US 2017005969781 cu») United States 2) Patent Application Publication co) Pub. No.: US 2017/0059697 A1 oy on my om an 2) (60 Gt Esmail IIDDEN ULT SONIC SENSOR ASSEMBLY Applicant: Tesla Motors, Inc, Palo Alto, CA (US) Inventor: Adnan Esmail, Palo Alo, CA (US) Assignee: Tesla Motors, Ine, Palo Alto, CA (US) Appl. No, File: 18/283,221 Aug. 31, 2016 Related U.S. Application Data Provisional aplication No. 62/212,529, filed on Avg 31, 2015, Publication Classitieation Int. Cl Gois 7521 (2006.01) Boos Sos (2005.01) GoIs 15/0 (2006.01) (43) Pub. Date: Mar. 2, 2017 (2) s.c1 cre GOIS 7/821 2013.01); GOIS 15/00 (2013.01); Bad S412 (2013.01) on ABSTRACT An ultrsonie sensor assembly is placed against an inside surface of a panel for sensing objets on an opposite side of the panel and includes an ultrasonic sensor, a preload structure, # coupling element, andl a damping material The preload structure applies preload on the ultrasonic sensor ‘oward the inside surface of the panel. The coupling element interfaces between the uiltmscnic sensor and the inside surface of the panel. The damping materials placed against the inside sutface but not where the coupling element interfaces between the ultrasonic sensor and the inside surface. The coupling element may include a matrix material {hat is reinforced with a fillerPatent Application Publication Mar. 2, 2017 Sheet 1 of 5 US 2017/0059697 Al FIG. 1Patent Application Publication Mar. 2, 2017 Sheet 2 of 5 US 2017/0059697 Al 206 FIG. 2Patent Application Publication Mar. 2, 2017 Sheet 3 of 5 US 2017/0059697 Al 500 502 506 508 FIG. 3Patent Application Publication Mar. 2,2017 Sheet 4 of 5 US 2017/0059697 AL FG. 4Patent Application Publication Mar. 2,2017 Sheet Sof 5 US 2017/0059697 ALUS 2017/0059697 Al HIDDEN ULTRASONIC SENSOR ASSEMBLY CROSS REFERENCE TO RELATED 'APPLICATIONS| {0001} The present application claims priority pursuant 10 35 USC. $119(e) t© US. Provisional Application No. 62/212,529, filed 31 Aug. 2015, entitled “Hidden Ultrasonic Sensor Assembly”, which is hereby incorporated herein by reference in its entirety and made part of the present US. Uaility Patent Application forall purposes BACKGROUND 10002] Fora few decades, some vehicle models have bees ‘equipped with proximity sensors to help the driver avoid running into obstacles in cerain situations, such as whea ‘Boing in reverse. These sensors have generally been of the ‘exposed type, where the vehicle has a small opening in a panel or fascia, and the sensor is mounted in the opening Where it extends somewhat from the surface, To make the sensors less visually distracting, they are sometimes colored based on the vehicle surface where they are mounted. Nevertheless, the sensors are usually noticeable, as they are ‘often placed in otherwise smooth decorative surlaces BRIEF DESCRIPTION OF DRAWINGS 10003] FIG. 1 shows a partial ewss section of an example ‘fan ultrsonie sensor assembly when mounted inside 3 body panel {0004} FIG, 2 shows the sensor opening of damping material having an acoustic foam {0005} FIG. 3 illustrates a field of view for a hidden Uultasonie sensor assembly. 10006] FIG. 4 shows an example of @ hidden ultrasonic sensor on a vehiele with dual hinge doors 10007] FIG. § shows an example of a hidden ultrasonic sensor on vehiele frontend, DETAILED DESCRIPTION 10008] This document deseribes examples of systems and Techniques for mounting an ultrsonie sensor assembly’ on the inside of exterior vehicle surfaces where its not visible from the outside (i, the sensor is Whidden”), such tha the sensor ean range trough the material and detect objects near the vehicle. This not only eliminates the unsightly sensor hheads that can be seen dotting the bumper fascia of many Vehicles, hu it also eretesineressed Mleibiliy by allowing the assembly to be mounted behind pansl materials of “different transmissive properties, such as metals and plastic 10009] An ultrasonic sensor assembly is configured for ‘mounting on the inside surface ofa vehicle panel to old an ultrasonic sensor against the inside surface with a certain amount of preload, The prefoad serves to ensure proper transmission and reception of acoustic waves By the Sensor through the panel. The assembly can include a holder of ‘other bracket with any suitable numberof Teps, such as theee Jegs. For example, the holder ean be positioned in