Graphite Thermal Layer for Ultrasound Probe Heat Dissipation
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Solution Overview
Problem
Conventional ultrasound imaging probes face challenges in thermal dissipation at high acoustic power levels, leading to temperature limitations that compromise image quality and require reducing power or resolution to prevent overheating.
Innovation Solution
A thermally conductive material layer, such as graphite, is applied to the internal and external surfaces of the ultrasound probe's support structure, including coupling surfaces and ferrules, to enhance heat dissipation from the sensor to non-heat generating components, allowing for continuous high-resolution imaging at full power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional heat spreaders are used, then heat dissipation is provided, but thermal dissipation capability is insufficient at high acoustic power levels
Solution Approach 1:
The patent changes the material parameter from traditional heat spreader materials to graphite material, which has superior thermal conductivity. This parameter change enables the probe to dissipate heat effectively at high acoustic power levels, resolving the contradiction between thermal dissipation capability and acoustic power handling
Solution Approach 2:
The patent uses composite material structure by applying graphite material layer to the coupling surfaces and support structure of the probe. This composite approach combines the acoustic transmission properties of the probe materials with the exceptional thermal conductivity of graphite, achieving both high power handling and effective heat dissipation
2Temperature
If acoustic power is reduced to prevent overheating, then temperature limits are maintained, but image quality deteriorates
Solution Approach 1:
By changing the thermal conductivity parameter of the probe materials to graphite, the system can maintain high acoustic power without exceeding temperature limits. This resolves the contradiction by allowing full power operation while maintaining acceptable temperature levels, thus preserving image quality
3Temperature
If graphite material layer is applied to coupling surfaces and support structure, then thermal dissipation is enhanced, but device complexity increases
Solution Approach 1:
The graphite material layer serves multiple functions simultaneously: it provides exceptional thermal conductivity for heat dissipation, maintains acoustic transmission properties, and can be applied as a coating or integrated into the support structure. This multi-functionality reduces the need for separate cooling components, thereby limiting the increase in device complexity
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 solution effectively reduces surface temperature by up to 8 degrees Celsius, enabling prolonged high-power imaging without thermal shutdown, surpassing the limitations of traditional heat spreader designs.
Implementation Method 1
The material layer facilitates the transfer and dissipation of heat from the heat-generating components of the ultrasound imaging probe, such as the ultrasound sensor, to the non-heat generating components of the ultrasound imaging probe, such as the support structure
Data Source
Figure 1
Figure 2A~2C
Figure 3A~3D
AI summary
An ultrasound imaging probe including a handle configured for handheld use; a support structure disposed within the handle and comprising a thermally-conductive material, the support structure further comprising a coupling surface and an external surface, the coupling surface disposed at a distal portion of the support structure; a continuous material layer coupled to the support structure, such that the continuous material layer is disposed on the coupling surface and the external surface, the continuous material layer thereby providing a heat transmission path between the coupling surface and the external surface; and an ultrasound sensor coupled to the support structure at the coupling surface and directly in contact with the continuous material layer at the coupling surface, such that heat from the ultrasound sensor is transmitted away to the support structure via the heat transmission path of the continuous material layer.