Ultrasonic Transducer Cover with Chemical Blocking Layer
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Solution Overview
Problem
Ultrasonic handpieces experience insulation degradation due to chemical permeation through the transducer cover during sterilization processes, particularly when exposed to hot water containing alkaline or acidic chemicals, leading to weakened ultrasonic vibration and performance issues.
Innovation Solution
A transducer cover with a coaxially laminated structure comprising a vibration absorbing layer made of synthetic resin and a chemical blocking layer made of impermeable synthetic rubber, where the chemical blocking layer extends beyond the vibration absorbing layer to prevent chemical permeation, formed through compression molding and thermal curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single-layer transducer cover made of silicon rubber is used, then the cover has good elasticity and vibration absorption, but chemicals can permeate through the cover during hot water washing with alkaline or acidic chemicals, causing insulation degradation of the transducer
Solution Approach 1:
The patent applies composite materials by combining two different synthetic resin layers with complementary properties: an inner layer with vibration absorption characteristics and an outer layer with chemical impermeability. This composite structure resolves the contradiction by integrating the vibration absorption capability of the inner layer with the chemical barrier properties of the outer layer, preventing chemical permeation while maintaining the necessary elasticity and vibration absorption for transducer functionality.
Solution Approach 2:
The transducer cover is segmented into two distinct functional layers: an inner vibration absorbing layer and an outer chemical blocking layer. Each layer performs its specific function independently, with the inner layer handling vibration absorption and the outer layer providing chemical impermeability. This segmentation allows each layer to be optimized for its specific purpose, resolving the contradiction between vibration absorption and chemical resistance.
2Object-affected harmful factors
If the transducer cover is made impermeable to chemicals, then chemical permeation is blocked, but the cover may not provide adequate vibration absorption and elasticity needed for transducer functionality
Solution Approach 1:
The composite material structure resolves this contradiction by assigning different material properties to different layers: the inner layer uses a synthetic resin optimized for vibration absorption and elasticity, while the outer layer uses a synthetic resin optimized for chemical impermeability. This allows the impermeable outer layer to block chemicals without compromising the vibration absorption capability of the inner layer.
Solution Approach 2:
By segmenting the transducer cover into two functional layers, the patent allows the outer layer to provide chemical impermeability while the inner layer maintains vibration absorption capabilities. The segmentation ensures that the impermeable property is localized to the outer layer only, preserving the elastic and vibration-absorbing properties needed for transducer operation.
3Reliability
If a two-layer laminated structure is used, then both vibration absorption and chemical blocking functions are achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent merges two separate functional requirements (vibration absorption and chemical blocking) into a single integrated transducer cover component through laminated construction. By combining the inner vibration absorbing layer and outer chemical blocking layer into one unified structure that functions as a single unit, the patent achieves both functions simultaneously without requiring separate components or complex assembly procedures.
Solution Approach 2:
The laminated transducer cover structure provides multi-functionality by simultaneously achieving vibration absorption, chemical blocking, and structural integrity in a single component. This universal design allows the cover to perform multiple functions that would traditionally require separate parts, simplifying the overall device while achieving the desired combined functional performance.
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
Effectively blocks chemical permeation and maintains insulation integrity by sealingly attaching the layers around the transducer, preventing chemical adhesion to electrodes and ensuring consistent ultrasonic performance even under harsh sterilization conditions.
Implementation Method 1
a vibration absorbing layer of a generally cylindrical form made of a synthetic resin having a vibration absorbing property
Implementation Method 2
a chemical blocking layer of a generally cylindrical form made of a synthetic resin which is impermeable to water and chemicals
Implementation Method 3
formed through compression molding and thermal curing
Implementation Method 4
formed through compression molding and thermal curing
Data Source
AI summary
A transducer cover for use in an ultrasonic medical instrument having a transducer is disclosed. The transducer cover includes a vibration absorbing layer of a generally cylindrical form made of a synthetic resin having a vibration absorbing property, and a chemical blocking layer of a generally cylindrical form made of a synthetic resin which is impermeable to water and chemicals. The vibration absorbing layer and the chemical blocking layer are coaxially laminated, and capable of sealing arrangement over and around the transducer. Also disclosed is an ultrasonic medical instrument having an ultrasonic transducer and the transducer cover, and a method for forming the transducer cover over and around an ultrasonic transducer of an ultrasonic medical instrument.