Acoustic Matching Layer Material Set for Probe Formability
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Solution Overview
Problem
Existing acoustic matching layers for acoustic wave probes face challenges in maintaining uniform acoustic characteristics and formability during secondary processing, such as cutting or dicing, which affects the efficiency and quality of the acoustic wave probe.
Innovation Solution
A material set comprising a base resin made of an epoxy resin and metal particles with a monodispersity of 40% to 80% is used, along with a curing agent, to form a sheet shape with improved mechanical strength and reduced variation in acoustic characteristics, enabling high-yield production with minimal cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If metal particles with low monodispersity are used in the acoustic matching layer, then the material can be easily formed, but the acoustic characteristics become non-uniform
Solution Approach 1:
The invention changes the particle size distribution parameter by specifying a monodispersity of 40% to 80%, which optimizes the balance between formability and acoustic uniformity. This parameter control ensures that the metal particles are distributed uniformly enough to provide consistent acoustic characteristics while maintaining sufficient flowability for easy formation during secondary processing such as cutting or dicing.
2Reliability
If the acoustic matching layer is made with high metal particle content to increase acoustic impedance, then the acoustic impedance matches better, but the mechanical strength decreases
Solution Approach 1:
The invention uses a composite material consisting of metal particles dispersed in a binder material. This composite structure allows the acoustic matching layer to achieve the desired acoustic impedance through the metal particles while the binder material provides the necessary mechanical strength and cohesion to maintain structural integrity during handling and secondary processing.
Solution Approach 2:
The invention applies different materials with different properties to different functional requirements: metal particles are used where acoustic impedance is needed, while the binder material is used where mechanical strength is needed. This local quality approach allows each component to fulfill its specific function optimally without compromising the other.
3Productivity
If the acoustic matching layer undergoes secondary processing like cutting or dicing, then the production efficiency increases, but cracking occurs reducing yield
Solution Approach 1:
The invention optimizes the particle size distribution parameter (monodispersity of 40% to 80%) to improve the material's formability. This optimized distribution allows the acoustic matching layer to be cut or diced into desired shapes during secondary processing without cracking, thereby enabling high-yield production while maintaining production efficiency.
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 material set allows for the formation of acoustic matching layers with enhanced formability and uniform acoustic characteristics, leading to more efficient ultrasound transmission and reception with reduced reflection at the interface, thereby improving the overall performance of acoustic wave probes.
Implementation Method 1
a base resin made of a resin composition including an epoxy resin and metal particles; and separately a curing agent for the epoxy resin
Data Source
Figure 1
AI summary
Provided are a resin composition for an acoustic matching layer; an acoustic matching sheet formed from the composition; an acoustic wave probe; an acoustic wave measuring apparatus; a method for manufacturing an acoustic wave probe; and a material set, for an acoustic matching layer, that is suitable for preparation of the composition, in which the resin composition for an acoustic matching layer includes a binder including a resin; and metal particles having a monodispersity of 40% to 80%, wherein the monodispersity is calculated by equation (1): monodispersity%=standarddeviationofparticlesizesofmetalparticles/averageparticlesizeofmetalparticles×100.