U.S. patent application number 15/107729 was filed with the patent office on 2018-12-20 for method for producing an ultrasonic sensor for a motor vehicle.
This patent application is currently assigned to VALEO Schalter und Sensoren GmbH. The applicant listed for this patent is VALEO SCHALTER UND SENSOREN GMBH. Invention is credited to Wolfgang Hamm, Hans-Wilhelm Wehling.
Application Number | 20180364353 15/107729 |
Document ID | / |
Family ID | 52278561 |
Filed Date | 2018-12-20 |
United States Patent
Application |
20180364353 |
Kind Code |
A9 |
Wehling; Hans-Wilhelm ; et
al. |
December 20, 2018 |
METHOD FOR PRODUCING AN ULTRASONIC SENSOR FOR A MOTOR VEHICLE
Abstract
The invention relates to a method for producing an ultrasound
sensor (20) for a motor vehicle, in which method, for the
ultrasound sensor (20), a diaphragm (23) for emitting ultrasound
signals in an emitting direction (21) and a sensor housing (24) are
provided, in and/or on which sensor housing the diaphragm (23) is
fastened, wherein the sensor housing (24) has a front side (25),
which points in the emitting direction (21) of the diaphragm (23),
and a rear side (26), which points in a rearward direction (27)
which is opposite to the emitting direction (21), and wherein, on
the front side (25), the sensor housing (24) is formed with a
front-side opening (28) for the diaphragm (23), wherein the front
side (25) of the sensor housing (24) is connected to a cap (52)
which is composed of a foil and by way of which the front-side
opening (28) of the sensor housing (24) is covered in the emitting
direction (21), wherein the diaphragm (23) is inserted at least
regionally into a receptacle (53) of the cap (52) and, here, a
front side (22), which points in the emitting direction (21), of
the diaphragm (23) is connected to a base (55) of the receptacle
(53) of the cap (52).
Inventors: |
Wehling; Hans-Wilhelm;
(Bietigheim-Bissingen, DE) ; Hamm; Wolfgang;
(Bietigheim-Bissingen, DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
VALEO SCHALTER UND SENSOREN GMBH |
Bietigheim-Bissingen |
|
DE |
|
|
Assignee: |
VALEO Schalter und Sensoren
GmbH
Bietigheim-Bissingen
DE
|
Prior
Publication: |
|
Document Identifier |
Publication Date |
|
US 20180172826 A1 |
June 21, 2018 |
|
|
Family ID: |
52278561 |
Appl. No.: |
15/107729 |
Filed: |
December 4, 2014 |
PCT Filed: |
December 4, 2014 |
PCT NO: |
PCT/EP14/76559 PCKC 00 |
371 Date: |
June 23, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G01S 7/521 20130101;
G01S 2015/938 20130101; G10K 9/22 20130101; G01S 15/931
20130101 |
International
Class: |
G01S 15/93 20060101
G01S015/93; G01S 7/521 20060101 G01S007/521; G10K 9/22 20060101
G10K009/22 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 23, 2013 |
DE |
10 2013 022 061.0 |
Claims
1. A method for producing an ultrasound sensor for a motor vehicle,
the method comprising, for the ultrasound sensor; providing a
diaphragm for emitting ultrasound signals in an emitting direction;
and providing a sensor housing, in and/or on which sensor housing
the diaphragm is fastened, wherein the sensor housing has a front
side, which points in the emitting direction of the diaphragm, and
a rear side, which points in a rearward direction which is opposite
to the emitting direction, and wherein, on the front side, the
sensor housing is formed with a front-side opening for the
diaphragm; connecting the front side of the sensor housing to a cap
which is composed of a foil and by way of which the front-side
opening of the sensor housing is covered in the emitting direction;
inserting the diaphragm at least regionally into a receptacle of
the cap; and, connecting a front side, which points in the emitting
direction, of the diaphragm to a base of the receptacle of the
cap.
