Ultrasonic Sensor Housing Decoupling Element Molding
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Solution Overview
Problem
The existing methods for producing ultrasonic sensors for motor vehicles are complex and require additional assembly steps, increasing the number of individual parts and assembly tolerances, which complicates the manufacturing process.
Innovation Solution
A method involving a sensor housing formed from two separate housing shells with a decoupling element sprayed onto the inner surfaces, allowing the membrane to be inserted and clamped between the shells, eliminating the need for an additional assembly step and reducing parts and tolerances, while ensuring reliable fixation and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a decoupling element is assembled separately into the sensor housing, then the membrane is properly decoupled from the housing, but the assembly process becomes complex with additional steps and more individual parts
Solution Approach 1:
The decoupling element is integrated directly into the sensor housing as a single component during the molding process, eliminating the need for separate assembly of the decoupling element. The housing and decoupling element form one piece, reducing the number of individual parts and assembly steps while maintaining the vibration decoupling function.
Solution Approach 2:
The decoupling element is pre-formed as an integral part of the sensor housing during the molding process, before the membrane is installed. This preliminary integration eliminates subsequent assembly operations and ensures proper decoupling functionality from the outset.
2Adaptability or versatility
If multiple individual parts are used in the sensor assembly, then each component can be optimized independently, but the number of assembly tolerances increases
Solution Approach 1:
By merging the housing and decoupling element into a single integrated component, the invention eliminates the accumulation of assembly tolerances that would result from joining multiple parts. The single-piece construction ensures precise geometric relationships without the need for tolerance stacking across multiple components.
3Device complexity
If a decoupling element is integrated into the sensor housing, then the number of parts is reduced, but the production process becomes more complex
Solution Approach 1:
The decoupling element is pre-integrated into the housing during the molding process itself, so that what appears to be a complex integrated structure is actually created as a single operation. This preliminary formation during manufacturing eliminates the need for subsequent assembly steps, making the overall production process simpler despite the integrated design.
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
Simplifies the assembly process, reduces assembly tolerances, and provides a reliable and sealed ultrasonic sensor with minimized parts, enhancing production efficiency and environmental protection.
Implementation Method 1
the decoupling element is sprayed onto an inner surface of the sensor housing
Implementation Method 2
a membrane, which for this purpose is excited to a mechanical vibration by means of a piezo element
Implementation Method 3
The transmitted ultrasonic signal then reflects on the obstacle and then reaches the ultrasonic sensor again as an echo. The echo excites the membrane again to a mechanical vibration
Implementation Method 4
a decoupling element which is arranged between the sensor housing and the membrane for the vibration-related decoupling of the membrane from the sensor housing
Data Source
Figure 1
Figure 2~4
Figure 5~7
AI summary
The invention relates to a method for producing an ultrasonic sensor (1) for a motor vehicle by providing a sensor housing (2), a membrane (5) for transmitting and/or receiving ultrasonic signals, and a decoupling element (6), which is arranged between the sensor housing (2) and the membrane (5), wherein the decoupling element (6) is extruded onto an internal surface of the sensor housing (2) after which the membrane (5) is inserted into the sensor housing (2).