Acoustic Matching Layer Resin Composition for Ultrasonic Probes
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Solution Overview
Problem
Acoustic probes used in acoustic measuring apparatuses face challenges with mechanical strength and consistency in acoustic characteristics due to variations in the acoustic matching layer, leading to inefficient ultrasonic wave propagation and reduced product lifespan.
Innovation Solution
A resin composition comprising specific epoxy resins, a polyamine compound, and metal particles is used to form an acoustic matching layer with enhanced mechanical strength and reduced variation in acoustic characteristics, improving the efficiency of ultrasonic wave propagation and product durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional resin compositions are used for the acoustic matching layer, then the acoustic probe can be manufactured, but the mechanical strength is insufficient and there is large variation in acoustic characteristics
Solution Approach 1:
The patent uses a composite resin composition comprising multiple components: epoxy resin (A), polyamine compound (B1) with specific molecular structure containing oxygen-containing aliphatic hydrocarbon groups, and polyamine compound (B2) as curing agents. This multi-component composite system provides both high mechanical strength and consistent acoustic characteristics by combining the beneficial properties of different materials while maintaining uniform dispersion and curing behavior throughout the acoustic matching layer.
Solution Approach 2:
The patent specifies precise parameter ranges for the resin composition components, including the molecular structure of polyamine compound (B1) with oxygen-containing aliphatic hydrocarbon groups having specific carbon atom numbers, and the ratio of (B1) to (B2). By controlling these chemical and physical parameters within defined ranges, the invention achieves optimal balance between mechanical strength and acoustic characteristic consistency.
2Length of moving object
If the acoustic matching layer is made thinner to reduce size, then the acoustic probe becomes more compact, but the mechanical strength during cutting processing becomes insufficient
Solution Approach 1:
The enhanced composite resin system provides high mechanical strength even at thin dimensions, enabling the acoustic matching layer to be made thinner while maintaining sufficient strength during cutting processing and subsequent use.
Solution Approach 2:
By optimizing the chemical composition parameters, particularly the use of polyamine compound (B1) with oxygen-containing groups that enhance intermolecular interactions, the resin achieves higher mechanical strength at reduced thickness, allowing thinner acoustic matching layers to withstand cutting processing.
3Measurement precision
If the acoustic matching layer is made thinner to improve resolution, then the acoustic probe achieves better imaging resolution, but the product lifespan is reduced due to insufficient mechanical strength
Solution Approach 1:
The robust composite resin composition maintains high mechanical strength at thin dimensions, allowing the acoustic matching layer to be made thinner for improved imaging resolution while ensuring sufficient durability for long-term product use.
Solution Approach 2:
The optimized chemical parameters of the resin system, particularly the molecular structure and ratios of polyamine compounds, provide enhanced mechanical properties that enable thin acoustic matching layers to achieve both high imaging resolution and extended product lifespan.
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 proposed solution results in an acoustic probe with high mechanical strength and consistent acoustic characteristics, enhancing the efficiency of ultrasonic wave propagation and extending the product's lifespan by stabilizing the dispersion of metal particles within the matching layer.
Implementation Method 1
a polyamine compound (B1) which has an aliphatic hydrocarbon group having an aliphatic hydrocarbon chain into which at least one oxygen atom is incorporated; and metal particles (C), wherein the polyamine compound (B1) and the epoxy resin (A) fill gaps between the metal particles (C) and serve as dispersion media for the metal particles (C)
Implementation Method 2
an epoxy resin (A) and a polyamine compound (B1)... The cured product having high mechanical strength and little variation in intrasheet acoustic characteristics
Implementation Method 3
The acoustic impedance of the acoustic matching layer is between the acoustic impedance of a living body or the acoustic lens and the acoustic impedance of the piezoelectric element, which increases the efficiency of propagation of ultrasonic waves
Data Source
Figure 1
AI summary
Provided is a resin composition for an acoustic matching layer and containing an epoxy resin (A), a specific polyamine compound (B), and metal particles (C), wherein the epoxy resin (A) includes at least one type of epoxy resin from among bisphenol A epoxy resins, bisphenol F epoxy resins, and phenol novolac epoxy resins. Additionally provided are a cured product using said composition, an acoustic matching sheet, an acoustic wave probe, an acoustic wave measurement device, a production method for an acoustic wave probe, and a materials set for an acoustic matching layer.