2. The method according to claim 1, wherein, before the connection
of the cap to the sensor housing, the diaphragm is inserted into
the receptacle of the cap and is connected to the base of the
receptacle.
3. The method according to claim 1, wherein, firstly, the cap is
connected to the front side of the sensor housing, and
subsequently, the diaphragm is inserted in the emitting direction
into the sensor housing through a rear-side installation opening
which is formed on the rear side of the sensor housing, and said
diaphragm is placed, through an interior space and the front-side
opening of the sensor housing, into an installed position at the
front side of the sensor housing, and said diaphragm is connected,
in the installed position, to the base of the receptacle.
4. The method according to claim 1, wherein the diaphragm is
received in the receptacle with an accurate fit.
5. The method according to claim 1, wherein the cap is produced
from a foil with a thickness of less than 0.5 mm.
6. The method according to claim 1, wherein the cap is, on an inner
side facing toward the sensor housing, formed with a coating
composed of copper.
7. The method according to claim 1, wherein the front side of the
diaphragm is connected to the base of the receptacle of the cap by
way of an adhesive pad.
8. The method according to claim 1, wherein the cap is mounted onto
the front side of the sensor housing.
9. The method according to claim 1, wherein the cap is welded to
the sensor housing by way of a laser welding apparatus.
10. The method according to claim 1, wherein an intermediate space
between the diaphragm and the sensor housing and/or an interior
space of the diaphragm is filled with a single-component sealing
compound.
11. An ultrasound sensor for a motor vehicle, comprising: a
diaphragm for emitting ultrasound signals in an emitting direction;
and a sensor housing, in and/or on which the diaphragm is fastened,
wherein the sensor housing has a front side, which points in the
emitting direction of the diaphragm, and a rear side, which points
in a rearward direction which is opposite to the emitting
direction, and wherein, on the front side, the sensor housing has a
front-side opening for the diaphragm, wherein the front side of the
sensor housing is connected to a cap which is composed of a foil
and by way of which the front-side opening of the sensor housing is
covered in the emitting direction, wherein the diaphragm is
inserted at least regionally into a receptacle of the cap and a
front side, which points in the emitting direction, of the
diaphragm is connected to a base of the receptacle of the cap.
12. Motor vehicle having an ultrasound sensor according to claim
11.
Description
[0001] The invention relates to a method for producing an
ultrasound sensor for a motor vehicle, in which method, for the
ultrasound sensor, a diaphragm for emitting ultrasound signals in
an emitting direction and a sensor housing are provided, in and/or
on which sensor housing the diaphragm is fastened, wherein the
sensor housing has a front side, which points in the emitting
direction of the diaphragm, and a rear side, which points in a
rearward direction which is opposite to the emitting direction, and
wherein the sensor housing is, on the front side, formed with a
front-side opening for the diaphragm. The invention also relates to
an ultrasound sensor for a motor vehicle, and to a motor vehicle
having an ultrasound sensor of said type.
[0002] Ultrasound sensors for motor vehicles are already prior art
and may, in a manner known per se, be installed in the front region
and in the rear region of a motor vehicle, for example on the
bumpers. The ultrasound sensors are assigned to driver assistance
devices and provide information regarding the surroundings of the
vehicle, more precisely regarding the distances between the
vehicle, on the one hand, and the obstructions situated in the
surroundings thereof, on the other hand. Driver assistance devices
may in this case be, for example, parking assistance systems,
systems for blind spot monitoring, systems for maintaining
inter-vehicle distance, braking assistance systems and the
like.
[0003] It is already known for ultrasound sensors of said type to
be arranged in unconcealed and thus visible fashion in associated
paneling parts, for example in bumpers. This means that they are
arranged in cutouts or passage openings extending all the way
through the associated paneling part of the vehicle and are visible
from the outside. Here, the pot-shaped diaphragm of the ultrasound
sensor--the so-called aluminium pot --extends through the passage
opening of the paneling part, such that a front side of the
diaphragm terminates flush with the outer surface of the paneling
part.
