Flush-Mounted Ultrasonic Sensor for Hole-Free Vehicle Bumpers

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Solution Overview

Problem

Existing ultrasonic sensors for vehicles protrude significantly from the vehicle body, compromising design aesthetics when retrofitted, and require attachment holes that complicate installation.

Innovation Solution

An ultrasonic sensor design featuring a magnetic substance and a diaphragm attached to the vehicle's outer plate, allowing ultrasonic oscillation without protrusion and eliminating the need for attachment holes, utilizing an electromagnetic transducer and a thin-film diaphragm that oscillates along the axial direction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If existing ultrasonic sensors are retrofitted to vehicles, then ultrasonic detection function is achieved, but the sensor protrudes significantly from the vehicle body compromising design aesthetics

Engineering Contradiction:

Improveultrasonic detection functionVSAvoidvehicle body appearance

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

The sensor unit is merged with the vehicle body by attaching it to the outer plate (bumper), making the sensor structure an integrated part of the vehicle body rather than a separate protruding component. This merging allows the sensor to maintain its detection function while becoming visually integrated with the vehicle's design.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The sensor components (electromagnetic transducer, magnetic substance, diaphragm) are nested within a compact structure that attaches to the outer plate. The electromagnetic transducer and magnetic substance are positioned on opposite sides of the outer plate, with the diaphragm nested between them, creating a space-efficient configuration that minimizes protrusion.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If existing ultrasonic sensors are retrofitted to vehicles, then ultrasonic detection function is achieved, but attachment holes are required complicating installation

Engineering Contradiction:

Improveultrasonic detection functionVSAvoidinstallation process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The attachment holes, which complicate installation, are extracted from the design. Instead of requiring holes in the outer plate, the sensor unit utilizes the outer plate itself as a mounting surface, attaching to it without penetrating it. This extraction of the problematic attachment holes simplifies the installation process while maintaining secure attachment.

Inventive Principle:

Principle #2Taking out (Extraction)

3Speed

If a diaphragm is joined to the outer surface of the outer plate, then ultrasonic oscillation is enabled, but an internal space must be formed between the diaphragm and outer surface

Engineering Contradiction:

Improveultrasonic oscillation responseVSAvoidinternal space structure

Core Design Contradiction:

SpeedVSDevice complexity

Solution Approach 1:

The internal space is created in the thickness direction of the diaphragm rather than requiring lateral expansion. By joining the diaphragm's outer edge to the outer surface and allowing the diaphragm to oscillate in the thickness direction, the internal space is formed in a dimension that does not increase the sensor's lateral footprint or overall complexity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Facilitates a sleek design and simplified installation by integrating the sensor with the vehicle's bumper without protrusion, ensuring effective ultrasonic transmission and reception performance while suppressing misdetection and improving design aesthetics.

Implementation Method 1

an electromagnetic transducer configured with a conversion function between an oscillating magnetic field and an electric signal

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

the diaphragm is able to ultrasonically oscillate by being joined to an outer surface of the outer plate

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Data Source

PatentUS12555557B2Ultrasonic sensor

Publication Date: 2026.02.17 DENSO CORP

AI summary

An ultrasonic sensor includes a magnetic substance, a diaphragm, and an electromagnetic transducer. The electromagnetic transducer is disposed opposing the magnetic substance across an outer plate of a vehicle. The diaphragm has the shape of a thin film with a film thickness direction along an axial direction parallel to a directional axis. The diaphragm is able to ultrasonically oscillate by being joined to an outer surface of the outer plate at an outer edge in a radial direction crossing the directional axis. With the outer edge of the diaphragm joined to the outer surface of the outer plate, an internal space that expands and contracts along the axial direction in response to ultrasonic oscillation of the diaphragm is formed between the diaphragm and the outer surface of the outer plate.