Ultrasonic Sensor Mounting Structure With Flush Resonant Sealing
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Solution Overview
Problem
When an ultrasonic sensor is mounted in a through hole of an outer plate member like a vehicle bumper, steps, biased gaps, or inclinations can form between the sensor and the bumper, deteriorating the appearance of the outer plate member.
Innovation Solution
A sensor mounting structure is designed with an ultrasonic sensor positioned inward of the through hole and a sealing member spaced apart from the sensor, covering the through hole. This configuration allows ultrasonic waves to pass through the hole and be received by the sensor via the sealing member, which is configured to resonate with the ultrasonic waves and have a natural frequency close to that of the sensor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the ultrasonic sensor is arranged in the through hole such that the sensor surface is exposed to the outside, then the sensor can directly transmit and receive ultrasonic waves, but steps or biased gaps are formed between the sensor and the outer plate member surface, deteriorating the appearance
Solution Approach 1:
A sealing member is introduced as an intermediary component between the ultrasonic sensor and the outer plate member. The sealing member covers the through hole and has an outer surface that is substantially flush with the outer plate member surface, eliminating steps and gaps while still allowing ultrasonic waves to pass through to reach the sensor.
2Shape
If the sealing member is placed close to the ultrasonic sensor to cover the through hole, then the appearance is improved by eliminating steps, but the ultrasonic wave transmission may be affected
Solution Approach 1:
The sealing member is designed with specific parameter optimizations: its thickness is controlled to be 0.5-2.0 mm, and its natural frequency is set to deviate by 5% or less from the ultrasonic sensor's frequency. These parameter changes ensure the sealing member is thin enough to allow effective ultrasonic transmission while maintaining appearance quality.
Solution Approach 2:
The sealing member is configured to resonate with the ultrasonic wave frequency transmitted by the sensor. This resonance characteristic enhances the transmission of ultrasonic waves through the sealing member, ensuring that appearance improvement does not compromise sensor functionality.
3Strength
If the sealing member is made with the same thickness as the outer plate member, then the structural integrity is maintained, but the ultrasonic wave transmission is attenuated
Solution Approach 1:
The sealing member thickness is specifically optimized to be less than the outer plate member thickness (0.5-2.0 mm versus typically 3-5 mm for bumpers). This parameter change reduces ultrasonic wave attenuation while maintaining sufficient structural integrity for appearance purposes.
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 effectively suppresses the deterioration of the outer plate member's appearance by maintaining the aesthetic integrity while ensuring the ultrasonic sensor functions optimally, with enhanced wave transmission and reception capabilities.
Implementation Method 1
an ultrasonic wave transmitted from the ultrasonic sensor passes through the through hole and propagates to an outside via the sealing member, and a reflected wave reflected from the outside passes through the through hole via the sealing member and is received by the ultrasonic sensor
Implementation Method 2
the sealing member is configured to resonate with the ultrasonic wave transmitted by the ultrasonic sensor
Data Source
AI summary
A sensor mounting structure includes: an outer plate member provided with a through hole; an ultrasonic sensor arranged more inward than the through hole; and a sealing member arranged spaced apart from the ultrasonic sensor, the sealing member covering the through hole. The sensor mounting structure is configured such that an ultrasonic wave transmitted from the ultrasonic sensor passes through the through hole and propagates to an outside via the sealing member, and a reflected wave reflected from the outside passes through the through hole via the sealing member and is received by the ultrasonic sensor.