Ultrasonic Flow Meter Electrode Roughening for Reliable Bonding
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Solution Overview
Problem
Compact ultrasonic flow meters face challenges in fixing smaller transducers, battery lifetime, and maintaining costs, particularly due to the limitations of wrap-around electrodes which are less suitable for smaller piezoelectric ultrasonic transducers, leading to increased costs and potential signal distortion.
Innovation Solution
A method involving surface roughening of the electrode and electrically conductive layer, followed by adhesive application and curing, to establish a strong and durable bonding and electrical connection without the need for wrap-around electrodes, using non-conductive adhesive to ensure effective mechanical fixation, acoustic coupling, and electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wrap-around electrodes are used to establish electrical contact to hidden electrodes, then electrical connection is established, but device complexity increases and manufacturing cost increases
Solution Approach 1:
The patent extracts the electrical contact function from the mechanical fixation structure by using a separate electrically conductive layer on the support substrate. This allows the electrode to be bonded directly to the conductive layer without requiring wrap-around structures, simplifying the overall device complexity while maintaining reliable electrical connection.
Solution Approach 2:
The patent segments the electrical connection function from the mechanical bonding function. The electrode is bonded to the support substrate via adhesive, while electrical contact is established through the electrically conductive layer on the substrate surface, separating these two functions into distinct components.
2Use of energy by moving object
If smaller piezoelectric ultrasonic transducers are used, then power consumption decreases and cost decreases, but fixation difficulty increases
Solution Approach 1:
The patent applies preliminary action by roughening the surface of the electrically conductive layer before bonding. This surface preparation creates anchoring structures that enhance adhesive bonding strength, making fixation easier and more reliable for smaller transducers without requiring complex fixation mechanisms.
Solution Approach 2:
The patent changes the surface parameter of the electrically conductive layer by roughening it, which modifies the adhesive bonding characteristics. This allows for stronger bonding of smaller transducers to the support substrate, overcoming the fixation difficulty associated with reduced transducer size.
3Reliability
If conductive adhesive is used to establish electrical connection, then electrical contact is established, but mechanical fixation strength decreases and short circuits may occur
Solution Approach 1:
The patent segments the electrical conduction function from the adhesive bonding function. A non-conductive adhesive is used for mechanical fixation, while electrical contact is established through the separate electrically conductive layer on the support substrate, eliminating the need for conductive adhesive and its associated problems.
Solution Approach 2:
The patent introduces an intermediary electrically conductive layer on the support substrate that mediates between the electrode and the support structure. This layer provides the electrical conduction path without requiring the adhesive to be conductive, allowing non-conductive adhesive to be used for strong mechanical bonding.
4Reliability
If wrap-around electrodes are used, then electrical contact is established, but ultrasound signal distortion increases
Solution Approach 1:
The patent extracts the electrical contact function from the wrap-around electrode structure. By using a flat electrically conductive layer on the support substrate instead of wrap-around electrodes, the ultrasound signal path is no longer obstructed or distorted by electrode material, improving measurement precision.
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
This approach allows for the use of smaller, cost-effective piezoelectric ultrasonic transducers with improved accuracy, reduced power consumption, and increased reliability, while avoiding the drawbacks of conductive adhesives, such as short circuits and inferior mechanical fixation, and enabling operation at higher temperatures.
Implementation Method 1
roughening the surface of one or both of the electrode and the electrically conductive layer; applying an adhesive to one or both of the electrode and the electrically conductive layer; assembling the electrode and the electrically conductive layer; curing the adhesive
Implementation Method 2
an electrode of a piezoelectric ultrasonic transducer
Data Source
AI summary
An ultrasonic flow meter comprising two piezoelectric ultrasonic transducers each comprising a first and a second electrode; an ultrasonic flow meter housing, at least a part of which forms a support substrate for supporting the two piezoelectric ultrasonic transducers on an electrically conductive layer of the support substrate; an adhesive applied between the electrically conductive layer and the first electrode; wherein at least the first electrode of each piezoelectric ultrasonic transducer has a roughened surface, and wherein electrical connection between the electrically conductive layer and the first electrode is formed by said roughening.