Semi-Rigid Acoustic Coupling Medium Manufacturing
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Solution Overview
Problem
Conventional ultrasound imaging techniques face challenges such as inadequate spatial resolution, tissue differentiation, and contamination issues with acoustic transmission gels, leading to suboptimal image quality and potential health risks.
Innovation Solution
The development of a semi-rigid acoustic coupling medium (SACM) manufactured using a method that involves forming a staged solution, mixing it with activator solutions, dispensing into a mold, and curing under an inert atmosphere, resulting in a hydrogel interface pad that provides effective acoustic coupling while minimizing contamination risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional acoustic transmission gels are used, then acoustic coupling is achieved, but contamination risks and inadequate spatial resolution occur
Solution Approach 1:
The patent employs an inert atmosphere (nitrogen or argon) during the polymerization process to prevent oxidation and contamination of the hydrogel components. This inert environment protects the monomers, crosslinkers, and catalysts from reacting with oxygen, thereby eliminating contamination risks while maintaining acoustic coupling reliability.
Solution Approach 2:
The patent creates a composite hydrogel system combining multiple components (monomers, polymers, crosslinkers) with specific acoustic properties. This composite material approach enables optimized acoustic impedance matching and spatial resolution while maintaining sterility through the inert atmosphere processing.
2Reliability
If conventional acoustic gels are used, then acoustic coupling is provided, but image quality and tissue differentiation are insufficient
Solution Approach 1:
The patent systematically adjusts critical parameters including monomer concentration, crosslinker ratio, catalyst amount, and polymerization temperature to optimize the hydrogel's acoustic properties. These parameter changes enable precise control over acoustic impedance, attenuation, and spatial resolution, directly improving image quality and tissue differentiation while maintaining reliable acoustic coupling.
3Reliability
If a staged polymerization process is used, then acoustic coupling properties are optimized, but manufacturing complexity increases
Solution Approach 1:
The patent divides the polymerization process into distinct stages: (1) mixing monomers and crosslinkers in an inert atmosphere, (2) initiating polymerization with controlled catalyst addition, and (3) curing to final properties. This segmentation allows each stage to be optimized independently for acoustic properties while maintaining overall process manageability through clear procedural steps.
4Object-affected harmful factors
If deoxygenated water and inert atmosphere are used, then contamination is minimized, but manufacturing time and process complexity increase
Solution Approach 1:
The patent performs preliminary deoxygenation of water and preparation of the inert atmosphere before initiating the polymerization process. By pre-establishing the oxygen-free environment and preparing all components in advance, the contamination prevention measures are integrated into the workflow without adding significant time delays, as the inert atmosphere serves as the continuous reaction environment.
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 SACM offers superior acoustic and mechanical properties, ensuring improved image quality by reducing acoustic impedance mismatch and enhancing conformability to various patient geometries, while also being cost-effective, scalable, and suitable for mass production.
Implementation Method 1
forming a gel-sol by mixing the staged solution with a first network activator solution comprising a monomer activator and a second network activator solution comprising a polymer activator
Implementation Method 2
curing the gel-sol in the mold to produce a semi-rigid acoustic couplant
Data Source
AI summary
Disclosed are methods for scalable, cost-effective, and rapid production manufacturing and packaging a semi-rigid acoustic coupling medium that can be used for ultrasound diagnostic and treatment systems and techniques. In some aspects, a method includes forming a staged solution by adding together a stock solution comprising a monomer and a block copolymer in deoxygenated water and a primed solution comprising a covalent crosslinking agent and a catalyst; forming a gel-sol by mixing the staged solution with a first network activator solution comprising a monomer activator and a second network activator solution comprising a block copolymer activator; dispensing the gel-sol into a mold; and curing the gel-sol in the mold to produce a semi-rigid acoustic coupling material, where the method is carried under an inert atmosphere.