Multilayer backing absorber for ultrasonic transducer
09713825 ยท 2017-07-25
Assignee
Inventors
Cpc classification
G10K11/002
PHYSICS
Y10T428/24132
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y10T428/3154
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B06B1/06
PERFORMING OPERATIONS; TRANSPORTING
Y10T156/10
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
H04R17/00
ELECTRICITY
B06B1/06
PERFORMING OPERATIONS; TRANSPORTING
G10K11/00
PHYSICS
Abstract
A multilayer backing absorber for use with an ultrasonic transducer comprises a plurality of absorber elements, each absorber element having at least one metal layer and at least one adhesive layer, wherein the backing absorber is adapted to be coupled to a vibrating layer of the ultrasonic transducer.
Claims
1. A backing absorber for use with an ultrasonic transducer, comprising: a first absorber element having at least one homogeneous metal layer and at least one adhesive layer; and a second absorber element having at least one homogeneous metal layer and at least one adhesive layer, wherein said backing absorber is adapted to be coupled to a vibrating layer of said ultrasonic transducer, wherein said first and second absorber elements are effective to dampen ultrasonic signals emitted by said vibrating layer when said backing absorber is coupled to said vibrating layer, and wherein each absorber element further includes a polymer layer.
2. The backing absorber of claim 1, wherein each of said at least one metal layers is deposited on a corresponding one of said polymer layers to form a periodic grating of metal strips wherein the direction and period of the grating is the same for each absorber element.
3. The backing absorber of claim 2, wherein the vibrating layer comprises a 2-2 PZT composite having a plurality of elongated bars of PZT material and wherein the direction of the elongated metal area of the grating is perpendicular to said PZT bars.
4. The backing absorber of claim 1, wherein each of said at least one metal layers is deposited on a corresponding one of said polymer layers to form a periodic grating of metal strips wherein the direction or period of the grating is different for each absorber element.
5. The backing absorber of claim 4, wherein said direction of said grating is positioned at a 90 degree angle relative to the direction of the grating of each adjacent absorber element.
6. The backing absorber of claim 1, wherein each of said at least one metal layers is partially deposited on a selected area of a corresponding one of said polymer layers to form a boundary grading for reflecting backwards waves in such a way as to increase effective attenuation.
7. The backing absorber of claim 1, wherein the vibrating layer comprises one of a monolithic PZT plate, a 1-3 PZT composite, and a 2-2 PZT composite.
8. A method of making a backing absorber for an ultrasonic transducer, comprising: forming a first absorber element by coupling a first homogeneous metal layer to a first adhesive layer and coupling a first polymer layer to said first homogeneous metal layer; and forming a second absorber element by coupling a second homogeneous metal layer to a second adhesive layer and coupling a second polymer layer to said second homogeneous metal layer, wherein a surface of said first absorber element is configured to be coupled to a corresponding surface of a vibrating layer of said ultrasonic transducer for absorbing ultrasonic waves.
9. The method of claim 8 further comprising: forming an additional absorber element by coupling a third metal layer to a second adhesive layer; and bonding said additional absorber element to said second absorber element.
10. The method of claim 9 further comprising: repeating said forming of said additional absorber elements and said bonding of said additional absorber elements until a predetermined acoustic absorption value has been reached.
11. The method of claim 8, wherein said forming each absorber element further comprises depositing said metal layer on said polymer layer to form a periodic grating of metal strips wherein the direction and period of the grating is the same for each absorber element.
12. The method of claim 8, wherein said forming each absorber element further comprises depositing said metal layer on said polymer layer to form a periodic grating of metal strips wherein the direction or period of the grating is different for each absorber element.
13. The method of claim 12, wherein said direction of said grating is positioned at a 90 degree angle relative to the direction of the grating of each adjacent absorber element.
14. The method of claim 8, wherein said forming further comprises partially depositing said metal layers on a selected area of said polymer layers to form a boundary grading for reflecting waves in such a way as to increase effective attenuation.