[0004] Transducers or ultrasound sensors installed in concealed
fashion are also known. These are therefore not visible when the
paneling part is viewed from the outside, and are concealed by the
paneling part. In the case of ultrasound sensors installed directly
behind the paneling part in this way, ultrasound signals are
transmitted and received through the material of the paneling
part--normally plastic.
[0005] The focus of interest in the present case is in particular
on ultrasound sensors which are installed in visible and thus in
non-concealed fashion, the diaphragms of which are arranged in a
cutout extending all the way through the associated paneling part.
An ultrasound sensor of said type is normally fastened to the
paneling part by way of a bracket composed of plastic, wherein said
bracket is attached to the paneling part by way of a double-sided
adhesive tape, by hot caulking or else by way of ultrasound. The
ultrasound sensor can then be inserted into and fastened to the
bracket. The use of a bracket of said type for the visible
installation of an ultrasound sensor on a bumper is known for
example from document DE 10 2007 043 500 A1. Here, the sensor
housing including the diaphragm is engaged with detent action into
the bracket, which is connected directly to the bumper.
[0006] A method for producing an ultrasound sensor is known for
example from EP 2 027 580 B1. A first assembly is formed by virtue
of a piezo element being fastened to a diaphragm base of a
pot-shaped diaphragm. Said first assembly is then inserted into a
soft elastic decoupling element in order to form a second assembly.
Said second assembly formed in this way is then inserted with
detent action into a housing section of a sensor housing of the
ultrasound sensor in order to form a third assembly. The decoupling
element is inserted into the housing section in an installation
direction, which is opposite to the transmitting direction of the
ultrasound sensor.
[0007] A further method is described in DE 101 25 272 A1. In the
case of said production method, the diaphragm of the ultrasound
sensor is firstly placed into a two-component injection-moulding
installation. In a further working step, a plastics housing is
injection-moulded around the diaphragm. After the plastics housing
has cured, a rubber-like decoupling element is injection-moulded
between the diaphragm and the plastics housing in a further step.
In this way, exact and permanent positioning of the diaphragm
relative to the sensor housing is ensured.
[0008] A known method which serves for the production of an
ultrasound sensor and which is similar to the method from document
EP 2 027 580 B1 will be discussed in more detail below with
reference to FIG. 1: firstly, a pot-shaped diaphragm 1 and a
unipartite sensor housing 2 for an ultrasound sensor 3 are
provided. The diaphragm 1 is firstly equipped, externally, with a
surface protector. The sensor housing 2 is, from its front side 5
pointing in an emitting direction 4 of the diaphragm 1, designed
such that it can receive the diaphragm 1 together with a decoupling
element 6. For this purpose, the sensor housing 2 has a front-side
opening 7 which forms a receptacle for the diaphragm 1 and the
decoupling element 6. The diaphragm 1 has an encircling collar 8.
At the pre-assembly stage, the diaphragm 1 is firstly pressed into
the decoupling element 6. A unit formed by the diaphragm 1 and the
decoupling element 6 is then installed in correctly positioned
fashion into the sensor housing 2 or into the front-side opening 7
proceeding from the front side 5. Then, an additional decoupling
ring 19 with a silicone surface moulded thereon is pushed onto the
diaphragm 1 and mechanically fixedly connected to the sensor
housing 2 by way of laser welding. On a second assembly line, it is
then the case that a piezo element is inserted, in the emitting
direction 4, into an interior space 11 of the sensor housing 2
through a rear-side installation opening 10 of the sensor housing
2, and is fastened by way of an adhesive to a rear side 12, facing
toward the interior space 11, of a diaphragm base 13. A method of
said type, and the selection of a suitable adhesive, is described
in the document DE 10 2011 120 391 A1. In a further step, on the
second assembly line, contact elements 18, which are intended to
lead to the piezo element 9, are bent to, and a wire 17 is welded
on, and the plug connectors are pressed into the sensor housing 2
in the emitting direction 4. Here, the wire is inserted into the
sensor housing 2 through the rear-side installation opening 10 and
is then welded onto the piezo element 9 by way of a laser and
solder. Then, the interior space of the pot-shaped diaphragm 1 is
filled, from the rear side and thus through the rear-side
installation opening 10, with a sealing compound, and the
ultrasound sensor is subjected to aging for approximately 24 hours.
