Ultrasonic Transducer Matching Layer for Accurate Flow Measurement
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Solution Overview
Problem
Traditional ultrasonic flowmeters suffer from poor electrical performance and suboptimal acoustic matching due to the use of materials like plastic, peek, or low-viscosity epoxy resin in the acoustic matching layer, leading to significant measurement errors.
Innovation Solution
A transducer with an acoustic matching layer made of a composite material comprising silver and epoxy resin, featuring a backing with an irregular surface and vent holes, along with a limiting mechanism to ensure secure assembly and acoustic damping, enhances electrical performance and acoustic matching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional materials (plastic, peek, or low-viscosity epoxy resin) are used for the acoustic matching layer, then the transducer structure is simple and easy to manufacture, but the electrical performance is poor and acoustic matching is suboptimal, resulting in significant measurement errors
Solution Approach 1:
The patent uses a composite material consisting of conductive rubber base material and metal particles (such as aluminum powder or silver powder) for the acoustic matching layer. This composite structure combines the acoustic properties of rubber with the electrical conductivity of metal particles, simultaneously improving electrical performance and acoustic matching to reduce measurement errors while maintaining manufacturability
Solution Approach 2:
The patent modifies the material parameters of the acoustic matching layer by adjusting the type, size, and concentration of metal particles in the conductive rubber composite. By optimizing these parameters, the material achieves both good electrical conductivity and acoustic matching characteristics, resolving the contradiction between measurement precision and ease of manufacture
2Reliability
If the acoustic matching layer uses materials with poor electrical performance, then the manufacturing process is simpler, but signal transmission quality deteriorates and measurement errors increase
Solution Approach 1:
The conductive rubber composite material combines the acoustic damping properties of rubber with the electrical conductivity of metal particles, creating a material that simultaneously improves signal transmission quality and maintains reasonable device complexity through a single integrated layer rather than multiple separate components
3Measurement precision
If traditional acoustic matching materials are used, then the transducer structure remains simple, but acoustic matching effect is suboptimal leading to measurement errors
Solution Approach 1:
The patent employs a composite material system where conductive rubber serves as the base material and metal particles are dispersed within it. This composite approach improves acoustic matching effect and measurement precision while keeping the structural complexity low, as it replaces traditional single-material layers with a functionally superior composite that can be applied using similar 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
The transducer achieves superior electrical properties, excellent acoustic matching, and minimal measurement errors, ensuring accurate flow measurement results by stabilizing signal transmission and reducing noise interference.
Implementation Method 1
a piezoelectric ceramic plate, serving as an acoustic transmitting and receiving element, is adhered to the inner end of the backing
Implementation Method 2
the acoustic matching layer of the body is made of a composite material comprising silver and epoxy resin
Implementation Method 3
the composite material contains 2 to 4 parts by weight of silver powder and 6 to 8 parts of ab adhesive
Implementation Method 4
a compression spring is arranged between the inner side surface of the compression nut and the outer end of the backing
Data Source
AI summary
The present invention relates to the field of flow measurement technologies, specifically to a transducer, manufacturing method and flow measurement device. It comprises a body and an acoustic communication rod, wherein the body is fixedly connected to the acoustic communication rod, and the radiating surface of the body abuts against one end of the acoustic communication rod, thereby achieving signal transmission. The key feature is that the acoustic matching layer of the body is made of a composite material comprising silver and epoxy resin. The composite material contains 2 to 4 parts by weight of silver powder and 6 to 8 parts of AB adhesive. This transducer exhibits excellent electrical performance and superior acoustic matching effect, resulting in minimal measurement error when applied in a flow measurement device.