Enclosed Ultrasonic Sensor Structure with Wave Damping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing sensor structures for ultrasonic testing and structural monitoring are prone to damage and functionality impairment due to mechanical stress, environmental influences, and inefficient wave transmission, particularly when applied to materials like fiber composites or lithium-ion cells.
Innovation Solution
A sensor structure with a substrate enclosing an emitter and receiver, using flexible materials to protect and optimize their functions, and incorporating damping elements to prevent direct wave transmission through the substrate, while allowing efficient wave propagation through the material being tested.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the piezo element is firmly attached to the body to transmit excitation energy efficiently, then the energy transmission efficiency is improved, but the piezo element is more prone to damage and breakage due to mechanical stress
Solution Approach 1:
The sensor structure is divided into separate functional components: the piezo element (emitter/receiver), the substrate providing mechanical protection, and the adhesive layer for attachment. This segmentation allows each component to optimize its specific function while reducing stress concentration on the piezo element.
Solution Approach 2:
The substrate acts as a cushioning layer that absorbs and distributes mechanical stresses before they reach the piezo element. This protective enclosure prevents direct transmission of harmful mechanical forces to the brittle piezo material, thereby preventing damage while maintaining operational integrity.
2Power
If the piezo element is made of ceramic material for efficient ultrasonic generation, then the ultrasonic generation efficiency is improved, but the piezo element becomes brittle and susceptible to damage
Solution Approach 1:
A flexible substrate encloses the ceramic piezo element, providing mechanical protection while allowing the piezo material to maintain its brittle ceramic properties for efficient ultrasonic generation. The substrate absorbs mechanical shocks and prevents direct stress concentration on the ceramic material.
Solution Approach 2:
The sensor structure combines different materials with complementary properties: ceramic piezo elements for ultrasonic generation, flexible substrate material for mechanical protection and stress distribution, and adhesive materials for secure attachment. This composite approach allows each material to perform its optimal function.
3Ease of operation
If electrical contacts of the piezo element are exposed for functionality, then the electrical connectivity is improved, but the electrical contacts are more prone to damage and breakage due to mechanical tension
Solution Approach 1:
The electrical contacts are nested within the substrate structure, which encloses and protects them from mechanical damage. The substrate provides a protective environment while maintaining electrical connectivity through integrated contact paths that are shielded from external mechanical tension.
Solution Approach 2:
The substrate acts as a protective shell that encloses the electrical contacts, preventing direct exposure to mechanical tension and environmental damage while maintaining electrical connectivity. The flexible nature of the substrate allows it to accommodate stresses without transmitting them to the contacts.
4Ease of operation
If the piezo element is exposed to the environment for functionality, then the operational accessibility is improved, but the functionality is impaired by environmental influences such as moisture, dust, and temperature fluctuations
Solution Approach 1:
The substrate serves as a protective shell that encloses the piezo element, shielding it from environmental influences such as moisture, dust, and temperature fluctuations. The flexible substrate maintains the piezo element's functionality while providing a barrier against harmful environmental factors.
Solution Approach 2:
The substrate creates a protected, inert environment around the piezo element, isolating it from harmful external conditions. This enclosed environment maintains stable operational conditions for the piezo element while allowing it to function effectively.
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 sensor structure provides robust and efficient ultrasonic wave transmission, protecting the emitter and receiver from mechanical and environmental stress, while ensuring accurate structural integrity monitoring of materials.
Implementation Method 1
In ultrasonic testing, for example, mechanical waves with frequencies in an ultrasonic range are excited in the body to be tested
Implementation Method 2
incorporating damping elements to prevent direct wave transmission through the substrate
Data Source
AI summary
In an embodiment a sensor structure for arrangement on a body includes a substrate in which at least one emitter and at least one receiver are integrated such that the substrate at least partially encloses the emitter and the receiver and only one emission surface of the emitter and only one detection surface of the receiver are free of the substrate.