Ultrasound Probe Transducer Grooving for Curved TOF Inspection
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Solution Overview
Problem
Conventional ultrasonic probes face challenges in bending the transducer element to curved surfaces due to insufficient flexibility, leading to gaps, disconnections, and performance issues, particularly when the base block has varying curvatures, affecting Time of Flight inspections.
Innovation Solution
The transducer element is designed with alternating shallow and deep grooves on a flexible printed circuit board, allowing it to conform to different curvatures without gaps or disconnections, using a base block with sound-absorbing material and a reflective layer to maintain performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the transducer element is made rigid to maintain structural integrity, then manufacturing precision is improved, but flexibility deteriorates making it difficult to bend along curved base block surfaces
Solution Approach 1:
The transducer element is divided into multiple independent transducer units that can be separately positioned and attached to the base block. Each unit can be independently adjusted to conform to the curved surface, while maintaining structural integrity through the segmentation of functional components.
Solution Approach 2:
The patent employs flexible printed circuit boards (FPC) as the substrate for mounting piezoelectric elements. The FPC can be bent and deformed to match the curved surface of the base block, providing the necessary flexibility while maintaining electrical connections and structural support for the transducer elements.
2Adaptability or versatility
If the transducer element is bent to conform to curved surfaces, then adaptability is improved, but manufacturing precision deteriorates due to gaps and misalignment
Solution Approach 1:
The FPC is pre-formed with the appropriate curvature and groove patterns before the piezoelectric elements are mounted. This preliminary shaping ensures that when the elements are attached, they are already positioned correctly to conform to the base block surface, eliminating alignment issues during final assembly.
Solution Approach 2:
The patent introduces grooves at specific locations on the FPC to create localized flexibility zones. These grooves allow the FPC to bend precisely where needed while maintaining rigidity in other areas to ensure proper positioning and alignment of the piezoelectric elements with the base block surface.
3Adaptability or versatility
If strong stress is applied to bend the transducer element, then adaptability is improved, but reliability deteriorates due to wiring disconnection
Solution Approach 1:
The FPC is specifically designed with flexible materials and constructed with multiple layers that can withstand repeated bending without breaking the wiring. The flexible nature of the FPC allows it to be bent to match curved surfaces while the inherent flexibility of the material prevents wiring disconnection that would occur with rigid circuits under similar stress.
4Adaptability or versatility
If the base block has varying curvatures to match complex surfaces, then adaptability is improved, but device complexity increases
Solution Approach 1:
The base block is divided into multiple regions with different curvatures, and corresponding transducer units are segmented to match each region. This segmentation allows the overall system to conform to complex surfaces with varying curvatures while keeping each individual transducer unit and its mounting structure relatively simple.
Solution Approach 2:
The FPC is designed with grooves at specific locations to create localized flexibility zones. These grooves allow the FPC to bend precisely where needed to match the base block curvature variations, while maintaining rigidity in other areas to ensure proper positioning of the piezoelectric elements.
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 design ensures proper assembly and reduces defects, improving the accuracy of ultrasonic imaging by preventing gaps and disconnections, enhancing the flexibility and durability of the transducer element.
Implementation Method 1
a transducer that converts high-frequency power into ultrasonic vibration
Implementation Method 2
a base block with sound-absorbing material
Implementation Method 3
a reflection layer disposed between the piezoelectric transducer and the FPC
Data Source
AI summary
A transducer element for an ultrasound probed that is disposed on a base block includes a first portion having a first curvature and a second portion having a second curvature with a radius shorter than the first curvature. The transducer element includes an FPC disposed across the first portion and the second portion and a laminate including a transducer disposed on the FPC. The laminate including the transducer includes a layer of a piezoelectric element, wherein the laminate including the transducer includes a relatively shallow groove that does not completely cut the layer of the piezoelectric element and a relatively deep groove that completely cuts the layer of the piezoelectric element, the relatively shallow groove and the relatively deep groove are alternately disposed at a position corresponding to the first portion, and a plurality of the relatively deep grooves are contiguously disposed at a position corresponding to the second portion.