15. An ultrasonic transducer assembly, comprising: a vibrating layer for generating ultrasonic waves; and a backing absorber coupled to said vibrating layer for absorbing said ultrasonic waves, said backing absorber having a plurality of absorber elements, each absorber element including a metal layer, a polymer layer, and an adhesive layer.
16. The ultrasonic transducer assembly of claim 15, wherein the vibrating layer comprises one of a monolithic PZT plate, a 1-3 PZT composite, and a 2-2 PZT composite.
17. A backing absorber for use with an ultrasonic transducer, comprising: a first absorber element having at least one homogeneous metal layer and at least one adhesive layer; and a second absorber element having at least one homogeneous metal layer and at least one adhesive layer, wherein said backing absorber is adapted to be coupled to a vibrating layer of said ultrasonic transducer, wherein said first and second absorber elements are effective to dampen ultrasonic signals emitted by said vibrating layer when said backing absorber is coupled to said vibrating layer, and wherein each of said at least one metal layers forms a periodic grating of metal strips, wherein the direction or period of the grating is different for each absorber element.
18. The backing absorber of claim 17, wherein said direction of said grating is positioned at a 90 degree angle relative to the direction of the grating of each adjacent absorber element.
Description
BRIEF DESCRIPTION OF THE FIGURES
(1) Understanding of the present invention will be facilitated by consideration of the following detailed description of the preferred embodiments of the present invention taken in conjunction with the accompanying drawings, in which like numerals refer to like parts and in which:
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION
(15) Reference will now be made in detail to the present exemplary embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
(16)
(17) Insets in
(18) When a monolithic layer (or non-composite) of PZT is used in a thickness vibration mode, a feature of its vibration is compared with a composite structure as described. When the thickness dimension or direction expands during vibration, the dimensions of the planar directions have to become smaller. Conversely, when the thickness dimension shrinks, the planar dimensions have to expand. Since the planar dimensions are much larger than the wavelength, the piezoelectric layer cannot vibrate in these planar directions. This inability to vibrate in the planar directions suppresses the vibration in the thickness direction.
(19) When PZT material is cut in the thickness direction so as to possess a small dimension relative to the planer direction, the vibration into the planar direction is enabled and thickness vibration is enhanced. This means the effective elastic constant in the thickness direction is lowered (becoming effectively a softer material) and its acoustic impedance is lowered. Further, the ultrasonic waveform is excited and also receives acoustic signals with higher sensitivity.
(20) Still referring to
(21) In the case described above the resonance bandwidth becomes too broad and sensitivity as a whole for the transducer structure 1 is not sufficiently high. If the absorption by the backing material 6 is not high enough, then the wave 8 is reflected at the end surface 9 of backing material 6 and propagates back to the piezoelectric material layer 2, generating multiple peaks on the frequency response curve by constructive or destructive interference and causing pulse waveform distortions. Thus the wave 8 transmitted into backing material 6 should be absorbed.
(22) For an actual transducer, some suitable amount of reflection from boundary 7 is needed to provide the necessary sensitivity and bandwidth. The thickness of backing material 6 is limited by the available space for transducer structure 1 and the backward propagating wave 8 has to be absorbed while propagating and before reflecting off of end surface 9. Therefore, if a thick backing layer can be used, the backing layer absorption coefficient does not have to be very large for sufficient attenuation of the reflection. However, if the thickness of the backing material 6 has certain size (e.g. thickness) limitations, then the absorption coefficient has to be larger than that of a larger layer to achieve the desired result.
(23) Depending on the piezoelectric material and structure (e.g. monolithic PZT plate, 1-3 or 2-2 composite, or single crystal), the acoustic impedance will vary and therefore the sensitivity and bandwidth are different. The impedance and attenuation of the backing absorber material may be adapted according to the particular requirements.