the center ‘of the assembly, and the (three) legs can extend radially fom the holder in a symmetrically spaced relationship. These and ‘ther features ofthe assembly can be formed by an injection ‘molding process. At the end of each leg is «pad. The pad is ‘configured for being attached to the inside surface to mount Mar. 2, 2017 the holder in place. In some implementations, an adbesive is used for attachment. For example, a UV polymerizing adhesive can be used [0010] Reganting the mode of attachment to the inside surface, the Sensor bracket wil be spring-loaded to impart a ‘normal foree on the sensor face against the panel. For this reason, a counter force will be pling against the bond sites fof the sensor bracket. This bond line will therefore be under ‘constant tension, The adhesive system should bond well 10 the bracket material and the panel surface material. Por ‘example, it should perform well over an intended service temperature range as well as survive ina wet eavironment, all while maintaining sufficient bond stength to suppor the ‘constant tensile load. When a sensor is bond directly to the inner surface of an outer wehicle panel (a*Class A” surface), the adhesive system should additionally impart minimal stresses due shrinksge-upon-curing, or theanal expansion ‘mismatch, Thats, distoron ofthe outer surface of the panel should be prevented for aesthetic and other reasons [0011] ‘The bracket can have a housing at its center. This housing can be configured for having the ultrasonic sensor ‘mounted thereto or therein. For example, the housing ean include a biasing element such asa spring that gets om the sensor ina direction towad the inside surface, The sensor bracket will be under light load throughout its fe. One ean therefore choose a material forthe bracket that has sufficient slilfless to minimize stress relaxation, withstand environ- ‘meatal stress cracking or comosion, and maintain dimen- sional stability over the fll sevice temperature range and ia a wet environment [0012] The bracket inthis example penerates the preload ‘on the sensor by being mounted onto the same inne surface that the sensor acts against. In other implementations, how- ever, another structure ean instead or additionally be used For example, the preload can be generated by revcting off sanather door panel ofa frame: [0013] FIG. 1 shows a partial erss section of the ultra sonie sensor assembly when mounted inside panel 200. For ‘example, this ean be a body pane tha has an outer surface 2200, (2. facing away from a vehicle) and an nner surface 2008 (e.2 facing into the vehicle). A sensor 108 ean be ‘mounted inside the housing. For example, this ean be an lirasonie sensor configured for generating acoustic waves, ‘which are used as object-detecting signals and for receiving echo retimn signals when an object is detected, In some implementations, the sensor 108 operates at about 50 kHz ‘and generates vibrations that can be about 500 nm peak-to- peak. This creates an acoustic field on de panel surface that ropsgates off that surface and outward, The acoustic waves ff the reflected returns, moreover, transmit through the various layers of matter with some amount of absorption, reflection, and transmission, [0014] The sensor 108 (here partially shown) is mounted {o the imer surface 2008 through an opening 404 formed in damping material 204. Here, the damping, material 204 is visible on only ane side of the sensor 108, but in some implementations, it ean surround the sensor 108. A leg 10 extends from the housing and can have a length suitable for providing a certain preload on the sensor against the inner surface, One or more pads (not shown) can be attached on the log (eat the end thereof, the pad{s) configured for being movnied to the inaer surface through other openings {formed in the damping material, The damping material 204 serves to focus acoustic energy and can reduce ring dowUS 2017/0059697 Al time. That i, the sensor 108 coupled to the inner surface 2008 causes vibrations that propagate nidally outward on the panel, andthe damper ean help direct that burst in the Intended direction (Le, toward the outside) as well as reduce ‘oscillations inthe system afer such an acoustic burst [0015] The damping material 208 should dampen the pane] vibrations over the fiequeney (ultrasonic) and Intended service