Sensor structure for casting concrete

Abstract

[Problem] To reduce the thickness of a sensor structure for casting concrete. [Solution] At least one electric component 6 is mounted to a circuit board 5 to form an electric circuit. A recessed portion 5a is provided in the circuit board 5 and is recessed from one of surfaces of the circuit board 5. A sensor unit 4 includes a detection unit 4a which is exposed to the outside so as to face a filling space for the concrete and a pressure sensor which detects a pressure at the detection unit 4a. This sensor unit 4 is accommodated in the recessed portion 5a.

Description

Sensor structure for pouring concrete

[0001] The present invention relates to a sensor structure for pouring concrete, and more particularly to a thin sensor structure.

[0002] Conventionally, when constructing concrete structures such as tunnels, bridges, levees, and building foundations, pressure sensors are used to monitor the condition of the concrete filled in the filling space. For example, Patent Document 1 discloses a tunnel lining arch concrete pouring control sensor that detects the pressure in a filling space formed between the natural ground wall and a movable formwork when fresh concrete is filled into the filling space. As shown in Figure 9, this fresh concrete pouring control sensor 20 is small and protected by a mold 21. Multiple sensors 20 are installed directly on the natural ground wall or on a waterproof sheet attached to the wall using adhesive or the like. Furthermore, this sensor 20 is connected to a data processing box located near the work site via a communication cable 22.

[0003] Patent No. 6179767

[0004] Meanwhile, construction sites require that pressure sensors installed in filled spaces be small. Because pressure sensors are embedded inside concrete or similar materials, the concrete is damaged by an amount equal to the size of the sensor. Therefore, a large sensor size may affect the strength and long-term durability of the structure. In this regard, in the above-mentioned Patent Document 1, the pressure sensor (fresh concrete pouring control sensor) is attached to the surface of a circuit board and protrudes above the board by the height of the pressure sensor, leaving room for miniaturization in the height direction, i.e., thinning.

[0005] The present invention has been made in view of the above circumstances, and its object is to make a sensor structure for pouring concrete thinner.

[0006] To solve this problem, the present invention provides a sensor structure for pouring concrete, which includes a circuit board, at least one electrical component, a first recess, and a sensor unit. The at least one electrical component is attached to the circuit board to form an electrical circuit. The first recess is provided in the circuit board and recessed from one surface of the circuit board. The sensor unit includes a detection section exposed to the outside so as to face the filling space of the concrete, and a pressure sensor that detects the pressure of the detection section. The sensor unit is housed in the first recess.

[0007] In the present invention, the first recess is preferably a through-hole penetrating the front and back of the circuit board. The electrical component is preferably electrically connected to a bottom terminal of the sensor unit housed in the first recess. Furthermore, the sensor unit may have a temperature sensor for detecting the temperature of the detection portion.

[0008] In the present invention, the circuit board may be provided with a second recess recessed from the other surface opposite to the one surface of the circuit board. In this case, it is preferable that the electrical component is accommodated in the second recess.

[0009] The present invention may further include a thin-plate resistive sensor attached to one surface of the circuit board. The present invention may also include a third recess and an acceleration sensor. The third recess is provided in the circuit board and is recessed from the other surface opposite the one surface of the circuit board. The acceleration sensor is housed in the third recess.

[0010] According to the present invention, the sensor structure can be made thinner by accommodating the sensor unit in the first recess and embedding it in the circuit board, thereby reducing damage to concrete due to the size of the sensor structure and effectively reducing the possibility of a decrease in the strength and long-term durability of the structure.

[0011] Overall view of the sensor structure Perspective view of the sensor unit Cross-sectional view of the sensor body Cross-sectional view of the sensor body according to the first modified example Cross-sectional view of the sensor body according to the second modified example Cross-sectional view of the sensor body according to the third modified example Descriptive view of a data management system for a plurality of sensor structures Descriptive view of a data management system using wireless communication Descriptive view of the prior art

[0012] FIG. 1 is an overall view of a sensor structure for pouring concrete according to this embodiment. This sensor structure 1 is used to detect the pressure of concrete or similar materials (e.g., mortar, grout, etc.) filled in a predetermined filling space and to grasp the filling condition when constructing structures such as tunnels, bridges, levees, and building foundations. In this specification, concrete and similar materials are collectively referred to as "concrete." The sensor structure 1 includes a sensor main body 2 and a cable 3. The sensor main body 2 is small and thin, measuring, for example, approximately 2 cm in length and width and 4 mm in height, and incorporates a sensor unit 4 (see FIG. 2 ). The sensor main body 2 has a detection section 4a on its top surface, exposed to the outside and facing the filling space of the concrete. The condition of the filled concrete is detected via the detection section 4a. The cable 3 is connected to the sensor main body 2. The cable 3 serves to supply power to the sensor main body 2 and to output signals from the sensor main body 2 to the outside.

