Ultrasonic Probe With Vertically Offset Bond Lines for Liquid Ingress
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Solution Overview
Problem
The bond lines in ultrasonic probes can become paths for liquid penetration, leading to potential short circuits and corrosion due to the permeability of plastics used in the assembly, despite the use of adhesives like PVC and epoxy resins, which are not fully impermeable to liquids and gases.
Innovation Solution
The ultrasonic probe design includes vertically offset bond lines between the probe case and inner housing, with specific adhesive thicknesses and materials to enhance chemical and water resistance, and additional features like annular grooves and O-rings to prevent liquid ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive bond lines are used to join the probe case and inner housing, then assembly is simplified and thermal conductivity is maintained, but liquid penetration paths are created leading to potential short circuits and corrosion
Solution Approach 1:
The probe case and inner housing are divided into multiple segments with bond lines positioned at different heights. This segmentation creates a stepped configuration where the first bond line is at a first height and the second bond line is at a second height, preventing liquid from traveling horizontally along a single bond line level and thus reducing liquid penetration while maintaining assembly simplicity
Solution Approach 2:
The bond lines are arranged in the vertical dimension at different heights rather than being collinear. By positioning the first bond line at a first height and the second bond line at a second height, the liquid penetration path is disrupted through vertical offsetting, transforming a potential horizontal liquid flow path into a complex multi-level structure that resists liquid ingress
2Reliability
If plastic materials are used for the probe case, then chemical and heat resistance is achieved, but gas permeability allows water vapor to pass through condensing into liquid water
Solution Approach 1:
An O-ring seal is introduced as an intermediary element between the probe case and inner housing. The O-ring, made of elastomeric material, fills the gap between components and provides a water vapor impermeable barrier, preventing water vapor from penetrating through the plastic probe case while maintaining the chemical and heat resistance properties of the plastic material
Solution Approach 2:
The assembly combines plastic materials (for chemical and heat resistance) with elastomeric sealing materials (for vapor impermeability). This composite approach allows the probe case to maintain its plastic construction for chemical resistance while incorporating sealing elements that prevent water vapor penetration, creating a multi-functional material system
3Ease of manufacture
If the bond lines are positioned at the same height, then assembly is simplified, but liquid can easily penetrate along the bond line from the front end to the back end
Solution Approach 1:
The bond lines are positioned asymmetrically in terms of their vertical positions. The first bond line is at a first height while the second bond line is at a second height, creating an asymmetric configuration that disrupts liquid flow paths. This asymmetric positioning makes it difficult for liquid to travel along the bond lines from the front end to the back end while maintaining manufacturing simplicity
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 significantly reduces liquid penetration, enhancing the ultrasonic probe's durability and preventing short circuits and corrosion, while maintaining thermal conductivity and ease of assembly.
Implementation Method 1
The inner housing, which is divided into an upper surface side portion and a bottom surface side portion, and the probe case can be bonded together using a water-resistant adhesive such as a polyvinyl chloride (PVC) resin-based adhesive, an epoxy resin-based adhesive, and the like.
Implementation Method 2
The inner housing, which is divided into an upper surface side portion and a bottom surface side portion, and the probe case can be bonded together using a water-resistant adhesive such as a polyvinyl chloride (PVC) resin-based adhesive, an epoxy resin-based adhesive, and the like.
Implementation Method 3
the ultrasonic transducer included in the ultrasonic probe vibrates in response to an applied voltage and generates heat because it is a constituent element that generates ultrasonic waves
Implementation Method 4
the ultrasonic transducer included in the ultrasonic probe vibrates in response to an applied voltage and generates heat because it is a constituent element that generates ultrasonic waves
Implementation Method 5
Water vapor that enters the inside of the ultrasonic probe condenses into liquid water when the internal temperature drops below a dew point
Implementation Method 6
the ultrasonic probe may be provided with a metal inner housing that is thermally connected to the ultrasonic transducer. Since the inner housing must have high thermal conductivity
Data Source
AI summary
An ultrasonic probe including an ultrasonic transducer, a metallic inner housing thermally connected to the ultrasonic transducer, and a probe case surrounding the inner housing. The bond lines of the probe case and the bond lines of the inner housing are offset in height from each another.