Ultrasound Transducer Lead Insulation for Short Circuit Prevention
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Solution Overview
Problem
Existing ultrasound transducers face challenges in preventing short circuits between leads and piezoelectric devices during the manufacturing process, particularly when bending the leads to connect them to the piezoelectric devices in a convex array configuration, which can lead to improper alignment and contact issues.
Innovation Solution
The use of insulation sheets on the leads and a manufacturing method that involves curving the leads to connect them to the piezoelectric devices with a joint material, ensuring proper alignment and preventing short circuits by increasing the contact area and using insulation materials to maintain rigidity and correct bending direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If leads are curved to connect to piezoelectric devices in a convex array configuration, then proper alignment and contact are achieved, but short circuits between leads and piezoelectric devices occur during manufacturing
Solution Approach 1:
An insulation sheet is introduced as an intermediary component between the leads and the piezoelectric devices. The sheet has an insulating layer that prevents short circuits while allowing the leads to be properly aligned and connected to the piezoelectric devices in a convex array configuration.
Solution Approach 2:
The insulation sheet is prepared in advance with the insulating layer formed on its surface before the leads are connected to the piezoelectric devices. This preliminary preparation ensures that the insulation is already in place to prevent short circuits during the manufacturing process.
2Reliability
If insulation sheets are added to prevent short circuits, then reliability improves, but device complexity increases
Solution Approach 1:
A thin film insulation sheet is used to prevent short circuits between the leads and piezoelectric devices. The thin film structure provides the necessary insulation function while minimizing the increase in device complexity and maintaining a compact design.
3Strength
If leads are pressed to piezoelectric devices with joint material, then joint strength improves, but manufacturing complexity increases
Solution Approach 1:
The insulation sheet serves as a mediator that facilitates the connection process. It allows the leads to be pressed onto the piezoelectric devices with joint material while preventing short circuits, thereby improving joint strength without significantly complicating the manufacturing process.
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 effectively prevents short circuits and improves the joint strength between the leads and piezoelectric devices, ensuring reliable ultrasound wave transmission and reception in ultrasound transducers.
Implementation Method 1
The ultrasound transducer includes plural piezoelectric devices that convert an electrical pulse signal into an ultrasound pulse to emit to the subject of observation, and that converts an ultrasound echo reflected on the subject of observation into an electrical echo signal to output
Implementation Method 2
a plurality of sheets that are arranged to prevent the leads from being in contact with each other, each sheet being provided on the lead and having an insulation property
Data Source
AI summary
An ultrasound transducer includes: a flexible board configured to receive and output an electrical signal through a signal line; a plurality of piezoelectric devices that are electrically connected to the board and are aligned in a row, each piezoelectric device being configured to transmit and receive an ultrasound wave; a plurality of leads extending the signal line and protruding from an end portion of the board, each lead being electrically connected to the piezoelectric device in a curved manner; and a plurality of sheets that are arranged to prevent the leads from being in contact with each other, each sheet being provided on the lead and having an insulation property.