Flexible Delay Line Mold Casting for Ultrasonic Transducers

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Solution Overview

Problem

Current ultrasonic transducer delay lines are typically made of rigid materials like plexiglass, which require machining and have long lead times, making them unsuitable for rapid non-destructive inspection demands, especially in field applications where flexibility and quick production are needed.

Innovation Solution

A method of creating a flexible delay line using a mold with a desired geometry, applying a flexible material, curing it, and removing it to form a flexible delay line that conforms to the transducer face, allowing it to adapt to flat, irregular, or curved surfaces, using materials like rapid curing silicone rubbers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If rigid materials like plexiglass are used to make delay lines, then manufacturing precision and structural stability are improved, but manufacturing complexity and lead time increase significantly

Engineering Contradiction:

Improvedelay line geometry precisionVSAvoiddelay line manufacturing ease

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent changes the material parameter from rigid (plexiglass) to flexible (silicone rubber), which fundamentally alters the manufacturing approach from precision machining to mold casting. This parameter change enables NDI personnel to manufacture delay lines without specialized machining capabilities, directly resolving the contradiction between manufacturing precision and ease of manufacture.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses a mold as a template to copy the desired delay line geometry directly into the flexible material. This copying approach eliminates the need for complex machining operations while maintaining geometric precision, as the mold itself defines the final shape through casting rather than subtractive manufacturing.

Inventive Principle:

Principle #26Copying

2Stability of the object's composition

If rigid materials are used for delay lines, then structural stability is improved, but adaptability to different surfaces deteriorates

Engineering Contradiction:

Improvedelay line structural stabilityVSAvoidsurface conformability

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The patent changes the material parameter from rigid to flexible, which simultaneously provides both structural stability for the delay line function and adaptability to conform to irregular surfaces. The flexible material maintains its dimensional stability while gaining the ability to adapt to different geometries, resolving the contradiction between stability and adaptability.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces dynamic flexibility to the delay line structure, allowing it to adapt its shape to match the inspection surface while maintaining functional stability. The flexible material can deform to conform to irregular surfaces but returns to its molded geometry for consistent ultrasonic performance, combining adaptability with stability.

Inventive Principle:

Principle #15Dynamics

3Manufacturing precision

If traditional manufacturing methods are used, then manufacturing precision is maintained, but productivity and response time deteriorate

Engineering Contradiction:

Improvedelay line geometry precisionVSAvoiddelay line production rate

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces the mechanical machining system with a chemical curing system. Instead of using precision machining tools to carve the delay line from rigid material, the invention uses mold casting with rapid-curing flexible material. This substitution dramatically increases productivity while maintaining geometric precision through the mold template, enabling same-day or next-day production.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent prepares a mold in advance with the exact desired geometry, so that when the flexible material is applied and cures, the precise shape is already predetermined. This preliminary preparation of the mold eliminates time-consuming machining operations and enables rapid production while maintaining manufacturing precision.

Inventive Principle:

Principle #10Preliminary action

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 rapid on-site or in-lab production of flexible delay lines that improve near-surface resolution and adaptability for non-destructive inspection of various components, reducing inspection time and meeting demand for quick and flexible inspection solutions.

Implementation Method 1

curing the flexible material in the mold

Methodology Applied

Scientific EffectCuring: Phase Change

Data Source

PatentUS9435770B2Method of making a flexible delay line, a flexible delay line and a transducer

Publication Date: 2016.09.06 GE INFRASTRUCTURE TECH LLC

AI summary

A method of making a flexible delay line for a transducer, a flexible delay line, and a transducer are provided. The method includes providing a mold having a desired geometry, applying a flexible material to the mold, curing the flexible material in the mold, and removing the cured material from the mold. The cured material forms a flexible delay line having a geometry conforming to a face of the ultrasonic transducer. The flexible delay line for a transducer includes a flexible material having an aperture shaped to receive a face of the transducer. The flexible delay line is operable to conform to a flat or an irregular surface.