Ultrasound Transducer Matching Layer Thickness Control
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Solution Overview
Problem
Current methods for manufacturing acoustic matching layers for ultrasound transducers are time-consuming and expensive due to the need for precise grinding to achieve the correct thickness and acoustic impedance, which limits efficiency and cost-effectiveness.
Innovation Solution
The use of a single layer of mono-disperse polymer particles mixed with smaller particles in a polymer resin, pressed between conformal surfaces during curing, to define the thickness and acoustic impedance of the matching layer, with optional metal or electrically isolating surface coatings for enhanced conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If grinding is used to achieve correct thickness of matching layer, then manufacturing precision is improved, but productivity deteriorates due to time-consuming repeated measurements and grinding steps
Solution Approach 1:
The patent applies preliminary action by pre-forming the matching layer to the exact desired thickness during the molding process itself, rather than requiring subsequent grinding and measurement steps. The conformal molds are designed with the precise thickness specification, so the layer is created correctly from the start, eliminating iterative refinement operations.
Solution Approach 2:
The patent replaces the mechanical grinding system with a molding system. Instead of using grinding tools to remove material and achieve thickness, the process uses conformal molds to shape the matching layer material directly to the required thickness during curing, substituting a forming operation for a subtractive manufacturing operation.
2Manufacturing precision
If multiple grinding and measurement steps are performed to obtain correct thickness, then manufacturing precision is improved, but loss of time increases due to repeated interruptions
Solution Approach 1:
The desired thickness is predetermined and built into the conformal mold design before manufacturing begins. The matching layer is formed to the exact specification in a single operation without requiring interruptions for measurement and adjustment, eliminating time loss from repeated cycles.
Solution Approach 2:
The patent skips the iterative measurement and re-grinding steps entirely by using conformal molds that define the final thickness. The process rushes through to completion in a single forming operation rather than pausing multiple times for quality checks and adjustments.
3Ease of manufacture
If polymer resin is used as matching layer material, then ease of manufacture is improved, but thermal conductivity deteriorates
Solution Approach 1:
The patent uses composite materials by combining polymer resin with thermally conductive particles (such as aluminum oxide, boron nitride, or metal particles) to create a matching layer that maintains the ease of manufacture of polymers while achieving improved thermal conductivity through the particulate reinforcement.
4Reliability
If solid particles are mixed into polymer resin to define acoustic impedance, then acoustic performance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges multiple functions into a single manufacturing step: the conformal mold simultaneously defines the thickness, shapes the layer, and the polymer resin with embedded particles is cured in place. This combines molding, thickness control, and acoustic impedance specification into one integrated operation rather than separate steps.
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 method simplifies the manufacturing process, reduces costs, and enhances thermal and electrical conductivity, allowing for improved heat dissipation and electrical shielding in ultrasound transducer arrays.
Implementation Method 1
The mixture is before and during curing pressured between two conformal surfaces so that one obtains a single layer of the mono-disperse polymer particles between the conformal surfaces, defining the final thickness of the layer
Implementation Method 2
A metal surface layer, e.g. Ag, Au, Al or Cu, can be used to also make the matching layer electrically and thermally conductive
Implementation Method 3
A metal surface layer, e.g. Ag, Au, Al or Cu, can be used to also make the matching layer electrically and thermally conductive
Implementation Method 4
ii) vibrating membranes on the surface of a substrate material, such as Si, where the electro-mechanical coupling is either capacitive (cmut) or through layers of piezoelectric material (pmut)
Data Source
AI summary
An acoustic matching layer where the thickness is defined by a single layer of defined mono-disperse particles. The layer comprises a polymer base in which mono-disperse particles are embedded. The mono-disperse particles can be coated with a solid material that participates in the definition of the acoustic impedance of the layer. The polymer base can include smaller solid particles that participates in the definition of the acoustic impedance of the layer. The invention also provides a method of manufacturing.