Ultrasound Probe Solid Intermediate Layer Acoustic Coupling
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Solution Overview
Problem
Conventional ultrasonic probes face limitations in maintaining effective acoustic coupling between the transducer and the housing due to air pockets, with adhesives and liquid couplings failing at extreme temperatures and introducing measurement uncertainties with waveguides.
Innovation Solution
A thin, relatively soft solid intermediate layer is used between the ultrasonic transducer and the housing, with the ultrasonic window's surface having a predetermined roughness and the transducer subjected to a force to ensure plastic deformation, maximizing contact area and stability across a wide temperature range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is used to bond the ultrasonic transducer and the ultrasonic window, then the connection strength is improved, but the resistance to heat is poor leading to gas inclusions and detachment at high temperatures
Solution Approach 1:
A solid intermediate layer is introduced between the ultrasonic transducer and the ultrasonic window to serve as a mediator. This intermediate layer provides both strong mechanical bonding and thermal stability, eliminating the need for adhesives that fail at high temperatures. The intermediate layer maintains reliable acoustic coupling across a wide temperature range from -40°C to +150°C.
2Reliability
If wet coupling with oil-based liquids is used, then the acoustic coupling is improved, but the stability at high and low temperatures is poor due to outgassing and loss of contact-promoting effect
Solution Approach 1:
The solid intermediate layer acts as a stable intermediary that replaces volatile liquid couplings. It maintains consistent acoustic coupling properties across extreme temperatures without outgassing or losing contact-promoting effects, providing reliable performance from -40°C to +150°C.
Solution Approach 2:
The invention changes the physical state of the coupling medium from liquid to solid, fundamentally altering its temperature stability characteristics. The solid state eliminates volatility and outgassing issues while maintaining adequate acoustic coupling properties across a wide temperature range.
3Temperature
If ultrasonic waveguide is used to thermally insulate the ultrasonic transducer, then the thermal insulation is improved, but additional signal propagation time and measurement uncertainty are introduced
Solution Approach 1:
The solid intermediate layer serves as a thermal barrier that protects the ultrasonic transducer from temperature fluctuations in the medium being measured, while its direct contact with the ultrasonic window eliminates additional signal propagation paths that would introduce measurement uncertainty.
4Area of stationary object
If the contact surface area between ultrasonic transducer and ultrasonic window is increased, then the ultrasonic signal transmission is improved, but air pockets form reducing acoustic coupling
Solution Approach 1:
The solid intermediate layer fills the gap between the ultrasonic transducer and ultrasonic window, providing continuous acoustic coupling across the entire contact surface. This eliminates air pockets that would otherwise form at interfaces, ensuring reliable ultrasonic signal transmission through the full contact area.
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 configuration enhances ultrasonic signal transmission by minimizing air interfaces and maintaining contact integrity at varying temperatures, avoiding the limitations of adhesives and waveguides, while ensuring accurate measurements.
Implementation Method 1
the solid intermediate layer nestles against the ultrasonic window of the housing, at least through plastic deformation
Implementation Method 2
an ultrasonic transducer arranged in the housing, with the ultrasonic transducer being able to generate and/or detect ultrasonic signals
Data Source
Figure 1
AI summary
Described and illustrated is an ultrasonic probe (1), in particular for an ultrasonic flow meter, comprising a housing (2) and an ultrasonic transducer (3) arranged in the housing (2), wherein ultrasonic signals can be generated and/or detected by the ultrasonic transducer (3) and the ultrasonic signals can be emitted and/or received by the ultrasonic transducer (3) via an ultrasonic window (4) of the housing (2). The invention is based on the objective of creating a transition between the ultrasonic transducer (3) and the ultrasonic window (4) that no longer exhibits – at least partially – the disadvantages of known intermediate layers between the ultrasonic transducer (3) and the ultrasonic window (4).The problem according to the invention is solved by providing a thin, relatively soft solid intermediate layer (5) between the ultrasonic transducer (3) and the ultrasonic window (4) of the housing (2), the surface of the ultrasonic window (4) in contact with the solid intermediate layer (5) having a predetermined roughness, and the ultrasonic transducer (3) being subjected to a force, wherein the materials of the solid intermediate layer (5) and the ultrasonic window (4), the predetermined roughness of the surface of the ultrasonic window (4), and the force are coordinated such that the solid intermediate layer (5) is at least also pressed against the ultrasonic window (4) of the housing (2) by means of plastic deformation.