[0013] 2 is a perspective view of the sensor unit 4. The above-mentioned detection unit 4a is provided at the top of the sensor unit 4, and a pressure sensor that detects the pressure of the detection unit 4a is provided inside the housing. In this embodiment, in addition to the pressure sensor, a temperature sensor that detects the temperature of the detection unit 4a is also provided. Furthermore, a rectangular base 4b is provided at the bottom of the sensor unit, and a plurality of bottom terminals 4c are provided at the four corners of the underside of this base 4b.

[0014] FIG. 3 is a cross-sectional view of the sensor body 2. The sensor body 2 is mainly composed of an insulating circuit board 5, at least one electrical component 6, and the sensor unit 4 described above. The circuit board 5 may be either a rigid board such as a glass epoxy board or a flexible board. The circuit board 5 has a recess 5a recessed from the upper surface of the circuit board 5, and the sensor unit 4 is housed in this recess 5a. In this embodiment, the recess 5a is a circular through-hole that penetrates the front and back of the circuit board 5. The sensor unit 4, which has a substantially cylindrical head, is inserted into the recess 5a from below, and the sensor unit 4 is fixed to the circuit board 5 with the lower surface of the circuit board 5 abutting against the rectangular base 4b. By embedding the sensor unit 4 in the circuit board 5 using the recess 5a in this way, the sensor body 2 is made thinner than a structure in which the sensor unit 4 is attached to the surface of the circuit board 5.

[0015] The electrical components 6 are components that constitute an electrical circuit including the sensor unit 4, and are typically integrated circuits (ICs). The electrical components 6 are attached to the underside of the circuit board 5 and are electrically connected to the bottom terminals 4c of the sensor unit 4 housed in the recess 5a. The circuit board 5 on which the sensor unit 4 and electrical components 6 are assembled is covered with a resin layer 7 that is thick enough to prevent the detection unit 4a from being exposed, in order to prevent the intrusion of water and other external elements. An adhesive layer 8, such as double-sided tape, is provided on the underside of the resin layer 7 to facilitate the installation of the sensor structure 1 at the installation location. The adhesive layer 8 is preferably butyl double-sided tape, which absorbs any unevenness on the adhesive surface.

[0016] Modified structures of the sensor body 4 will be described below with reference to FIGS. 4 to 6. Note that the same components as those in FIG. 3 are designated by the same reference numerals, and their description will be omitted. FIG. 4 is a cross-sectional view of the sensor body 2 according to a first modified example. In this modified example, the recess 5a is formed as a step having a predetermined depth rather than a through-hole, and the sensor unit 4 is housed therein. A contact hole 5d penetrating vertically is provided at the bottom of the recess 5a, and electrical connection between the bottom terminal 4c of the sensor unit 4 and the electrical component 6 is made via the contact hole 5d. By embedding the sensor unit 4 in the circuit board 5 using the stepped recess 5a in this way, the sensor body 2 can be made somewhat thinner, although not as thin as the configuration in FIG. 3.

[0017] 5 is a cross-sectional view of a sensor main body 2 according to a second modified example. In this modified example, a recess 5b is provided in the circuit board 5 at a mounting location of the electrical component 6, recessed from the underside of the circuit board 5, and the electrical component 6 is housed in this recess 5b. By embedding the electrical component 6 in the circuit board 5 using the recess 5b in this way, the sensor main body 2 can be made even thinner than the configuration shown in FIG.