On a further assembly line, a printed circuit board is then pressed
through the rear-side installation opening 10 onto plug connector
pins 14. Insulation displacement technology is used for this
purpose. The existing cavity or the interior space 11 of the sensor
housing 2 is finally filled with an electronics sealing compound,
and cured in a continuous furnace.
[0009] Most ultrasound sensors are nowadays produced in accordance
with the principle described above. Although said production
process has proven to be particularly reliable, a further challenge
however consists in further simplifying the production process of
the ultrasound sensors in order, in particular, to reduce
production costs. In particular, here, firstly the fastening of the
diaphragm to the decoupling element and the installation of said
unit on the sensor housing, and secondly the attachment of the
further decoupling ring and the welding process to the sensor
housing, have proven to be relatively cumbersome. Since, nowadays,
ultrasound sensors are used even for vehicles in low price
segments, for example in small vehicles, there is a corresponding
demand for adaptation of the production processes.
[0010] It is an object of the invention to specify a solution with
which, in the case of a method of the generic type mentioned in the
introduction, the outlay for the production of the ultrasound
sensor can be reduced in relation to the prior art, without the
characteristics of the ultrasound sensor itself being influenced,
and/or to provide a more cost-effective sensor.
[0011] Said object is achieved according to the invention by way of
a method, by way of an ultrasound sensor and by way of a motor
vehicle having the features of the respective independent patent
claims. Advantageous embodiments of the invention are specified in
the dependent patent claims, in the description and in the
figures.
[0012] A method according to the invention serves for the
production of an ultrasound sensor for a motor vehicle. The
ultrasound sensor is designed in particular for visible
installation in a cutout extending all the way through a paneling
part of the motor vehicle. For the ultrasound sensor, a diaphragm
for emitting ultrasound signals in an emitting direction and a
sensor housing are provided. The diaphragm is fastened in and/or on
the sensor housing. By way of the sensor housing, the ultrasound
sensor can then be installed, for example engaged with detent
action, on a bracket which is connected to the paneling part of the
motor vehicle. The sensor housing serves for accommodating
components of the ultrasound sensor. The sensor housing has a front
side, which points in the emitting direction of the diaphragm, and
a rear side, which points in a rearward direction which is opposite
to the emitting direction. The sensor housing is, on the front
side, formed with a front-side opening for the diaphragm. It is
provided according to the invention that the front side of the
sensor housing is connected to a cap which is composed of a foil
and by way of which the front-side opening of the sensor housing is
covered in the emitting direction, wherein the diaphragm is
inserted at least regionally into a receptacle of the cap and,
here, a front side, which points in the emitting direction, of the
diaphragm is connected to a base of the receptacle of the cap.
[0013] According to the invention, it is thus the case that a foil
cap or a foil hat-like structure, and thus a cover, is provided, by
way of which the front-side opening of the sensor housing is
covered in the transmitting direction of the diaphragm and which
has a receptacle which faces toward the interior space of the
sensor housing and into which the front side of the diaphragm,
through which the ultrasound signals are transmitted and which
points in the emitting direction, is received or introduced. By
virtue of the diaphragm being covered by way of the cap, it is
achieved that no additional seal is required, and it may also be
possible to dispense with the use of separate decoupling elements
by way of which the diaphragm in the prior art is installed on the
sensor housing. Specifically, the diaphragm is fastened by way of
the inherently rigid cap composed of foil to the sensor housing and
is thus reliably protected against external influences by the cap.
