Dense Transducer Array Viscoelastic Cable Harness
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Solution Overview
Problem
High-frequency wideband transducer arrays require densely packed elements with efficient conductor organization to maintain electro-acoustic performance, while existing technologies face challenges in managing numerous electrical wires and providing mechanical isolation between elements.
Innovation Solution
A cable harness component with a support structure made of viscoelastic material and embedded flexible circuits that organize conductors in a two-dimensional lattice, providing mechanical isolation and robust cabling for high drive signals, integrated with a polymer material to form a dense transducer array.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the number of elements in the transducer array increases to achieve fully populated radiating apertures, then the array coverage and acoustic beam steering capability are improved, but the element center to center spacing decreases and the complexity of organizing numerous electrical wires increases exponentially
Solution Approach 1:
The patent transitions from managing conductors in a one-dimensional linear fashion to a two-dimensional lattice structure. The cable harness component organizes numerous electrical wires by distributing them across a two-dimensional grid pattern, where conductors are routed through a matrix of channels or slots. This dimensional transformation allows the system to handle exponentially more conductors without proportionally increasing complexity, as the 2D layout provides natural grouping and routing paths that scale more efficiently with array size.
Solution Approach 2:
The cable harness component is divided into modular sections that correspond to groups of transducer elements. Each segment of the harness manages a specific subset of conductors, and these segments can be independently assembled and maintained. The conductor organization is segmented into logical groups that map to functional subsets of the array, allowing for localized management rather than requiring a single complex routing system for all conductors.
2Use of energy by moving object
If transducer elements are densely packed to achieve high-frequency wideband operation, then the operational bandwidth and frequency response are improved, but mechanical isolation between elements becomes more difficult to maintain
Solution Approach 1:
The patent introduces an intermediary material or structure between adjacent transducer elements that provides mechanical isolation while allowing acoustic coupling. This intermediary layer, which may be a damping material, isolating compound, or specialized structural element, prevents direct mechanical contact between densely packed elements while maintaining the acoustic field continuity needed for wideband operation. The intermediary acts as a buffer that decouples mechanical vibrations while preserving acoustic signal transmission.
Solution Approach 2:
The patent employs thin film or flexible shell structures as isolation barriers between elements. These thin isolating layers are acoustically transparent or transparent to the extent needed for wideband operation, yet provide sufficient mechanical decoupling. The flexible nature of these thin films allows them to conform to the densely packed element geometry while maintaining isolation, and they can be applied as coatings or laminates that do not significantly increase element spacing.
3Power
If the transducer array is designed to handle high drive signals for transmit operation, then the transmit power and signal strength are improved, but the robustness requirements for cabling increase
Solution Approach 1:
The patent combines multiple conductor functions into integrated cable assemblies that are specifically designed for high-power transmit operations. The cabling system merges power delivery, signal transmission, and mechanical support functions into unified harness components. Multiple conductors are bundled and shielded together in configurations that distribute mechanical and electrical stress, allowing the cabling to handle high drive signals without requiring individually oversized cables for each conductor.
Solution Approach 2:
The cabling system employs composite construction with multiple material layers including conductive cores, insulating layers, shielding materials, and reinforcement structures. This composite approach allows the cable assembly to simultaneously handle high electrical power, provide mechanical strength, and maintain electrical isolation. The combination of different materials with complementary properties enables the cabling to meet the demanding requirements of high-power transmit operations without excessive size or weight.
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 solution enables the formation of densely packed transducer arrays capable of transmitting and receiving high-frequency acoustic signals with mechanical isolation, efficient conductor management, and robust cabling, supporting both transmit and receive operations effectively.
Implementation Method 1
A cable harness component with a support structure made of viscoelastic material
Implementation Method 2
providing mechanical isolation between elements
Implementation Method 3
piezocomposite arrays... piezoceramic transducer arrays
Implementation Method 4
acoustic transducer having relatively high operational bandwidth
Data Source
AI summary
A transducer array assembly includes a support structure having a plurality of predetermined openings therein for accommodating transducer components. Flexible circuits are embedded in the support structure. Each flexible circuit has first ends being positioned in the support structure predetermined openings. Terminal blocks are joined to the second ends. Transducer elements are positioned in the support structure predetermined openings and placed in electrical communication with the flexible circuit first ends. A polymer material is provided surrounding the transducer elements, said support structure, and said flexible circuit first ends. There is also provided a method for manufacturing the transducer array.