Ultrasonic Transducer Module Stereolithographic Molding
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Solution Overview
Problem
The existing manufacturing methods for ultrasonic transducer modules result in a bulky casing with a cavity, which complicates assembly and increases the size of the module, potentially leading to deviations under external loads and inefficiencies in housing the ultrasonic transducer, relay board, and cable.
Innovation Solution
A method utilizing stereo lithographic molding to create a single-type resin casing that integrates the ultrasonic transducer, relay board, and cable, eliminating the need for a cavity and allowing for miniaturization by molding directly around these components, thus reducing the overall size and improving assembly precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional manufacturing methods are used to assemble the ultrasonic transducer, relay board, and cable in a housing portion, then the components can be housed, but a cavity is formed between the relay board and housing portion resulting in increased module size and assembly complexity
Solution Approach 1:
The patent combines the housing portion and relay board into a single integrated component manufactured via stereolithographic molding. The relay board is formed as an integral part of the housing structure, eliminating the cavity between them and removing the need for separate assembly steps. This merging of components directly reduces both module size and assembly complexity.
Solution Approach 2:
The patent performs preliminary positioning of the ultrasonic transducer and cable within the housing cavity before final molding. The stereolithographic process builds the housing around pre-positioned components, ensuring precise spatial relationships are maintained while eliminating post-assembly adjustments and reducing overall assembly complexity.
2Ease of manufacture
If the ultrasonic transducer and relay board are inserted obliquely downward into the housing portion, then assembly is performed, but the housing portion must accommodate this orientation creating a bulky structure with unnecessary cavity space
Solution Approach 1:
The housing portion and relay board are merged into a single stereolithographically molded component. The relay board is formed as an integral extension of the housing structure, eliminating the cavity that would otherwise be required to accommodate oblique insertion. This integration maintains assembly ease while significantly reducing housing volume.
3Ease of operation
If a cavity is formed between the relay board and housing portion, then components can be assembled, but the cavity creates instability and potential deviation under external loads
Solution Approach 1:
The relay board is integrated as an integral part of the housing structure through stereolithographic molding, eliminating the cavity between them. This integration provides rigid mechanical support and ensures stable component positioning under external loads, while the molded features maintain ease of assembly through built-in alignment and retention structures.
Solution Approach 2:
The patent employs stereolithographic molding to create complex three-dimensional structures with optimized geometries. The curved and contoured features of the molded housing provide superior mechanical interlocking and load distribution compared to traditional straight-edged assemblies, enhancing component stability while maintaining assembly ease.
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 approach enables the miniaturization of the ultrasonic transducer module, enhances assembly efficiency by eliminating the need for a cavity, and stabilizes the components within the casing, reducing the risk of deviation due to external loads.
Implementation Method 1
The ultrasonic transducer has a plurality of piezoelectric elements that convert an electric pulse signal into an ultrasonic pulse (acoustic pulse)
Implementation Method 2
convert an ultrasonic echo reflected from the observation target to an electric echo signal
Implementation Method 3
performing a first molding to form a first part of a casing by molding a single type of resin having an insulation property through a stereo lithographic molding method
Data Source
AI summary
A method of manufacturing an ultrasonic transducer module, the ultrasonic transducer module including an ultrasonic transducer, a cable electrically connecting the ultrasonic transducer and a board connectable to an ultrasonic observation device, and a relay board relaying electrical connection between the ultrasonic transducer and the cable, the method including: performing a first molding to form a first part of a casing by molding a single type of resin having an insulation property through a stereo lithographic molding method; and performing a second molding to form a second part of the casing in a state where the ultrasonic transducer, the relay board, and the cable are provided in the first part of the casing, the second part being manufactured by further molding the resin in a side of the first part, in which the ultrasonic transducer, the relay board, and the cable are arranged, through the stereo lithographic molding method.