Surface-Treated Tungsten Carbide Acoustic Matching Materials
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Solution Overview
Problem
Existing acoustic matching layers using tungsten carbide particles to increase acoustic impedance face a challenge in suppressing a decrease in acoustic velocity and variations in acoustic characteristics, particularly when used in the multi-layer structure of acoustic matching sheets.
Innovation Solution
A material for acoustic matching layers is formulated using tungsten carbide particles treated with specific surface treatment agents, such as aminosilane, mercaptosilane, isocyanatosilane, or zirconium/titanium alkoxide compounds, combined with an epoxy resin and a curing agent, to maintain acoustic velocity and reduce variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tungsten carbide particles are used to increase acoustic impedance, then acoustic impedance increases, but acoustic velocity decreases
Solution Approach 1:
The patent applies parameter changes by treating the surface of tungsten carbide particles with specific surface treatment agents (aminosilane, mercaptosilane, isocyanatosilane, or zirconium/titanium alkoxide compounds) to modify their acoustic properties. This surface treatment changes the physical and chemical parameters of the particle surface, enabling them to increase acoustic impedance while maintaining or improving acoustic velocity compared to untreated particles
Solution Approach 2:
The patent creates a composite material system by combining surface-treated tungsten carbide particles with a resin matrix. This composite structure allows the beneficial acoustic impedance properties of tungsten carbide to be realized while the resin matrix and surface treatment work together to maintain acoustic velocity, resolving the contradiction between these two acoustic parameters
2Reliability
If tungsten carbide particles are used to increase acoustic impedance, then acoustic impedance increases, but variations in acoustic characteristics increase
Solution Approach 1:
The surface treatment process modifies key parameters of the tungsten carbide particles including surface chemistry, surface energy, and surface morphology. These parameter changes result in more uniform acoustic characteristics by reducing variations between particles, while still maintaining the high acoustic impedance property
Solution Approach 2:
The surface treatment creates a more homogeneous distribution of acoustic properties throughout the acoustic matching layer. By treating all particles uniformly with the surface treatment agent, the patent reduces variations in acoustic characteristics and creates a more consistent material composition
3Reliability
If multi-layer structure with gradient acoustic impedance is provided, then ultrasonic wave propagation efficiency improves, but device complexity increases
Solution Approach 1:
The patent applies local quality by creating regions with different acoustic impedance characteristics within the acoustic matching layer. Through the distribution of surface-treated tungsten carbide particles at different concentrations or with different surface treatment levels, the material achieves a gradient acoustic impedance structure that optimizes ultrasonic wave propagation at different depths without requiring physically separate layers
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 solution effectively increases acoustic impedance while minimizing decreases in acoustic velocity and variations in acoustic characteristics, enhancing the performance of acoustic wave probes and ultrasound diagnostic devices.
Implementation Method 1
surface-treated tungsten carbide particles subjected to a surface treatment with a surface treatment agent of at least one kind of an aminosilane compound, a mercaptosilane compound, an isocyanatosilane compound, a thiocyanatosilane compound, a zirconium alkoxide compound, or a titanium alkoxide compound
Implementation Method 2
an epoxy resin (B) a curing agent
Data Source
Figure 1
AI summary
Provided are a material for an acoustic matching layer in which, while using tungsten carbide particles having a large specific gravity as a metal filler, it is possible to effectively increase an acoustic impedance of an acoustic matching sheet obtained by suppressing a decrease in acoustic velocity due to the formulation of the tungsten carbide particles, and it is also possible to suppress variations in acoustic characteristics in this acoustic matching sheet; an acoustic matching sheet; an acoustic wave probe; an ultrasound probe; an acoustic wave measurement apparatus; an ultrasound diagnostic apparatus; and a method for manufacturing an acoustic wave probe. The material for an acoustic matching layer contains the following components (A), (B), and (C): (A) an epoxy resin; (B) a curing agent; and (C) surface-treated tungsten carbide particles subjected to a surface treatment with a surface treatment agent including at least one of an aminosilane compound, a mercaptosilane compound, an isocyanatosilane compound, a thiocyanatosilane compound, an aluminum alkoxide compound, a zirconium alkoxide compound, or a titanium alkoxide csompound.