3D Printed Acoustic Backing with Integrated Infiltration Mold
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Solution Overview
Problem
The manufacturing of acoustic backings with a porous structure filled with filler material is challenging due to difficulties in ensuring full infiltration, leading to potential defects such as pockets of air that can result in scrapped transducers or noise during scans.
Innovation Solution
The method involves 3D printing a single part that includes both a porous structure and a solid structure, with the porous structure configured to attenuate acoustic energy. This single part is then infiltrated with filler material and cured, ensuring that the filler material remains within the porous structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional infiltration methods are used to fill porous acoustic backing structures, then filler material can be introduced into the porous structure, but air pockets and incomplete infiltration occur leading to defects
Solution Approach 1:
The patent changes the physical parameters of the infiltration process by applying vacuum pressure to remove air from the porous structure before filler material introduction. This parameter change (pressure differential) ensures complete infiltration and eliminates air pockets that would otherwise remain with traditional atmospheric pressure methods.
Solution Approach 2:
The patent performs preliminary actions by pre-treating the porous structure through vacuum drying to remove air and moisture before filler infiltration. This preliminary preparation ensures the porous structure is ready to accept filler material completely and uniformly, preventing future defects.
2Ease of manufacture
If the porous structure is left open during infiltration, then filler material can enter easily, but filler material leaks out during curing
Solution Approach 1:
The patent uses a flexible membrane that can dynamically change its state between open and closed positions. During infiltration, the membrane is open to allow filler material entry; during curing, it closes to retain the filler material. This dynamic adjustment resolves the contradiction between ease of infiltration and filler retention.
Solution Approach 2:
The flexible membrane acts as an intermediary element between the porous structure and the external environment. It mediates the conflict by selectively controlling material flow - permitting infiltration when needed and preventing leakage when required - without permanently modifying the porous structure.
3Adaptability or versatility
If multiple separate components are used for acoustic backing manufacturing, then each component can be optimized independently, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The patent combines the porous structure, infiltration mold, and retention mechanisms into a single integrated component that can be additively manufactured as one piece. This merging eliminates the need for multiple separate components and assembly steps, significantly improving manufacturing efficiency while maintaining the functional benefits of component optimization through additive manufacturing design.
Solution Approach 2:
The integrated component serves multiple functions simultaneously: it provides the acoustic backing porous structure, acts as the infiltration mold, and includes the flexible membrane for filler retention. This multi-functionality eliminates the need for separate optimized components while maintaining adaptability through additive manufacturing's design flexibility.
4Shape
If additive manufacturing is used to create the porous structure, then complex geometries can be achieved, but ensuring complete infiltration and avoiding defects becomes more difficult
Solution Approach 1:
The patent applies preliminary vacuum treatment to the additively manufactured porous structure before infiltration. This preliminary action removes air from the complex geometry's internal passages and pores, ensuring that subsequent filler material infiltration is uniform and complete throughout the complex shape, preventing air pocket defects.
Solution Approach 2:
The patent uses controlled pressure parameter changes during infiltration - applying vacuum to facilitate entry into complex geometries and then switching to positive pressure to ensure complete filling. These parameter changes overcome the infiltration challenges posed by complex additive manufacturing geometries.
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 enables the production of high-quality acoustic backings with improved acoustic attenuation and reduced scrap rates, while also reducing the risk of supply chain disruptions by integrating the infiltration mold within the additive manufacturing process.
Implementation Method 1
the porous structure is configured to attenuate acoustic energy
Implementation Method 2
the single part is configured both to enable the filler material to enter the porous structure during infiltration
Implementation Method 3
curing the single part
Data Source
AI summary
A method for manufacturing an acoustic backing of a transducer probe is provided. The method includes utilizing three-dimensional (3D) printing to print a single part including both a porous structure and a solid structure, wherein the porous structure is disposed within the solid structure, and the porous structure is configured to attenuate acoustic energy. The method also includes infiltrating the single part with filler material. The method further includes curing the single part, wherein the single part is configured both to enable the filler material to enter the porous structure during infiltration and to keep the filler material contained in the porous structure between the infiltration and curing of the single part.