The cap thus has the advantage that additional measures with regard
to the sealing of the sensor housing at the interface between
diaphragm and sensor housing, with the associated disadvantages
with regard to installation outlay and costs, are rendered
superfluous. Also, no problems arise with regard to ice formation
during the operation of the ultrasound sensor. Furthermore, the
diaphragm no longer needs to be coated with a surface protector,
whereby the outlay in terms of production is further reduced. Thus,
overall, the production outlay is reduced in relation to the prior
art, because it is merely necessary for the diaphragm to be
fastened in the receptacle of the cap, and for the cap to be
fastened to the sensor housing.
[0014] The cap or the foil pot is preferably punched out of a flat
foil strip on a production line and then deep-drawn in a tool under
the action of heat. It is thus possible to purchase a single long
foil strip without storage costs or packaging costs being incurred.
It is advantageously possible for the foil strip to be provided, on
one side, with a metal coating, in particular with a copper
coating, which, after the deformation to form the cap, is situated
on that side which faces toward the interior space of the sensor
housing.
[0015] Here, it is also possible to dispense with the encircling
collar of the diaphragm, such that the diaphragm is of pot-shaped
form and has no collar. Specifically, a collar for the fastening of
the diaphragm is no longer necessary.
[0016] With regard to the assembly sequence and the associated
installation direction, it is now possible for two alternative
embodiments to be provided:
[0017] On the one hand, the diaphragm may be inserted into the
receptacle of the cap, and connected to the base of the receptacle,
already before the connection of the cap to the sensor housing. It
is then possible for the unit composed of cap and diaphragm to be
connected to the front side of the sensor housing and thus fastened
to the sensor housing, in particular fastened with greater
dimensional accuracy or with narrower tolerances. In relation to
the prior art, it is thus possible for the diaphragm to be
installed on the sensor housing by way of the cap without great
outlay, without the need here for elastic or soft elastic
decoupling elements to be handled and welded to the housing.
Furthermore, the ultrasound sensor external dimensions can be
precisely set in this way.
[0018] On the other hand, provision may however also be made
whereby, firstly, the cap is connected to the front side of the
sensor housing, and subsequently, the diaphragm is inserted in the
emitting direction into the sensor housing through a rear-side
installation opening which is formed on the rear side of the sensor
housing, and said diaphragm is placed, through an interior space
and the front-side opening of the sensor housing, into an installed
position at the front side of the sensor housing and thus into the
receptacle of the cap, and said diaphragm is connected, in this
installed position, to the base of the receptacle. In this
embodiment, the diaphragm is thus installed not from the front side
of the sensor housing but from the rear side, and thus in the
emitting direction or in the transmitting direction of the
diaphragm. The installation of the diaphragm and of the further
components of the ultrasound sensor can thus be performed from only
a single installation side, specifically from the rear side,
through the rear-side installation opening. Thus, the production
outlay is reduced, because no components have to be inserted into
the interior of the sensor housing from the front side. This
reduces not only the production outlay but also the production
costs.
[0019] The diaphragm is preferably received in the receptacle of
the cap with an accurate fit. This means in particular that the
radius of the receptacle of the cap substantially corresponds to
the outer radius of the diaphragm, and therefore at least a
front-side section of the diaphragm is adapted in terms of its
dimensions and its shape to the receptacle of the cap. Thus, a
form-fitting connection is produced between the cap and the
diaphragm. Thus, the base of the cap basically vibrates together
with the front side of the diaphragm and therefore does not
influence the vibration characteristics of the diaphragm, and also
does not prevent the propagation of the ultrasound signals.
Furthermore, the diaphragm can thereby be kept very stable during
operation.
[0020] The cap is preferably produced from a foil with a thickness
of less than 0.5 mm, in particular with a thickness of 0.2 or 0.25
or 0.3 mm. A particularly thin film of said type likewise permits
unobstructed propagation of the ultrasound signals, and thus does
not influence the operation of the diaphragm.
