housing 2 is formed in a hollow cylindrical shape within the axial end region on the side facing the membrane bottom 6, and a single front cap 14 is connected to the sensor housing 2 by a snap connection in this axial end region.

[0044] Furthermore, it will be obvious to those skilled in the art that such a configuration, equipped with a similar sensor housing 2 and a similar front cap 14, can also be applied to the embodiments shown in Figures 2a to 4b. This application relates to the invention described in the claims, but also includes the following other embodiments. 1. Sensor housing (2) And, Connected to the sensor housing (2) An ultrasonic sensor for a powered vehicle comprising a pan-shaped membrane (5) , Membrane (5) Membrane base (6) for transmitting and / or receiving ultrasonic signals And, Me Membrane wall (7) connected to the membrane bottom (6) and to have death, Applicable A portion of the membrane wall (7) is inserted into the sensor housing (2). hand, Se Nsa Housing (2) 、 A first sealing material (10) for filling the internal space of the housing segment (9) on the side facing the membrane bottom (6) is provided for a powered vehicle. super It is a sound wave sensor, The first encapsulating material (10) is at least partially embedded in the internal space of the membrane (5) surrounded by the membrane wall (7). , applicable The membrane (5) is formed by the first encapsulating material (10) and the shape of the sensor housing (2). join An ultrasonic sensor (1) characterized by the following: 2. shape Conclusion The ultrasonic sensor (1) described above, characterized in that the force acts in at least one axial direction (Z) and at least one circumferential direction (R). 3. The ultrasonic sensor (1) according to the 1 or 2 above, characterized in that a gap is formed in the internal housing space between the outside of the membrane wall (7) that is inserted into the sensor housing (2) and the inside of the housing wall of the housing segment (9), and the first sealing material (10) is at least partially inserted into the gap. 4. An ultrasonic sensor (1) of any one of the above characteristics, characterized in that a ring-band-shaped projection (11) is provided at the axial end of the membrane wall (7) opposite to the membrane bottom (6), surrounding the axial end of the membrane wall (7) and extending outward in the circumferential direction. 5. A notch corresponding to the projection (11) of the membrane wall (7) is provided within the first encapsulating material (10). , applicable The projection (11) is positioned within the notch, thereby allowing at least the axis Direction (Z) and circumferential direction (R ) shape join The ultrasonic sensor (1) described above, characterized in that the above-mentioned 4 is in operation. 6. A ring-shaped flexible molded body (13) is positioned within the axial segment of the gap on the side facing the membrane bottom (6), and the projection (11) rests on the molded body (13). ,shape condition Conclusion If Center Acts in the direction (Z) Let An ultrasonic sensor (1) characterized by having any one of the above 2 to 4. 7. The first sealing material (10) is located within the internal space of the housing. 、 Circumferential direction (R) to , Ha Any one of the above ultrasonic sensors (1) is characterized in that the first encapsulating material (10) extends to the inside of the housing wall of the wodging segment (9), and the first encapsulating material (10) extends to the inside of the membrane wall (7) in the circumferential direction (R) within the membrane internal space. 8. Any one of the above ultrasonic sensors (1), characterized in that the first encapsulating material (10) extends axially (Z) within the internal space of the membrane to the inside of the membrane bottom (6). 9. An ultrasonic sensor device (1) of any one of the above, characterized in that the first encapsulating material (10) is integrally formed from the first material. 10. An ultrasonic sensor (1) according to any one of 1 to 8 above, characterized in that the first encapsulating material (10) extends within the internal space of the membrane in the axial direction (Z) along only one segment of the membrane wall (7) facing away from the membrane bottom (6), but a second encapsulating material (12) is arranged in direct contact with the first encapsulating material (10) and extends within the internal space of the membrane from the first encapsulating material (10) in the axial direction (Z) to the inside of the membrane bottom (6) and in the circumferential direction (R) to the inside of the membrane wall (7). [Explanation of symbols]

[0045] 1. Ultrasonic sensor 2 Sensor Housings 3 connection pins 4 Wiring board 5 Membrane 6. Membrane base 7 Membrane wall 8 Covers 9. Sensor housing housing segments 10. First encapsulating material 11 Protrusion 12. Second encapsulation material 13 Molded body 14 Front cap R circumferential direction Z axis direction

Claims

1. The device comprises a sensor housing (2) and a pot-shaped membrane (5) connected to the sensor housing (2). The membrane (5) has a membrane bottom (6) for transmitting and / or receiving ultrasonic signals, and a membrane wall (7) connected to the membrane bottom (6). A portion of the membrane wall (7) extends into the sensor housing (2), An ultrasonic sensor for a powered vehicle, wherein a first sealing material (10) that fills the internal space of the housing segment (9) on the side of the sensor housing (2) facing the membrane bottom (6) is disposed within the internal space of the housing, An ultrasonic sensor (1) characterized in that the first encapsulating material (10) is integrally formed, the first encapsulating material (10) is at least partially embedded in the internal space of the membrane (5) surrounded by the membrane wall (7), the membrane (5) is shape-coupled to the sensor housing (2) by the first encapsulating material (10), and the shape coupling acts in the axial direction (Z) and the circumferential direction (R).

2. The ultrasonic sensor (1) according to claim 1, characterized in that a gap is formed in the internal housing space between the outside of the membrane wall (7) that extends into the sensor housing (2) and the inside of the housing wall of the housing segment (9), and the first sealing material (10) is at least partially inserted into the gap.

3. The ultrasonic sensor (1) according to claim 1 or 2, characterized in that a ring-band-shaped projection (11) extending circumferentially outward is provided at the axial end of the membrane wall (7) opposite to the membrane bottom (6), surrounding the axial end of the membrane wall (7).

4. The ultrasonic sensor (1) according to claim 3, characterized in that a notch corresponding to a projection (11) of the membrane wall (7) is provided in the first encapsulating material (10), the projection (11) is positioned within the notch, and a shape coupling acts at least in the axial direction (Z) and the circumferential direction (R).

5. The ultrasonic sensor (1) according to claim 3, characterized in that a ring-shaped flexible molded body (13) is positioned within the axial segment of the gap on the side facing the membrane bottom (6), the projection (11) rests on the molded body (13), and the shape coupling is applied in the axial direction (Z).

6. The ultrasonic sensor (1) according to claim 1 or 2, characterized in that the first encapsulating material (10) extends in the circumferential direction (R) within the internal space of the housing to the inside of the housing wall of the housing segment (9), and the first encapsulating material (10) extends in the circumferential direction (R) within the internal space of the membrane to the inside of the membrane wall (7).

7. The ultrasonic sensor (1) according to claim 1 or 2, characterized in that the first encapsulating material (10) extends in the axial direction (Z) within the internal space of the membrane to the inside of the membrane bottom (6).

8. The first encapsulating material (10) extends within the internal space of the membrane, in the axial direction (Z), along only one segment of the membrane wall (7) that faces away from the membrane bottom (6). The ultrasonic sensor (1) according to claim 1 or 2, characterized in that a second encapsulating material (12) is arranged in direct contact with the first encapsulating material (10) and extends within the internal space of the membrane from the first encapsulating material (10) axially (Z) to the inside of the membrane bottom (6) and circumferentially (R) to the inside of the membrane wall (7).

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