Ultrasound Sensor Connector With Adhesive-Free RF Coupling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing sensor connectors for ultrasound sensing elements face issues in harsh environments due to material degradation, chemical reactions, and high complexity, leading to unreliable connections and increased costs.
Innovation Solution
A sensor connector design featuring a conductive coupler with a compressible conductive pad and a RF connector, eliminating the need for adhesive by using a press-fit mechanism and reflow solder paste for reliable and cost-effective connections, while maintaining electrical integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive is used to connect the conductive pad to the sensing element, then the connection is initially secure, but the adhesive degrades or undergoes chemical reactions in harsh environments, leading to unreliable connections
Solution Approach 1:
The invention removes the adhesive from the connection system entirely. The conductive pad is directly bonded to the sensing element electrode through a metal-to-metal bond achieved via reflow soldering, eliminating the adhesive layer that degrades in harsh environments. This extraction of the problematic adhesive component resolves the contradiction between initial connection security and long-term durability.
Solution Approach 2:
The invention replaces the adhesive with a solder-based bonding approach that creates a permanent, non-degrading metal bond. The solder joint is designed to be robust and resistant to environmental degradation, effectively creating a connection that does not have the lifespan limitations of adhesive-based systems.
2Reliability
If complex connector components are used to ensure reliable connection, then connection reliability improves, but device complexity and cost increase
Solution Approach 1:
The invention merges multiple functions into the connector body itself. The connector body directly houses the conductive pad that contacts the sensing element, eliminating the need for separate adhesive layers, additional bonding components, or complex assembly structures. This integration reduces device complexity while maintaining reliable electrical connection through the direct metal-to-metal bond.
Solution Approach 2:
The connector body is designed to perform multiple functions: it provides mechanical support, establishes electrical connection through the conductive pad, and facilitates soldering directly to the sensing element. This multi-functionality reduces the need for additional specialized components, thereby reducing overall device complexity while ensuring reliable connection.
3Ease of manufacture
If adhesive is used for bonding, then initial assembly is simplified, but material degradation and chemical reactions occur in harsh environments
Solution Approach 1:
The invention replaces the chemical bonding mechanism of adhesive with a metallurgical bonding mechanism using reflow soldering. This substitution creates a metal-to-metal bond that is resistant to environmental degradation, chemical reactions, and material breakdown. The soldering process provides both ease of manufacture through standardized procedures and long-term resistance to harsh environmental conditions.
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 provides a more reliable, cost-effective, and durable connection for ultrasound sensors in harsh environments by avoiding adhesive-related issues and reducing the complexity of components, ensuring longer lifespan and improved signal integrity.
Implementation Method 1
a compressible conductive pad positioned in and protruding from the pad retaining recess
Implementation Method 2
reflow solder paste for reliable and cost-effective connections
Data Source
AI summary
A coupler for coupling an RF connector to an ultrasound sensing element. The coupler includes a conductive coupler body with a first end and a second end. The first end includes a pad retaining recess with a compressible conductive pad positioned in and protruding from the pad retaining recess. The second end either includes an opening for receiving a male pin of a radio frequency (RF) connector or is shaped to be press-fitted into the female pin opening of an RF connector, to conductively connect the pin with the coupler body. A sensor connector is also disclosed.