[0021] In one embodiment, the cap may, in particular on an inner
side facing toward the sensor housing, be formed with a coating
composed of metal, in particular of copper. A metallic coating of
said type has the advantage that the cap is thus of electrically
conductive form and forms a particularly good EMC (electromagnetic
compatibility) shield.
[0022] In one embodiment, the cap may be covered with a coat of
colour paint, in particular of the same colour as the vehicle
and/or of a colour according to customer preference. In particular,
the foil from which the cap is formed may already be a foil with a
coat of colour paint. That is to say, the cap may have colour paint
on the outer side, such that an ultrasound sensor of the desired
colour is assembled already during the assembly process, and later
painting can be dispensed with. It is thus possible to realize a
high-quality overall appearance of the paneling part of the motor
vehicle. It is thus possible to ensure a uniform, uninterrupted
colour design by way of the coat of colour paint.
[0023] The front side of the diaphragm is preferably connected to
the base of the receptacle of the cap by way of an adhesive pad.
The front side of the diaphragm thus bears on the inner side of the
base of the cap via the adhesive pad. Said adhesive pad may for
example be a double-sided adhesive pad with a thickness of 0.05 mm.
The use of the adhesive pad has the advantage in particular that no
dosing of a liquid adhesive, and no curing under the action of
heat, is necessary, whereby the required production time is
reduced.
[0024] In one embodiment, the cap is mounted onto the front side of
the sensor housing. The installation can thus be performed without
great outlay.
[0025] Provision may also be made for the cap to be welded to the
sensor housing, in particular by way of a laser welding apparatus.
By way of the welding process, a very strong and/or sealed
connection is realized which can withstand even relatively high
forces during the operation of the motor vehicle. Furthermore, use
may be made here of existing laser installations.
[0026] It may also be provided that an intermediate space between
the diaphragm and the sensor housing and/or an interior space of
the diaphragm is filled with a sealing compound, in particular with
a single-component sealing compound. Use may for example be made of
a silicone sealing compound, in particular a single-component
silicone sealing compound, and/or an insulation foam, in particular
a single-component foam, for example PU foam. It is then possible
to dispense with an external decoupling ring between the ultrasound
sensor and the paneling part of the vehicle. The advantage of a
single-component silicone sealing compound consists in the easy
application, and also in the fact that the sealing compound does
not foam.
[0027] The invention also relates to an ultrasound sensor for a
motor vehicle, having a diaphragm for emitting ultrasound signals
in an emitting direction, and having a sensor housing, in and/or on
which the diaphragm is fastened, wherein the sensor housing has a
front side, which points in the emitting direction of the
diaphragm, and a rear side, which points in a rearward direction
which is opposite to the emitting direction, and wherein, on the
front side, the sensor housing has a front-side opening for the
diaphragm. The front side of the sensor housing is connected to a
cap which is composed of a foil and by way of which the front-side
opening of the sensor housing is covered in the emitting direction,
wherein the diaphragm is inserted at least regionally into a
receptacle of the cap and a front side, which points in the
emitting direction, of the diaphragm is connected to a base of the
receptacle of the cap.
[0028] A motor vehicle according to the invention comprises an
ultrasound sensor according to the invention.
[0029] The preferred embodiments presented with regard to the
method according to the invention, and the advantages thereof,
apply correspondingly to the ultrasound sensor according to the
invention, and to the motor vehicle according to the invention.
[0030] Further features of the invention will emerge from the
claims, from the figures and from the description of the figures.
All of the features and feature combinations mentioned above in the
description, and the features and feature combinations mentioned
below in the description of the figures and/or shown in the figures
alone, may be used not only in the respectively specified
combination but also in other combinations or individually.
