Ultrasonic Probe Acoustic Matching Layer and Moisture Protection
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Solution Overview
Problem
Existing ultrasonic devices face issues with moisture exposure leading to electrode corrosion and increased electric resistance due to the moisture permeability of traditional joint sealing materials used in bulk-type ultrasonic transducers.
Innovation Solution
The ultrasonic device incorporates a base with ultrasonic transducer elements, an acoustic matching layer, protective films with lower moisture permeability than the acoustic matching layer, and wall portions with different acoustic impedance to prevent ultrasonic crosstalk and protect electric conductors from moisture, while maintaining effective ultrasonic wave transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If silicone rubber containing filler is used as the joint sealing material, then crosstalk between adjacent acoustic matching pieces is prevented, but moisture passes through the silicone rubber to reach the electrode causing corrosion and increased electric resistance
Solution Approach 1:
The joint sealing material is divided into two distinct functional segments: the acoustic matching layer (made of silicone rubber with filler) that prevents crosstalk, and the protective film (made of moisture-impermeable material) that protects the electrode from moisture. This segmentation allows each layer to specialize in one function without compromising the other.
Solution Approach 2:
Different regions of the joint sealing structure are assigned different material properties: the acoustic matching layer has acoustic impedance matched to prevent crosstalk, while the protective film has low moisture permeability to protect the electrode. Each layer's quality is optimized for its specific local function.
2Object-generated harmful factors
If the acoustic matching layer is used to seal between transducer elements, then crosstalk is prevented, but the moisture permeability of the acoustic matching layer allows moisture to reach the electric conductors
Solution Approach 1:
The protective film acts as an intermediary layer between the acoustic matching layer and the electric conductor. It mediates by blocking moisture from reaching the conductor while allowing the acoustic matching layer to perform its crosstalk prevention function independently.
Solution Approach 2:
The joint sealing structure uses a composite of two different materials: silicone rubber with filler for acoustic matching and crosstalk prevention, and a moisture-impermeable material for protective film. The composite structure combines the advantages of both materials while mitigating their individual disadvantages.
3Reliability
If a protective film with lower moisture permeability is introduced, then electrode protection from moisture is improved, but the structure becomes more complex
Solution Approach 1:
The protective film is implemented as a thin film layer that can be deposited or applied over the electric conductor. This thin film approach provides effective moisture protection while adding minimal structural complexity and maintaining compatibility with existing manufacturing processes.
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 configuration effectively prevents ultrasonic crosstalk and provides reliable moisture protection for electric conductors, enhancing the durability and performance of the ultrasonic device.
Implementation Method 1
the vibration film of an ultrasonic transducer element vibrates ultrasonically
Implementation Method 2
the wall portions having an acoustic impedance that is different from an acoustic impedance of the acoustic matching layer
Implementation Method 3
the moisture permeability of the protective films is smaller than that of the acoustic matching layer
Data Source
AI summary
An acoustic matching layer is formed on individual ultrasonic transducer elements on a base. Electric conductors are arranged between adjacent ultrasonic transducer elements, the electric conductors being connected to electrodes of the ultrasonic transducer elements. Protective films overlap the electric conductors. The protective films have smaller moisture permeability than the acoustic matching layer. Wall portions are arranged on the protective films, the wall portions separating portions of the acoustic matching layer that are respectively located on adjacent ultrasonic transducer elements from each other at least in a part of a height range with respect to a height direction from the base, and having an acoustic impedance that is different from the acoustic impedance of the acoustic matching layer.