Ultrasonic Sensor Cushion Member Vibration Damping
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Solution Overview
Problem
Existing ultrasonic sensors face issues with excessive vibration damping, difficulty in positioning terminals accurately, and challenging wiring connections due to the configuration of components and filling processes.
Innovation Solution
The ultrasonic sensor design incorporates a cushion member to buffer vibrations, allowing for easy positioning of terminals and reduced damping, along with a cantilever structure and opening portion for easier connection and filling with foamable resin, which minimizes vibration interference and facilitates assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the substrate is fixed in direct contact with the case, then the structure is simple and easy to manufacture, but the vibration of the piezoelectric element is transmitted to the case and substrate causing excessive damping
Solution Approach 1:
The patent introduces a cushion member as an intermediary component between the case and the substrate. This cushion member absorbs and isolates the vibrations, preventing them from being transmitted to the substrate and causing damping. The cushion member acts as a mediator that resolves the contradiction by allowing simple assembly while preventing harmful vibration transmission.
2Reliability
If the substrate is covered with an elastic member filled in the case, then the vibration damping is reduced, but the positions of the substrate and terminals are displaced by the filling process making positioning difficult
Solution Approach 1:
The patent applies preliminary action by pre-positioning the substrate and terminals on the cushion member before the case is filled with the elastic material. This ensures that the terminals are accurately positioned at desired locations before the filling process begins, preventing displacement during assembly while still allowing the elastic member to provide vibration damping.
3Reliability
If the wire and lead wires are bonded to terminals by soldering after assembly, then the connections are secure, but the wiring becomes very difficult due to increased wire length and excessive stress on bonding portions
Solution Approach 1:
The patent applies preliminary action by performing the wiring and bonding operations before the case is assembled and filled. This allows the wires to be properly routed and connected to terminals while they are still accessible, avoiding the need for excessively long wires and reducing stress on bonding portions. The connections are established in advance when the structure is still open and manageable.
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
This design reduces vibration damping, enhances terminal positioning accuracy, and simplifies the connection process, resulting in improved assembly efficiency and stable reverberation characteristics without excessive stress on wiring.
Implementation Method 1
a piezoelectric element (16) provided on an inner side of a bottom (12a) of the case (12)
Implementation Method 2
the inside of the case 2 is filled with the foamable resin 4, the vibration of the overall case 2 is suppressed. Further, the ultrasonic wave generated in the inside of the case 2 is scattered and absorbed by a large number of foam pores in the foamable resin 4
Data Source
AI summary
An ultrasonic sensor includes a case having a substantially cylindrical shape with a bottom. The case has a piezoelectric element provided on the bottom, and a cushion member is engaged with a side portion of an opening of the case. A substrate and pin terminals are engaged in and held by a holding portion of the cushion member. On the substrate, electrodes that are connected to the pin terminals are provided. An opening portion is provided in a top surface of the cushion member. Lead wires that are electrically connected to the piezoelectric element extend out from the opening portion and are connected to the electrodes. The inside of the case is filled with an elastic resin from the opening portion.