High-Alumina Cement Backing Layer for Ultrasonic Transducers
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Solution Overview
Problem
Current ultrasonic transducers face limitations in operating at high temperatures due to material degradation and increased attenuation, requiring cooling systems and leading to reduced continuous operating temperatures, which causes delays and inefficiencies in applications like oil and gas processing.
Innovation Solution
A compact ultrasonic transducer with a backing layer material composed of stainless steel powder, cement, and optional superplasticizer, designed to maintain stability and dampen vibrations up to 650°C, eliminating the need for cooling systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional backing materials are used in ultrasonic transducers, then the transducer can operate at normal temperatures, but the material capability to dampen reverberations is reduced at high temperatures above 600°C
Solution Approach 1:
The patent applies composite materials by combining stainless steel powder (304 or 316 grade) with alumina cement in a matrix to create a backing material that maintains structural integrity and dampening properties at temperatures up to 650°C. The composite structure allows the material to resist thermal degradation while preserving vibration damping capability.
Solution Approach 2:
The patent changes the physical and chemical parameters of the backing material by using high-alumina cement with specific powder-to-cement ratios and controlling the curing process at elevated temperatures. These parameter changes enable the material to maintain its dampening properties at high operating temperatures where conventional materials would degrade.
2Temperature
If cooling systems are added to maintain piezoelectric element temperature, then the transducer can operate in high temperature environments, but the device complexity increases
Solution Approach 1:
The patent extracts and eliminates the cooling system from the ultrasonic transducer design by developing a backing material that inherently withstands high temperatures up to 650°C. This removal of the cooling subsystem simplifies the overall device while enabling operation in high-temperature environments.
Solution Approach 2:
The backing material serves itself by providing thermal stability and vibration damping without requiring external cooling mechanisms. The high-alumina cement composite inherently resists thermal degradation, allowing the transducer to operate autonomously in high-temperature environments.
3Device complexity
If conventional backing materials are used, then the transducer structure is simple, but significant changes in attenuation coefficient occur as temperature rises, requiring plant shutdowns
Solution Approach 1:
The high-alumina cement composite material provides stable attenuation characteristics across the operating temperature range up to 650°C. This stability allows continuous operation of ultrasonic transducers in high-temperature industrial processes without requiring shutdowns for temperature-related recalibration or replacement.
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
Enables continuous operation at high temperatures without cooling systems, enhancing reliability and efficiency in industries like oil and gas, nuclear, and medical fields by providing stable signal transmission and precision.
Implementation Method 1
a backing material positioned above the piezoelectric element to reduce reverberations inside the transducer
Implementation Method 2
a backing layer material... disposed on one side of the piezoelectric element to attenuate vibrations
Implementation Method 3
a piezoelectric element, positioned between two electrodes, designed to generate the ultrasonic pulse when a voltage is applied across the electrodes
Implementation Method 4
the backing element material renders the ultrasonic transducer stable at temperatures of up to about 600° C.
Implementation Method 5
the cement is at least one of a calcium aluminate cement (CAC), a molten cement and a refractory cement
Data Source
AI summary
It is provided a backing layer material resistant to temperature of up to about 600° C. comprising stainless steel powder, cement, water, and optionally at least one adjuvant, a ultrasonic transducer comprising said backing layer material conferring stability to the a ultrasonic transducer to temperature of up to about 600° C.