Ultrasonic Probe Joining via Interlocking Concave-Convex Surfaces

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Solution Overview

Problem

Existing methods for joining ultrasonic transducers on curved surfaces often result in misalignment, leading to degraded ultrasonic image quality due to positional and frequency band deviations.

Innovation Solution

The use of concave-convex shapes on both the curved surface of the support and the flexible member, which are corresponding and engaged with each other, prevents misalignment by ensuring precise positioning and maintaining the flatness of ultrasonic transducers during the curving process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the flexible sheet is joined on the curved surface without concave-convex engagement structures, then the joining process is simple, but joining misalignment occurs causing positional misalignment of ultrasonic transducers

Engineering Contradiction:

Improvejoining process simplicityVSAvoidjoining alignment precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The curved surface and joining surface are divided into corresponding concave and convex segments that interlock with each other. The concave portions on one surface engage with convex portions on the other surface, creating multiple localized engagement points that collectively ensure precise alignment without requiring complex overall structures.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The concave-convex engagement structures utilize asymmetric geometries where the concave portions and convex portions are not axisymmetric in each direction. This asymmetry ensures that only one specific relative position between the flexible sheet and curved surface allows proper engagement, thereby preventing joining misalignment and ensuring accurate positioning of ultrasonic transducers.

Inventive Principle:

Principle #4Asymmetry

2Adaptability or versatility

If the flexible sheet is curved to fit the curved surface, then the ultrasonic probe can be formed, but positional misalignment of ultrasonic transducers occurs degrading image quality

Engineering Contradiction:

Improvecurved surface adaptationVSAvoidtransducer positioning accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The concave-convex engagement structures are pre-formed on both the curved surface and the joining surface before the flexible sheet is curved and joined. These pre-formed structures act as positioning guides that maintain transducer alignment accuracy throughout the curving process, ensuring that ultrasonic transducers remain in their correct relative positions even as the flexible sheet conforms to the curved surface.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS7739913B2Joining method for curved surfaces, and ultrasonic probe and manufacturing method thereof

Publication Date: 2010.06.22 FUJIFILM CORP

AI summary

A head of an ultrasonic probe is formed by joining a flexible sheet holding a plurality of ultrasonic transducers to a curved surface of a support. Concave-convex shapes (concave-convex surfaces) are provided on the curved surface of the support and a joining surface of the flexible sheet. The concave-convex surfaces correspond to each other, and are engaged with each other to determine relative positions of the flexible sheet and the support when they are joined. Each of grooves on the concave-convex surface is positioned between adjacent ultrasonic transducers.