temperature range (@-2.. ~40 to 90 C). The ‘damping material 204 should therefore be bonded intimately to the pane! 200 and remain bonded throughout its service Jif. Panel damping ean be accomplished in several ways. “Tins damping material 204 may include, but isnot listed 1o, viscoelastic material that absorbs and dissipate acoustic ‘energy Va strain and shear, a containe-layer system, panel stiffening material, and/or combinations of these. Para ‘ters that characterize a specific pplication can include & high resonant frequency (e., about 50 KEi2), the intended service temperature range, survivability in a wet environ- rent, and the ability of the material to withstand conan ‘manufacturing processes, such at a heating stage that may be part of a painting process, In some implementations, the ‘damping material 204 includes hutyl rubber. For example, the surface area and material thickness can be selected 0 achieve a beneficial signal-to-noise ratio across an intended range of operating temperatures. [0016] The damping material 204 can be mounted onto the inner surface 2008 in any suitable way, for example by a sive. The size, shape and thickness of the damping ‘material 204 can be selected based on the characteristics of the implementation and its intended use. ‘The damping material 204 can have one or mee openings that expose part ‘of the underlying inside surface 2008, such as the opening 404, For example, this ean be one of mote circular opening (@). The openings can he used by the sensor 108 andor the assembly pads [0017]. When the sensor 108 operstes, it goes through fring phase where the acoustic Waves are generated, fl- Jowed by a ring down phase where the sensor 108 is no Jonger signaling but some amount of residual vibrations ‘occu. Assuming that at east one abject i located within the range of the sensor 108, the sensor 108 should eventually receive an echo retum signal. 10018] To improve transmission and reception, andl reduce noise, « coupling element 206 can be placed between the sensor 108 and the inaer surface 2008 ofthe panel 200, This ‘coupling element 206 interfaces between the sensor 108 and the pane! 200 such that one side ofthe coupling element 206 ‘buts the sensor 108 surface aad the ollier side abuts the inner surface 2008 of the pane 200. The assembly can benefit fom acoustic impedance matching provided by the ‘coupling element. For example, as the acoustic wave is transmitted from the sensor 108 and into the panel 200 material, the coupling element 206 can seek to mateh the scoutic impedance across cach of these layers as well as Possible to reduce reflection. The material ofthe coupling ‘element 206 should therefore interface intimately with the sensor 108 membrane and the panel 200 to transfer acoustic ‘energy elicienty [0019] For example, here « material 208 of the eovpling ‘element 206 is schematically shown to include a matrix 210 that inchides one or more types of filler 212. The material 208 can he chosen based on the ability to funtion aver @ temperitife range andlor to withstand a wet envionment. ln some implementations, the filler 212 ean be a rigid oF sil Mar. 2, 2017 ‘orhigh-modulus membrane or acoustic transducing element, such as a mesh, andthe matrix can include a viscoelastic oF elastomeric material. For example, a Silicone matrix with a Iiherglss filler a be used. The high-modulus material ean provide low acoustic impedance and. good vibrational energy tunsler, while a compliant matrix: material ean ‘maintain intimate wetting of the two surfioes with minimal fcoustc losses. The coupling clement 206 may be pos tioned on a faceof the sensor 108. For example, the coupling 206 material and the sensor 108 face cat have the same iameter 0020} In an implementation, an ultrasonic sensor assem- "e mounted inside a body panel. The body pane! can ted to, door skin forthe door ofa vehicle this ean be a door at second 708 of seats, For example, a second-row door can be of the ‘dual-hinge type, which is configured for opening and closing substantially ina vertical direction, For example, any or all structures described in the following US, patents ean be used: US. Pat. Nos.8.440,015;8,511,738; 8,511,739: andlor 1D678,154, the contents of each of which are incorporated herein by reference in thet entirety [0021] A harness or other conductor ean be used with the