[0018] 6 is a cross-sectional view of a sensor main body 2 according to a third modified example. In this modified example, in addition to the sensor unit 4, multiple resistive sensors 9 and an acceleration sensor 10 are added. The resistive sensors 9 are thin plates and are attached to the upper surface of the circuit board 5. A recess 5c is provided on the circuit board 5 at the mounting location of the acceleration sensor 10, recessed from the lower surface of the circuit board, and the acceleration sensor 10 is housed in this recess 5c. By embedding the acceleration sensor 10 in the circuit board 5 using the recess 5c in this way, a thin structure can be achieved even when multiple sensors are integrated.

[0019] FIG. 7 is an explanatory diagram of a centralized management system for multiple sensor structures 1. This system includes multiple sensor structures 1, a hub 11, and a recorder 13. The multiple sensor structures 1 are installed at different locations in the concrete filling space, and monitor the filling status of the concrete at each installation location. Pressure data and temperature data acquired by the multiple sensor structures 1 are collected by the hub 11 and then centrally recorded by the recorder 13. The recorder 13 stores the pressure data and temperature data received from the hub 11 and displays the pressure data and temperature data for each installation location on a screen. This allows a viewer of the screen of the recorder 13 to view the data for each installation location in an integrated manner. The recorder 13 may also calculate the developed strength of the concrete using temperature and time data.

[0020] 8 is an explanatory diagram of a centralized management system using wireless communication. In this system, pressure data and temperature data acquired by a plurality of sensor structures 1 are wirelessly transmitted from a transmitter 14 to a receiver 12, and stored in a recorder 13 on the receiver 12 side. When a request is received from a mobile terminal 15, the recorder 13 wirelessly transmits data related to the request to the mobile terminal 15. This allows a person viewing the screen of the mobile terminal 15 to view the data for each installation location in an integrated manner.

[0021] As described above, according to this embodiment, the sensor structure 1 can be made thinner by the amount that the sensor unit 4 is housed in the recess 5a and embedded in the circuit board 5. This reduces damage to concrete caused by the size of the sensor structure 1, effectively reducing the possibility of a decrease in the strength and long-term durability of the structure.

[0022] REFERENCE SIGNS LIST 1 sensor structure 2 sensor body 3 cable 4 sensor unit 4a detection section 4b base 4c bottom terminal 5 circuit board 5a to 5c recess 5d contact hole 6 electrical component 7 resin layer 8 adhesive layer 9 resistive sensor 10 acceleration sensor 11 hub 12 receiver 13 recorder 14 transmitter 15 portable terminal

Claims

1. In a sensor structure for pouring concrete, A circuit board; At least one electrical component attached to the circuit board and constituting an electrical circuit; a through hole that is a first recess provided in the circuit board and that penetrates from one surface of the circuit board to another surface opposite the one surface; a sensor unit having a detection section exposed to the outside so as to face a filling space of concrete or the like, and a pressure sensor for detecting a pressure of the detection section; the sensor unit is accommodated in the through hole, and the sensor unit is fixed to the circuit board in a state in which a part of the sensor unit abuts against the other surface of the circuit board, Sensor structure for pouring concrete.

2. The sensor unit further has a base located on the opposite side of the detection portion across the circuit board when the sensor unit is disposed in the through hole, The base portion abuts against the other surface of the circuit board. The sensor structure for pouring concrete according to claim 1.

3. A portion of the sensor unit closer to the detection unit than the base is insertable into the through hole, the base portion is formed larger than the through hole so as to abut against the other surface of the circuit board; The sensor structure for pouring concrete according to claim 2.

4. 2. The sensor structure for pouring concrete as described in claim 1, wherein the electrical component is electrically connected to a bottom terminal of the sensor unit housed in the through hole.

5. 3. The sensor structure for pouring concrete according to claim 1, wherein the sensor unit further comprises a temperature sensor for detecting a temperature of the detection portion.

6. a second recess provided on the circuit board and recessed from the other surface opposite to the one surface; 3. The sensor structure for pouring concrete according to claim 1, wherein the electrical component is accommodated in the second recess.

7. 3. The sensor structure for pouring concrete as described in claim 1 or 2, further comprising a thin plate-shaped resistive sensor attached to said one surface of said circuit board.

8. a third recess provided on the circuit board and recessed from the other surface opposite to the one surface; an acceleration sensor accommodated in the third recess; The sensor structure for pouring concrete according to claim 1 or 2, further comprising: