Hidden Ultrasonic Sensor Assembly with Preload Coupling
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Solution Overview
Problem
Conventional ultrasonic sensors for vehicles are visually distracting due to their exposed nature and limited flexibility in mounting on different materials, such as metals and plastics.
Innovation Solution
A hidden ultrasonic sensor assembly is mounted inside vehicle panels, using a preload structure with a coupling element and acoustic foam to absorb airborne waves, allowing the sensor to detect objects without being visible from the outside and to function effectively through various materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic sensors are mounted in exposed openings in vehicle panels, then the sensors can detect objects effectively, but the sensors become visually distracting and noticeable
Solution Approach 1:
The sensor is extracted from the traditional exposed mounting position and relocated to the interior side of the vehicle panel. This allows the sensor to maintain its detection function while being hidden from external view, eliminating the visual distraction problem.
Solution Approach 2:
A coupling element is introduced as an intermediary between the ultrasonic sensor and the panel interior surface. This coupling element ensures proper acoustic contact and signal transmission while allowing the sensor to be mounted flush against the panel from the inside, maintaining both detection effectiveness and aesthetic appearance.
2Object-generated harmful factors
If ultrasonic sensors are mounted on the interior side of vehicle panels, then the sensors become hidden and visually appealing, but the mounting flexibility on different materials is limited
Solution Approach 1:
The coupling element is designed with universal adaptability to work with different panel materials (metal, plastic, etc.). It provides a standardized mounting interface that can accommodate various material types and thicknesses, enabling the hidden mounting solution to be applied across different vehicle components regardless of material composition.
Solution Approach 2:
The coupling element can be manufactured with varying parameters such as thickness, material composition, and acoustic properties to optimize performance for different panel materials. This allows the same basic mounting structure to be adapted to metal panels, plastic panels, or other materials by adjusting the coupling element's characteristics.
3Object-generated harmful factors
If ultrasonic sensors are mounted inside vehicle panels, then the aesthetic appearance is improved, but the signal transmission and reception through the panel material may be affected
Solution Approach 1:
The coupling element serves as an acoustic intermediary that optimizes the transmission of ultrasonic signals between the sensor and the panel material. It is designed to match acoustic impedances and minimize signal loss, ensuring reliable detection performance even when the sensor is mounted inside the panel rather than directly on the exterior surface.
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
The solution provides a visually appealing and flexible system for ultrasonic sensor mounting, enhancing signal transmission and reception while minimizing noise and maintaining structural integrity and aesthetic appeal across different materials and environments.
Implementation Method 1
acoustic foam to absorb airborne waves
Data Source
AI summary
An ultrasonic sensor assembly is placed against an inside surface of a panel for sensing objects on an opposite side of the panel and includes an ultrasonic sensor, a preload structure, a coupling element, and a damping material. The preload structure applies a preload on the ultrasonic sensor toward the inside surface of the panel. The coupling element interfaces between the ultrasonic sensor and the inside surface of the panel. The damping material is placed against the inside surface but not where the coupling element interfaces between the ultrasonic sensor and the inside surface. The coupling element may include a matrix material that is reinforced with a filler.