sensor assembly. ‘This allows another unit to power the Sensor 108 on and of, and to reoeive the sensor 108 output {or processing. For example, the sensor 108 can be coupled {0 a central vehicle body contoller or to a dedicated eon- troller for the door. [0022] The above is an example of an ultrasonic sensor assembly configured to be placed against an inside surface 2008 of panel 200 for sensing objects on an opposite side ‘of the panel 200. Such assembly’ includes an ultrasonic sensor and a preload sieuctire having the ultrasonic sensor ached thereto. Moreover, the preload stricture applies preload on the ulrasonie sensor toward te inside surface, A hidden ultrasonie sensor is more flexible and reliable to use when its vibration raqueney ean be adjusted tothe partiew- Jarmaterial used in the pane. For example, this improves the signal transmission strength through the material which Grell affects its usefulness. [0023] FIG. 2 shows structure 400 ofthe sensor opening 404 of the damping material 204, which is acoustic foam 408. Only a portion of the damping. material 204 is here shown for simplicity: The coupling element 206 is shown inside the opening 404. In some implementations, the open- ‘ng. 404 in the damping material 204 is larger than the coupling clement 206 such that an area of the inside panel surlace 2008 is exposed. Here, an area 410 is defined between the coupling clement 206 and the damping material 408. For example, this size differonce ean be selected t0 ‘ciltate installation ofthe sensor assembly. [024] However, having exposed metal can capture residual acoustic waves, which can create noise in the sensor signals. For example, the sensor 108 is radiating. both ‘outward aod inward, and i the inward radiation bounces of some stracture, such as a door inner frame, a residual fcoustic wave will come back and be picked up by the Sensor as an echo. [0025] For this reason, the assembly ean inclade the acoustic foam 408 that dampens or absorbs airborne acoustic ‘waves. For example, the acoustic foam 408 is ring sbapod and has an inner opening 404 that fits the sensor 206. Many ‘material constrictions can be used as acoustic absorbers, s.An acoustic materialUS 2017/0059697 Al ‘can be selected based on its ability 10 absorb ultrasonic frequencies, perform over an intended temperature range ‘and perform in a wet environment, In some implementa: tions, a ightweight elosed cell foam is used. For example, iftan acoustic foam wero absorb water and then freeze de to cold weather, it may not absorb sound as wel. 10026] FIG. 3 illustates a field of view for a hidden ultrasonic sensor assembly. Here, the assembly includes 2 sensor 800 that is placed agains the inside surface of panel 502, Any assembly siractures described elsewhere herein ‘ean also be used, steh 2s 2 coupling element that interfaces between the sensor and the pal. The field of view generally indicates the area in whieh the hidden seasor ean be used for object detection. Here, for example, the object was a pole having @ one-inch outer diameter, and the testing Was performed at 25 degrees C. The results inthis example show that the sensor has afield of view S04. Generally the field ‘of view can be characterized by its depth $06 from the panel ‘and its maximum width 808, Tn this example, the depth was 110 om and the wick was 100 cm, 10027] FIG. 4 shows an example of hidden ultrasonic sensor 600 on a vehicle 602 with dusl-hinge doors 604. The ‘doors 604 are here the eur passenger doors of the vehicle ach of these doors ean include a hidden ultrasonic sensor assembly for example in the lower door part thereof, which js the port that extends essentially down the side of the Vehicle when the door is loved. The upper door par, on the ‘ther hand, can form part of the vehicle's root when the door is closed 10028] The doors 604 are hinged to the vehicle body at a Spine are 606. For example, the spine area 606 ean include 4 cast alominum part that is part of the vehicle body. The spine area ean be covered by an applique or another cover pane. The applique can be made of any’ suitable material, ‘including, bul not limited wo, polycarbonate or @ mixture of polyearbonate and acrylonitrile butadiene styrene [0029] The doors 604 are configured o open ina substan- tally vertical direction. When the door 604 is in. an open position, some or