Ultrasonic Sensor Elastic Decoupling Gap-Free Seal
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Solution Overview
Problem
Ultrasonic sensors with decoupling elements face issues with gaps between the decoupling element and the diaphragm pot or housing, leading to parasitic sound emissions and amplified structure-borne noise, especially when the decoupling element is flush with the diaphragm pot, making visual inspection impossible and resulting in malfunctions.
Innovation Solution
A decoupling element made of elastic material with a continuous recess, where the inner wall is stretched to fit flush with the lateral surface of the diaphragm pot and housing, ensuring a form-fitting connection without gaps, achieved through contraction of the material and application of a paint layer, optimizing the geometry to prevent noise leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a decoupling element is used to dampen structure-borne noise and prevent parasitic sound emissions, then noise reduction is improved, but gaps may form between the decoupling element and the diaphragm pot or housing leading to sound penetration
Solution Approach 1:
The decoupling element is made of elastic material that can change its physical state between compressed and relaxed conditions. During assembly, the element is compressed to fit into the housing, then relaxes to expand and fill gaps against the diaphragm pot and housing surfaces, ensuring reliable acoustic sealing while maintaining noise dampening functionality
Solution Approach 2:
The decoupling element transitions from a static rigid component to a dynamic elastic component that adapts its shape and volume. The element is inserted in a compressed state, then naturally expands to conform to the housing and diaphragm pot surfaces, dynamically adjusting to ensure complete gap closure and reliable acoustic isolation
2Shape
If the decoupling element is made flush with the diaphragm pot for aesthetic purposes, then appearance is improved, but visual inspection for gap detection becomes impossible
Solution Approach 1:
A paint layer is applied to the housing surface in the region where the decoupling element makes contact. During assembly, any gaps between the elastic decoupling element and the housing allow the paint to seep through, creating visible markings that indicate the presence and location of gaps, thus enabling quality control inspection while maintaining the flush appearance
3Ease of manufacture
If the recess in the decoupling element is dimensioned for expansion-free accommodation of the diaphragm pot, then assembly ease is improved, but gaps may form leading to sound leakage
Solution Approach 1:
The elastic decoupling element is pre-compressed during assembly to fit into the housing recess. This preliminary compression allows easy insertion, and the subsequent natural relaxation of the elastic material creates expansion forces that push the element against the diaphragm pot and housing surfaces, ensuring gap-free contact and preventing sound leakage
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 solution ensures a gap-free connection, reducing parasitic noise emissions and structure-borne noise, enhancing sensor sensitivity and preventing false echoes by ensuring a secure, form-fitting assembly of the decoupling element with the diaphragm pot and housing.
Implementation Method 1
the inner wall of the decoupling element is stretched by contraction of the elastic material at least around a region of the lateral surface of the diaphragm pot and/or a layer of paint applied to the lateral surface of the lateral pot and the lateral surface of the housing
Data Source
Figure 1a
Figure 1b~2
AI summary
The present invention relates to an ultrasonic sensor comprising a diaphragm cup (1), a housing (2) and a decoupling element (3), wherein the diaphragm cup (1) and the housing (2) each have a lateral surface (4,5), wherein the decoupling element (3) is at least partially formed from an elastic material, wherein the decoupling element (3) has a continuous recess (6) which is delimited by an inner wall (7) of the decoupling element (3), wherein the diaphragm cup (1) and/or the housing (2) is/are at least partially arranged in the recess (6). In order to prevent sound from being transmitted through a gap between the diaphragm cup (1) and the decoupling element (3) and/or between the housing (2) and the decoupling element (3), the inner wall (7) of the decoupling element (3) is stretched, by contraction of the elastic material, at least around a region (8, 9, 10) of the lateral surface (4) of the diaphragm cup (1) and/or of a lacquer layer (11) applied to the lateral surface (4) of the diaphragm cup (1) and/or of the lateral surface (5) of the housing (1), which region extensively encircles the diaphragm cup (1) and/or the housing (2), in such a manner that the inner wall (7) is flush against the lateral surface (4) of the diaphragm cup (1) and/or the lacquer layer (11) applied to the lateral surface (4) of the diaphragm cup (1) and/or the lateral surface (5) of the housing (2) in this region.