Ultrasonic Sensor Cover with Composite Materials for Lift Resistance
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Solution Overview
Problem
Conventional ultrasonic sensors experience partial lift of the cover due to external forces, such as during car washing or waxing, due to the cover's weak structure and protrusion from the attachment hole, leading to potential misalignment and malfunction.
Innovation Solution
The ultrasonic sensor employs a cover made of multiple materials with different elastic moduli, where the side portion is made of silicone rubber and the bottom portion has a higher elastic modulus, providing enhanced strength and resistance to external forces, thereby preventing the cover from lifting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cover is made of elastic material to attenuate unwanted vibration, then vibration attenuation is improved, but the cover becomes susceptible to external force causing partial lift
Solution Approach 1:
The cover is divided into two regions with different material properties: a first region (side portion) made of elastic material for vibration attenuation, and a second region (bottom portion) made of rigid material for resistance to external force. This local differentiation allows each region to fulfill its specific functional requirement without compromising the other.
Solution Approach 2:
The cover combines two different materials (elastic and rigid) into a single composite structure. The elastic material provides vibration damping while the rigid material provides structural strength, creating a cover that simultaneously achieves both vibration attenuation and external force resistance.
2Shape
If the cover protrudes from the attachment hole to conceal the inner surface, then aesthetic appearance is improved, but the cover becomes vulnerable to external force during car washing or waxing
Solution Approach 1:
The cover maintains its protruding shape for aesthetic purposes, but only the side portion (first region) is made of elastic material. The bottom portion (second region) is made of rigid material that protrudes slightly less, providing structural support to prevent rolling up while maintaining the overall aesthetic appearance.
3Reliability
If the cover is made uniformly of elastic material, then vibration attenuation is achieved, but manufacturing complexity increases when trying to add structural reinforcement
Solution Approach 1:
The cover is segmented into two distinct regions (side portion and bottom portion) that can be manufactured separately and then assembled. This segmentation allows each part to be optimized independently for its specific function while simplifying the overall manufacturing process compared to creating a complex monolithic structure.
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 design effectively suppresses the partial lift of the cover when external forces are applied, ensuring the ultrasonic sensor remains securely attached and functional, even under conditions like car washing or waxing.
Implementation Method 1
an ultrasonic device including a piezoelectric element which constitutes a transmitting element and a receiving element
Implementation Method 2
a piezoelectric element which constitutes a transmitting element and a receiving element
Data Source
Figure 1A~1D
Figure 2A~2B
Figure 3A~3C
AI summary
The ultrasonic sensor includes a wave transmitting and receiving device and a cover. The wave transmitting and receiving device has a front surface including a wave transmitting and receiving surface and is configured to transmit and receive an ultrasonic wave through the wave transmitting and receiving surface. The cover covers the wave transmitting and receiving device so as to expose the wave transmitting and receiving surface. The cover is constituted by multiple portions, and the multiple portions are individually made of multiple materials different from each other.