Disposable Ultrasonic Sensor Using Adhesive Tape Coupling

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Solution Overview

Problem

Existing non-contact ultrasonic transducers require a coupling compound for effective operation, which is impractical in fast-moving applications, can damage surfaces, and is not suitable for sanitary environments, and are not easily movable or disposable.

Innovation Solution

A non-contact ultrasonic transducer with a piezoelectric element mounted in a housing, where one face of double-sided adhesive tape is attached to the housing and directly to the vessel or tube, eliminating the need for external coupling compounds and allowing easy mounting and removal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a coupling compound is used between the transducer housing and the vessel or tube, then ultrasonic energy transmission is improved, but the device becomes more complex and requires additional mounting steps

Engineering Contradiction:

Improveultrasonic energy transmissionVSAvoidmounting complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The adhesive tape combines the mounting function and coupling function into a single component. The tape is applied directly to the transducer housing front end and adheres to the vessel or tube surface, simultaneously providing mechanical attachment and ultrasonic coupling without requiring separate coupling compound application

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The adhesive tape is extracted from its traditional use as merely a mounting component and given the additional function of ultrasonic coupling. This eliminates the need for separate coupling compounds while maintaining effective ultrasonic energy transmission through the interface

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If a coupling compound is applied to each vessel or tube, then ultrasonic transmission is improved, but the productivity decreases due to time-consuming application

Engineering Contradiction:

Improveultrasonic energy transmissionVSAvoidmounting speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The adhesive tape is pre-applied to the transducer housing front end during manufacturing, so that when the transducer is mounted on a vessel or tube, the coupling interface is already prepared. This eliminates the need for operators to apply coupling compound to each individual vessel or tube, significantly improving mounting speed and productivity

Inventive Principle:

Principle #10Preliminary action

3Reliability

If a coupling compound is used, then ultrasonic transmission is improved, but the transducer cannot be easily moved or made disposable

Engineering Contradiction:

Improveultrasonic energy transmissionVSAvoidmounting flexibility

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The adhesive tape provides sufficient coupling for temporary applications, enabling the transducer to be easily removed and reused or disposed of after use. This is particularly valuable in medical procedures where disposable sensors are preferred for hygiene reasons, and in applications requiring frequent repositioning

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Reliability

If a coupling compound is used, then ultrasonic transmission is improved, but it can adversely affect the appearance of the tube or vessel

Engineering Contradiction:

Improveultrasonic energy transmissionVSAvoidappearance damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The adhesive tape provides the necessary coupling function without requiring visible coupling compounds to be applied to the vessel or tube surface. The tape itself becomes the coupling interface, eliminating the need for external compounds that would leave visible residue or require cleaning, thus preserving the appearance of the monitored surface

Inventive Principle:

Principle #26Copying

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

Enables efficient ultrasonic energy transmission without coupling compounds, facilitating quick and easy mounting/removal, and is suitable for fast-moving and sanitary applications, with potential for disposable use.

Implementation Method 1

One widely used form of such transducer has a housing that contains a piezo-electric element

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Implementation Method 2

The double-sided adhesive tape is preferably one that has a rubber based adhesive which is sufficient to provide the coupling between the piezoelectric element in the transducer housing and the outer surface of the vessel or tube on which the transducer is mounted so that ultrasonic energy can be transmitted into the vessel or tube or received after passing through it

Methodology Applied

Scientific EffectUltrasonic energy transmission: Ultrasound

Data Source

PatentUS7694570B1Non-invasive dry coupled disposable/reusable ultrasonic sensor

Publication Date: 2010.04.13 MEASUREMENT SPECIALTIES INC

AI summary

A non-invasive dry coupled disposable/reusable ultrasonic sensor has a housing and a piezoelectric element at one end of the housing to which connected signal leads are connected that extend out from the housing. A piece of double-sided adhesive tape has one adhesive side secured directly to the face at the one end of the housing with the other adhesive side to be secured directly to the outer surface of a pipe or vessel. The tape can cover the entire face of the one end of the housing or only that part that the piezoelectric element faces.