Flexible Ultrasound Transducer Array for Non-Planar Surfaces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional ultrasound inspection systems face challenges with non-planar surfaces, as transducer arrays with rigid frames struggle to accurately couple and generate response signals, leading to reduced inspection efficiency and increased time for curved surfaces.
Innovation Solution
A flexible ultrasound inspection system utilizing an organic circuit system with piezoelectric elements and a flexible substrate, integrated with organic field effect transistors, allows for a transducer array that can conform to complex surfaces and send sound signals in a selected sequence, improving coupling and inspection efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a transducer array with rigid frame is used, then inspection coverage area is increased, but coupling ability on non-planar surfaces deteriorates
Solution Approach 1:
The patent applies this principle by replacing the rigid frame with a flexible substrate that can conform to non-planar surfaces. The flexible substrate allows the transducer array to maintain contact and coupling ability on curved surfaces while preserving the multi-element array configuration for broad coverage area.
Solution Approach 2:
The patent applies this principle by making the transducer array structure dynamic and adaptable through the flexible substrate. The array can dynamically adjust its shape to match the inspected surface geometry, maintaining reliable coupling across varying surface conditions while keeping all transducers operational.
2Adaptability or versatility
If transducer array segments are made moveable, then conformance to curved surfaces is improved, but device complexity increases
Solution Approach 1:
The patent applies this principle by using a flexible substrate as a unified structure that inherently provides conformance to curved surfaces without requiring segmented moveable parts. This eliminates the complexity of mechanical joints, actuators, and control systems while achieving the same adaptability goal.
Solution Approach 2:
The patent applies this principle by merging the conformance function into the substrate itself rather than using separate moveable segments. The flexible substrate integrates both structural support and surface-adaptation functions, reducing overall device complexity while maintaining versatility.
3Device complexity
If organic circuit system with integrated transistors is used, then wiring complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies this principle by merging the circuit interconnection function directly into the flexible substrate through printed or deposited conductive traces. This integration eliminates separate wiring harnesses and connectors, reducing wiring complexity while the trace fabrication processes provide sufficient precision for the application.
Solution Approach 2:
The patent applies this principle by replacing mechanical wiring systems with deposited conductive patterns on the flexible substrate. This substitution reduces physical wiring complexity while the deposition processes achieve the necessary electrical connection precision through controlled material placement.
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 flexible ultrasound system enhances inspection efficiency by achieving better coupling and resolution on non-planar surfaces, reducing the need for extensive wiring and allowing for smaller piezoelectric element sizes, thus improving image generation and data processing.
Implementation Method 1
An apparatus comprises an array of piezoelectric elements, a flexible substrate formed on the array of piezoelectric elements and configured to substantially conform to a surface of a test object, and an organic circuit system connected to the array of piezoelectric elements and configured to cause the array of piezoelectric elements to send sound signals into the test object
Implementation Method 2
The organic circuit system is further configured to receive signals generated by the array of piezoelectric elements from detecting response sound signals in the test object
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A method and apparatus comprising an array of piezoelectric elements, a flexible substrate connected to the array of piezoelectric elements, and an organic circuit system formed on the flexible substrate and connected to the array of piezoelectric elements. The flexible substrate is configured to substantially conform to a surface of a test object. The organic circuit system is configured to cause the array of piezoelectric elements to send sound signals into the test object.