[0031] The invention will now be discussed in more detail on the
basis of some preferred exemplary embodiments and with reference to
the appended drawings, in which:
[0032] FIG. 1 shows, in a schematic illustration, a sectional view
through an ultrasound sensor according to the prior art; and
[0033] FIG. 2 shows, in a schematic illustration, a sectional view
through an ultrasound sensor according to a first embodiment of the
invention.
[0034] FIG. 2 shows an ultrasound sensor 20 according to an
embodiment of the invention. The ultrasound sensor 20 is provided
for installation on a paneling part of a motor vehicle, for example
on a bumper. Here, the ultrasound sensor 20 is provided in
particular for the visible, and thus non-concealed, installation on
the paneling part, such that, after installation on the paneling
part, a front side 62, pointing in the emitting direction 21 of a
diaphragm 23, of a cap 52 is visible from outside the motor
vehicle, and for example terminates flush with the outer surface of
the paneling part. It should however be understood that the
ultrasound sensor may alternatively also be installed in concealed
fashion. The ultrasound sensor is then not visible, and is
concealed by the paneling part, when the paneling part is viewed
from the outside. In that case, the ultrasound sensor would be
installed directly behind the paneling part, and ultrasound signals
would be emitted and received through the material of the paneling
part--normally plastic.
[0035] The ultrasound sensor 20 comprises a sensor housing 24 in
which the components of the ultrasound sensor 20 are accommodated
in protected fashion. By way of the sensor housing 24, the
ultrasound sensor 20 can be fastened to the paneling part. Here,
the sensor housing 24 is for example connected to a bracket and
fastened by way of the bracket to the paneling part. For example,
the sensor housing 24 is engaged with detent action into the
bracket. The sensor housing 24 is formed in one piece, for example
from plastic.
[0036] The sensor housing 24 has a front side 25, which points in
the emitting direction 21 or transmitting direction of the
diaphragm 23, and a rear side 26, which points in an opposite
direction 27. On the front side 25, there is formed in the sensor
housing a front-side opening 28 which is a passage opening.
Correspondingly, a rear-side installation opening 29 is also formed
on the rear side 26. In the non-installed state, an interior space
30 of the sensor housing 24 is thus delimited only in a radial
direction, and thus perpendicular to the emitting direction 21, by
the plastics material.
[0037] The sensor housing 24 furthermore has a plug connector 32 by
way of which the ultrasound sensor 20 can be electrically coupled
to a control unit of the motor vehicle.
[0038] The diaphragm 23 is of altogether pot-shaped form and is
composed for example of aluminium. The diaphragm 23 has a front
side 22 which points in the emitting direction 21 and by way of
which the ultrasound signals are emitted. The diaphragm 23 also has
a diaphragm base 33, which has the front side 22, and a cylindrical
encircling shell 34. At a rear side 35 situated opposite the front
side 22, the diaphragm 23 is open and has an opening 36. The
diaphragm 23 is formed without an encircling collar, and thus has
no collar.
[0039] On a rear side 38, which faces toward the interior space 30,
of the diaphragm base 33, there is arranged a piezo element 39
which is designed to excite the diaphragm 23. The piezo element 39
is supplied with electrical energy via a wire 40 and an electrical
contact element 41 and a contact pin 42.
[0040] The sensor housing 24 is, on its front side 25, formed with
an encircling seat 51 for the cap 52. The front-side opening 28 of
the sensor housing 24 and the diaphragm 23 are concealed by way of
the cap 52. The cap 52 is in this case formed from a foil, in
particular a plastics foil. It is in the form of a foil cup or a
foil hat-like structure and has a receptacle into which the
diaphragm 23 is inserted with an accurate fit. The front side 22 of
the diaphragm 23 is in this case adhesively bonded by way of an
adhesive pad 54 to an inner side, which faces toward the interior
space 30, and thus to a base 55, of the cap 52. Here, the shape of
the receptacle 53 is adapted to the shape of the diaphragm 23, such
that the internal diameter of the receptacle 53 substantially
corresponds to the external diameter of the diaphragm 23.