all of tie dace 604 is positioned above the rest ofthe Vehicle's roof, Its therefore desirable wo use & proximity sensor 9 sense obstructions above the vehicle 602, Because implementations deseribed herein facilitate use of hidden ultrasonic sensors that can range through varity of materials, such an assembly can advantageous} be installed om or near the vehicle's roof. Here, the sensor 600s shown in phantom because it is positioned underneath the applique tht covers the spine area 10030] The sensor 600 can be part ofan assembly that also lnchides any other sirvctures described elsewhere herein, sueh as a coupling element that interfaces between the sensor and the panel. Because plastic have different trans- missive properties than metal, some aspects of the install tion can be changed. For example, because plastic dampens ‘more than metal, the damping element can be made smaller ‘and/or thinaer. As auother example, the paste material ean be thinned down atthe sensor to improve transmission and reception, 10031] |The reof-mounted sensor 600 can operate in con- junetion with one or more other sensors, such as hidden ultrasonic sensors, For example, this sensor 600 anda sensor hidden in the oseer door part can both be ative when the ‘door is in motion, so that the system can perform object tection using both thei respective fields of view. Hiden Uullasonie sensors ean also or instead be placed elsewhere i Mar. 2, 2017 the vehicle. For example, one or more sensors can be Jnstled in frontend 608 or rear end 610. {0032} FIG. & shows an example of a hidden ultrasonic Scoso# 700 on vehicle font end 702. The iden etalon tthe scasor assembly provides a clean and clegantsotion for proximity detection. As such, several sensors ean be installed inthe frontend without becoming a visual distrac- tion Similarly, atleast one hidden sensor ean be povided anor are of the veil (not shown), such sender or area ead [0033] One oF more embodiments have been described hove with the aid of method steps illstating the perfor cof spesified functions ad relationship tere. The ‘oundares and sequence ofthese Functional viding blocks and method stepe have beea abitaly defined herein for convenience of description. Altemate boundaries and Sexjuences canbe defined so Tong a the specified functions tnd roltionships are appropriasly performed. Any sich alkemate boundaries or saquences are ths within the scope fnd spit of the claims, Furher, the boundaries of those Teton building blocks have been arbitarly defined for convenience of description. Alienate boundaries could be Getined as loag a the certain significant fonctions are appropriately performed. Similars. flow diagram. blocks may also have been aeitarly defiaad herein to illstate certsin signieantfuetionlit. {0034} ‘To the extent used, the flow diagram block bound aries and sequence could have been defined otherwise atid Stl perform the certain significant functionality. Such alter Bute definitions ofboth functional building blocks and low diagram blacks and sequences are this within the scope ad Spit of the elas, One of average skill a thea wil lao ‘Beognize that the functional building block, and other Ailsratve Blocks, modules and components erwin, can be plemented s illustrated or by discrete components, appli- cation spevific integrated iets, processors exceting Appropriate software and the like or any combination there: [0035] The one oF more embodiments are used herein ‘ihstrate one oe more apeets, one oF more Fates, one oF ‘more concepts, anor ne of ore examples. A physical embodiment of an apparatus, an article of manuftctre, a ‘machine, andor ofa process may include one or mar of the aspects, features, conceps, examples, ete. described with reference 10 one or more of the cinbodiments dscusted herein. Further, from Figure © Figure, the embodiments say incorporate the same or similarly named functions Ss, modules, et. that may tse the same or different referenoe numbers and, as such, the fanctions, steps, mode es, ete. may be the same or sinilae functions, steps, nol, et. or diferent ones (0036) While particular combinations of various functions und features of the one oe more embodiments have been expressly desribed hori, other combinations of these Features and functions age ikewise possible. The prosat disclosure snot limite by the particular examples