Ultrasonic Transducer Segmented Surface Thermal Stress
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Solution Overview
Problem
Conventional ultrasonic transducers for gas flow measurement face challenges in effectively coupling ultrasonic signals across varying acoustic impedances and maintaining efficient signal transmission while avoiding damage from thermal stress during assembly.
Innovation Solution
The ultrasonic transducer design incorporates a prestressed electromechanical transducer element with a segmented surface, a matching layer for impedance matching, and a helical compression spring for uniform force distribution, along with a coupling agent and a housing that limits thermal stress during assembly, ensuring efficient signal transmission and robust coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the electromechanical transducer element is metallurgically bonded to the ultrasonic window, then the coupling strength is improved, but thermal stress during assembly causes damage
Solution Approach 1:
A coupling agent layer is introduced between the electromechanical transducer element and the ultrasonic window. This intermediary layer enables effective ultrasonic coupling while avoiding direct metallurgical bonding, thereby preventing thermal stress damage during assembly. The coupling agent serves as a mediator that transmits ultrasonic energy without requiring high-temperature bonding processes.
2Reliability
If a coupling layer of ductile solid material is used between the transducer element and ultrasonic window, then signal transmission is improved, but the device complexity increases
Solution Approach 1:
The coupling agent's material parameters (viscosity, acoustic impedance) are optimized to achieve effective ultrasonic signal transmission. By carefully selecting and controlling the parameters of the coupling agent layer, reliable signal transmission is achieved without requiring complex multi-layer structures or additional components.
3Reliability
If the first surface of the transducer element is divided into segments, then the signal transmission efficiency is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The first surface of the electromechanical transducer element is divided into multiple segmented contact areas that interface with the coupling agent layer. This segmentation improves ultrasonic signal transmission efficiency by optimizing the contact interfaces. The segmentation pattern is designed to balance performance improvement with manufacturability, avoiding excessively complex precision requirements.
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 design enhances the accuracy and reliability of gas flow measurement by optimizing signal transmission across acoustic impedance differences and minimizing thermal damage during assembly, leading to improved performance and durability of the ultrasonic transducer.
Implementation Method 1
The transducers typically consist of an electromechanical transducer element, such as a piezoelectric element, and an ultrasonic window. Within the electromechanical transducer element, the ultrasonic waves are generated as acoustic signals
Implementation Method 2
This matching layer performs the function of transmitting the ultrasound signal and simultaneously reducing reflections caused by differing acoustic impedances at interfaces between two materials
Implementation Method 3
a helical compression spring for uniform force distribution
Implementation Method 4
A force distributed uniformly across the segments is advantageous
Data Source
Figure 1~3
AI summary
Disclosed is an ultrasonic transducer for an ultrasonic flow rate meter, comprising an electromechanical transducer element (5) that is preloaded against an ultrasonic window (4) of the ultrasonic transducer with the help of suitable means (10). A first surface (6) of the electromechanical transducer element (5) faces the ultrasonic window (4), while a second surface (7) thereof (5) opposite the first surface (6) is subdivided into multiple segments (9) which are electrically connected to the suitable preloading means.