[0041] The cap 52 is mounted axially onto the encircling seat 51 of
the sensor housing 24 at the front side and is welded to the sensor
housing 24 by way of a laser.
[0042] The cap 52 has a thickness of, for example, 0.2 or 0.25
mm.
[0043] Two alternative methods for the production and for the
assembly of the ultrasound sensor 20 will be discussed in more
detail below:
[0044] In both methods, the sensor housing 24, diaphragm 23 and the
cap 52 are firstly provided separately from one another. Here, the
cap 52 may be punched out of a thin foil strip on a production line
and then deep-drawn in a tool at a high temperature. Said foil
strip is provided, on one side, with a copper coating which, after
the deformation to form the cap 52, is situated in the receptacle
53 and thus bears against the inner side and is placed in contact
with the adhesive pad 54.
[0045] The diaphragm 23 is produced without a collar for prevention
of relative rotation, and also does not need to be coated. Thus, an
additional surface protector on the diaphragm 23 is dispensed with,
because said diaphragm is protected by the cap 52.
[0046] In the first method, it is then the case that the diaphragm
23 is adhesively bonded in correctly positioned fashion into the
receptacle 53 of the cap 52 by way of the adhesive pad 54,
specifically without thermal curing. Then, the cap 52 can be pushed
together with the diaphragm 23 onto the encircling seat 51 of the
sensor housing 24 and connected thereto by way of a laser welding
apparatus.
[0047] In the second method, it is firstly the case that the cap 52
is connected to the sensor housing 24 or alternatively to a
separate holding element inserted into the sensor housing 24. Then,
the diaphragm 23 is inserted into the interior space 30 through the
rear-side installation opening 29, and is thereby placed into the
installed position at the front side 25 and received in the
receptacle 53 of the cap 52. To permit this, the contact pin 42 is
relocated radially further outward, such that the interior space 30
is, in a radial direction, at least as large as the outer diameter
of the diaphragm 23, and said diaphragm can be inserted into the
interior space 30, and placed into the installed position, without
obstruction.
[0048] In both methods, it is then the case, in a further step,
that the piezo element 39 is installed. Here, the piezo element 39
is inserted into the interior space 30 from the rear side 26
through the rear-side installation opening 29, and is positioned
on, pressed against and adhesively bonded to the rear side 38 of
the diaphragm base 33. Here, use may for example be made of a
liquid adhesive, optionally also an adhesive which cures at cold
temperatures and which preferably cures in the absence of air, as
described in DE 10 2011 120 391 A1. Alternatively, use may also be
made of an adhesive pad.
[0049] It is then possible for the contact element 41 to be bent
from the sensor housing 24, and the wire 40 is welded on and
connected to the piezo element 39.
[0050] In both methods, it is then the case, in a further method
step, that an intermediate space 61 between the diaphragm 23 and
the sensor housing 24, and optionally also the interior space of
the diaphragm 23, and optionally also an adjoining region of the
interior space 30 of the sensor housing 24, is filled with a
sealing compound 60. Here, use is preferably made of a
single-component sealing compound, such as in particular a
single-component foam and/or a single-component silicone sealing
compound.
[0051] In a further assembly step, the printed circuit board 50 is
mounted or pushed onto the contact pins 42, 43.
[0052] A printed circuit board 50 is then mounted onto the contact
pins 42, 43. Subsequently, the space between the printed circuit
board 50 and the installation opening 29 may likewise be filled
with a sealing compound, for example a single-component foam and/or
a single-component silicone sealing compound. In addition or
alternatively to the sealing compound, use may also be made of a
plastics cover 49, in particular in the form of a plastics foil, to
cover the rear-side installation opening 29. Said plastics cover 49
may for example be welded to the sensor housing 24 by way of
ultrasound. It is optionally possible for an inner side of the
cover 49 or of the foil to be provided with a metal layer, composed
in particular of copper, which then acts as an additional EMC
shield.
* * * * *