Sonar Transducer Flex Tabs for Signal Uniformity
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Solution Overview
Problem
Sonar transducer assemblies face issues with undesired signals due to the elastic response of the printed circuit board (PCB) and inconsistencies in mechanical boundary conditions caused by solder connections, leading to degraded sonar images.
Innovation Solution
The use of flexible electrical connection tabs, or flex tabs, on the PCB to establish an electrical connection with transducer elements without soldering, thereby mitigating the elastic response and mechanical impedance issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If transducer elements are soldered to the PCB, then reliable electrical connection is achieved, but elastic response and mechanical impedance variations occur causing degraded sonar images
Solution Approach 1:
The patent introduces flexible tabs as an intermediary component between the transducer elements and the PCB. These tabs provide both electrical connection and mechanical isolation, acting as a mediator that eliminates direct rigid mechanical contact while maintaining electrical connectivity. This resolves the contradiction by decoupling the electrical connection function from the mechanical coupling that causes elastic response.
Solution Approach 2:
The patent segments the connection structure into distinct functional components: the rigid PCB, the flexible connection tabs, and the transducer elements. By dividing the connection path into separate segments with different mechanical properties, the design allows electrical continuity while preventing the transmission of elastic waves from the PCB to the transducer elements.
2Strength
If solder connections are used to attach transducer elements to the PCB, then mechanical strength is achieved, but element-to-element variations increase due to inconsistent mechanical boundary conditions
Solution Approach 1:
The patent achieves homogeneous mechanical boundary conditions for all transducer elements by using identical flexible tab connections for each element. This uniform connection method eliminates variations caused by manual soldering inconsistencies, ensuring that all elements experience the same mechanical constraints and electrical connection characteristics.
Solution Approach 2:
The flexible tabs are designed as simple, easily replaceable components that can be manufactured with high consistency. Rather than using complex solder joints that require precise manual application, the tabs provide a standardized, repeatable connection method that is both cost-effective and highly consistent across multiple elements.
3Device complexity
If the PCB serves as both electrical connection medium and structural support, then device complexity is reduced, but elastic response interference occurs
Solution Approach 1:
The patent segments the structural and electrical functions by introducing flexible tabs as a separate layer. The PCB maintains its structural support role while the flexible tabs handle the electrical connection function. This functional segmentation prevents the PCB's elastic response from directly coupling to the transducer elements while maintaining overall structural integrity.
Solution Approach 2:
The flexible tabs serve as an intermediary layer that decouples the structural PCB from the sensitive transducer elements. This intermediary structure allows the PCB to provide mechanical support without directly transmitting elastic waves to the transducers, effectively filtering out harmful vibrations while maintaining electrical connectivity.
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 reduces element-to-element variations and minimizes interference from the PCB's elastic response, resulting in clearer and sharper sonar images by ensuring uniform electrical signals from the transducer elements.
Implementation Method 1
Flexion of the flex tabs outwardly of the PCB plane causes an elastic force on each of the flex tabs to be applied to opposing ends of the transducer elements to create an electrical connection
Implementation Method 2
transducer elements, or simply transducers, convert electrical energy into sound or vibrations at a particular frequency
Implementation Method 3
The transducer receives the reflected sound (the 'sonar returns') and converts the sound energy into electrical energy
Data Source
Figure 1
Figure 2A
Figure 2B~2C
AI summary
A sonar transducer assembly comprising: at least one transducer element; a flexible printed circuit board (PCB) comprising at least one set of electrical connections for the at least one transducer element, wherein the PCB comprises flex tabs configured to flex; and a support structure comprising at least one aperture for the at least one transducer element, wherein the support structure is configured to: support the PCB; allow flexion of a pair of opposing flex tabs into the aperture; and retain the at least one transducer element in the at least one aperture, wherein the transducer element is installed through the pair of opposing flex tabs on the PCB and into the aperture causing the flex tabs to flex, wherein the flexion of the flex tabs causes an elastic force to be applied against opposing ends of the at least one transducer element.