ciclo herein and expressly incorporates these ober combinations What is claimed is 1. An ultrasonic sensor assembly configured to be placed ‘against an inside surface of a panel for sensing objects on an ‘opposite side of the panel, the ultrasonic sensor assembly comprisingUS 2017/0059697 Al ‘an ultrasonic sensor ‘ preload structure having the ultrasonic sensor attached thereto, the preload structure configured for applying & preload on the ulirwsonie sensor toward the inside surface; ‘coupling clement that interfaces between the ultrasonic ‘sensor and the inside surface ofthe panel; and ‘damping material placed against the inside surface and ‘not were the coupling element interfaces hetwoen the tlissonic sensor and the inside sur 2. The ultrasonic sensor assembly of claim 1, further ‘comprising an aooustie foam configured for absorbing air- ome acoustic waves, 3. The ultasonic sensor assembly of euim 2, wherein the acoustic foam is placed on top of the damping. materia 4. The ulirasonie sensor assembly of elaim 3, wherein the ‘damping material has an opening in which the coupling ‘leaient interfaces between the ulteasonie seasor and the inside surfaee, wherein the opening is larger than the cou- pling clement so that an anva of the inside surface exists between the coupling clement and the damping material and herein the acoustic foam is positioned so as to substantially ‘cover the area ofthe inside surface. 8. The ultrasonic sensor assembly of eam 1, the coupling ‘element comprises a matrix moterial that is reinforced with ‘filler. 6, The ultrasonic sensor assembly of esi $, wherein the matrix material comprises an elastomer or a viscoelastic material 7. The ultrasonic sensor assembly of elsim 6, wherein the ‘matrix materiel comprises Silicone 8, The ultrasonic sensor assembly of elaim $, wherein the filler comprises a mesh, 9. The ultrasonic sensor assembly of elsim $, wherein the ‘ler comprises fiberzass. 10. The ultrasonic sensor assembly of claim 1, wherein the panel is part of a door on a vehicle 1. The ultrasonic sensor assembly of elsim 19, wherein the door is a dual hinge door configured for opening and ‘losing substantially ina vertical direction. 12, The ulttasonie sensor assembly of claim 1, wherein the preload structure is configured for being attached to the inside surface Mar. 2, 2017 13, A method comprising fenerating ultrasonic waves through a panel by an ultra sonic sensor, the ultrasonic sensor Raving coupling Clement that interfaces between the ultrasonic sensor and an inside surface ofthe panel, the coupling element ‘comprising a matrix material that is reinforced with filler damping acoustic waves in the panel using a damping ‘material placed against the inside surface and aot where the coupling element interfaces between the ulrasonic sensor and the inside surface: absorbing. airbome acoustic waves using an acoustic foam, wherein the damping material has an opening in ‘which the coupling element interfaces between the Ultasonie sensor and the inside surface, wherein the ‘opening is lager than the coupling element 0 that an area of the inside surface exists between the coupling clement and the damping material, and wherein the ‘acoustic foam is positioned so as to substantially cover the area of the inside surface; and receiving aa echo retur wave through the pane using the ‘ultrasonic sensor 14, The method of claim 13, further absorbing airborne acoustic waves by an acoustic foam, 15, The method of elsim 14, wherein the acoustic fom is placed on top of the damping material 16, The method of elaim 18, wherein the damping mate- rial has an opening in which the coupling element interfaces between the ultrasonic sensor and the inside surface, ‘wherein the opening is larger than the coupling element $0 ‘hatan area of the inside sce exists between the coupling clement and the damping material, and wherein the acoustic Toam is positioned soa to substantially cover te area ofthe inside surface. 17. The method of claim 13, the coupling element com- prises matrix material that is reinforced with a fille 18, The method of elaim 17, wherein the mateix material comprises an elastomer or a viscoelastic material, 19, The method of elaim 17, wherein the mateix material comprises Silicone. 20. The method of claim 17, wherein the filler comprises fone oF more of a mesh or fiberglass