Ultrasonic Sensor Membrane Front-Side Assembly Method
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Solution Overview
Problem
The manufacturing process of ultrasonic sensors for motor vehicles is complex and costly, particularly in attaching the membrane to the decoupling element and assembling it on the sensor housing, which is a challenge for reducing production effort and costs, especially for low-price vehicles.
Innovation Solution
The method involves inserting the membrane into the sensor housing through a rear mounting opening and bringing it into a mounting position on the front side, eliminating the need for assembly from the opposite direction of emission, and using a front wall or opening to secure the membrane, which reduces manufacturing effort and eliminates the need for additional components like decoupling rings and surface protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the membrane is attached to the decoupling element and assembled from the opposite direction of emission, then the membrane can be securely fastened, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The patent applies inversion by assembling the membrane from the front side (emission direction) rather than the traditional rear side approach. The membrane is inserted through the front opening of the sensor housing and secured from the front, eliminating the need for complex rear-side attachment mechanisms and multi-step assembly processes while maintaining secure fastening.
Solution Approach 2:
The patent segments the assembly process into independent steps: first inserting the membrane through the front opening, then separately securing it with fastening elements. This segmentation allows for simpler, faster assembly operations compared to the integrated complex attachment process of prior art, while ensuring reliable membrane fastening.
2Reliability
If additional components like decoupling rings and surface protection are used, then the membrane assembly is more robust, but the device complexity and manufacturing costs increase
Solution Approach 1:
The patent merges the membrane, decoupling function, and sealing functions into a single integrated membrane structure. The membrane itself is designed to provide decoupling and sealing without requiring separate decoupling rings or additional surface protection components, thereby reducing device complexity while maintaining assembly robustness through the simplified front-side assembly process.
3Ease of manufacture
If the membrane is inserted through the rear mounting opening from the transmission direction, then the assembly process is simplified, but additional sealing measures and tolerance control are required
Solution Approach 1:
The patent inverts the traditional assembly direction by inserting the membrane from the front side through a front opening rather than from the rear. This inversion simplifies the assembly process by allowing direct access to the membrane mounting location, while the front-side securing method naturally accommodates tolerance variations without requiring additional sealing measures or strict tolerance control.
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 approach simplifies the assembly process, reduces manufacturing costs, and ensures reliable ultrasonic signal transmission without additional sealing measures or tolerance issues, while maintaining the quality of the ultrasonic sensor.
Implementation Method 1
a piezoelectric element, which is designed to transform electrical energy into mechanical vibrations
Implementation Method 2
a membrane for emitting ultrasonic signals in a transmission direction
Data Source
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AI summary
The invention relates to a method for producing an ultrasonic sensor (20) for a motor vehicle. A membrane (23) for emitting ultrasonic signals in a transmission direction (21) and a sensor housing (24) are provided for the ultrasonic sensor (20), said membrane (23) being secured in and/or on the sensor housing. The sensor housing (24) has a front face (25) which faces in the transmission direction (21) of the membrane (23) and a rear face (26) which faces in a backwards direction (27) opposite the transmission direction (21). The rear face (26) of the sensor housing (24) is formed with a rear-face assembly opening (29) for components of the ultrasonic sensor (20), and the membrane (23) is introduced into the sensor housing (24) through the rear-face assembly opening (29) in the transmission direction (21), brought into an assembly position on the front face (25) of the sensor housing (24) through an interior (30) of the sensor housing (24), and secured in the assembly position.