Ultrasonic Transducer Piezo Alignment Metal Disc
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Solution Overview
Problem
Existing ultrasonic transducer designs can lead to measurement errors and disrupted signals due to the piezo element not lying flat on the metal disc, often supported by angled sheet metal elements, which cause tilting and lateral displacement.
Innovation Solution
A redesigned metal disc with segmented holding elements that support the edge of the metal disc and prevent lateral displacement of the piezo element, featuring a first segment on the same plane as the disc and a second segment that protrudes, with specific edge surfaces to prevent tilting and ensure proper alignment, along with a λ/4 matching layer for optimal signal transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If angled sheet metal elements are used to support the piezo element, then the piezo element is secured from slipping sideways, but the piezo element may not lie flat on the metal disc causing measurement errors and disrupted ultrasonic signals
Solution Approach 1:
The holding element is divided into two functional segments: a first segment that provides lateral support to prevent sideways slipping, and a second segment that ensures the piezo element lies flat on the metal disc. This segmentation allows each part to perform its specific function optimally without compromising the other.
Solution Approach 2:
Different portions of the holding element are designed with different geometries and orientations to provide localized functions: the first segment extends radially to prevent lateral displacement, while the second segment is angled to ensure flat contact. This local differentiation resolves the contradiction by providing both lateral support and flat positioning simultaneously.
2Reliability
If the piezo element is supported on kinked edges of angled sheet metal elements, then lateral displacement is prevented, but ultrasonic signals are disrupted and measurement errors occur
Solution Approach 1:
The holding element is segmented into a first segment for lateral support and a second segment for ensuring flat contact. This segmentation eliminates the kinked edge configuration that disrupted ultrasonic signals while maintaining lateral displacement prevention capability.
Solution Approach 2:
The second segment of the holding element acts as an intermediary between the metal disc and the piezo element, providing a smooth transition surface that ensures flat contact and prevents signal disruption while the first segment provides the necessary lateral constraint.
3Ease of manufacture
If a single-plane metal disc design is used, then manufacturing is simpler, but the piezo element may tilt or displace laterally during assembly and operation
Solution Approach 1:
The holding element is divided into two segments with different orientations: the first segment lies on the same plane as the metal disc for simple manufacturing, while the second segment protrudes at an angle to provide precise positioning and prevent tilting during assembly and operation.
Solution Approach 2:
The holding element transitions from a two-dimensional planar configuration to a three-dimensional structure with a protruding second segment. This dimensional change enables the element to provide both lateral support and flat positioning functionality while maintaining compatibility with simple metal disc fabrication 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 solution reduces the risk of measurement errors by ensuring the piezo element remains flat and securely positioned, enhancing signal integrity and reducing thermal stresses through improved acoustic impedance and thermal expansion gradients.
Implementation Method 1
a piezoelectric element (12, 22) which generates an ultrasonic signal
Implementation Method 2
a λ/4 matching layer for optimal signal transmission
Data Source
Figure 1~2a
Figure 3~5
Figure 6~8a
AI summary
The invention concerns an ultrasonic transducer, comprising a coupling element which has a first recess, the first recess being provided for the arrangement of a piezoelectric element which feeds an ultrasound signal into the coupling element, and there being disposed between the piezoelectric element and the coupling element an intermediate layer which comprises a metal disc, the metal disc comprising retaining elements (a) each with a first segment lying on the same plane as the metal disc and projecting radially from the perimeter of the metal disc and (b) each having a second segment which adjoins the first segment, projects from the plane of the metal plate and is connected to the first segment.