(24) The acoustic impedance and absorption for a structure comprising a plurality of metal deposited polymer layers bonded by adhesive has performance features suitable for use as a practical backing absorber. The required bandwidth and sensitivity of an ultrasonic transducer may be different for different applications. There is a need to design the impedance and absorption which is suitable for the specific requirements. According to an aspect of the present invention, periodic structures with metal-adhesive multilayers and metal-polymer-adhesive multilayers adapted for mass-production are described herein. The impedance, absorption and velocity are indicated by design equations.
(25) The metal layers in the acoustic backing structure are relatively heavy and stiff. When the structure is vibrated during wave propagation the metal layers move but are not elastically deformed. The adhesive is comparatively soft and undergoes expansion/contraction due to the displacement of the metal layer. This motion gives the metal layers relatively high kinetic energy. Since the elastic loss factor of these adhesives is large, energy is lost through heat generation. This mechanism has high absorption. A polymer layer is somewhat stiffer than adhesive and has a similar role.
(26) Design equations of impedance, velocity and absorption and cut off frequency of a multilayer structure are given below. Referring to
(27) In a repeated system of mass-spring-mass-spring etc. a longitudinal displacement wave propagates with a constant velocity for a frequency range below a certain frequency (cut off frequency, fc). The wave propagates a long distance if all the springs are ideally lossless. However, above fc, the wave attenuates (exponentially decays) strongly with propagation distance. In this system propagation therefore exists only below fc. From the basic equations of sequentially connected mass and lossy spring models, the wave velocity and impedance and absorption coefficients may be obtained. In this calculation each layer thickness is assumed to be much less than the wavelength. The resultant exemplary values of a multilayer absorber configured in accordance with the principles of the present invention are provided below. The weight per unit area of elemental layer M=.sub.m h.sub.m+.sub.a h.sub.a, and unit area spring constant K=[(h.sub.m/.sub.mV.sub.m.sup.2)+(h.sub.a/.sub.aV.sub.a.sup.2)].sup.1, acoustic impedance Z.sub.o=(MK).sup.1/2, average propagation velocity V.sub.0=(h.sub.m+h.sub.a) (K/M) .sup.1/2 and absorption coefficient =(/2Q.sub.aV.sub.0), where is density, h is thickness, V.sub.m and V.sub.a are velocity in each material, and subscripts m and a stand for metal and adhesive. The relationships holds up to a maximum frequency, above that frequency the acoustic impedance starts to decrease and propagation does not exist at frequencies higher than fc for a lossless material. So the maximum frequency is defined as the cut off frequency, given by f.sub.c=(1/) (K/M).sup.0.5.
(28) In the embodiment of
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(30) Examples of acoustic impedance and absorption for structures of various metal layers bonded by adhesive are also provided. These exemplary embodiments may be suitable for use with 1-3 or 2-2 ceramic-polymer composite. Composite materials have lower acoustic impedance than a monolithic PZT plate. Measurements of material parameters were performed to obtain the high frequency material properties of adhesive and polymer in thin layer form, and density, propagation velocity, and material Q values were obtained. A first example of a design of a multilayer absorber using 50 um copper and 12 um adhesive with periodic ten combined elemental structure (N=10) has the impedance Z.sub.o=9 MRayl and velocity V.sub.o=1102 m/s (meters/second) and alpha ()=3420/m at 6 MHz and cut off is at f.sub.c=6.28 MHz. The attenuation during round trip is 34 dB (decibel). The total thickness is 620 um. This means the wave transmitted into the absorber has an attenuation of 34 dB when it comes back to the back plane of piezoelectric layer 34 where the absorber is attached. These results can be used for design of an ultrasonic transducer. A second example of another thickness combination is shown next, where 25 um copper and 25 um adhesive are used with ten periodic structures. The designed values are, Z.sub.o=4.7 MRayl, V.sub.o=925 m/s, =7470/m at 5.5 MHz, fc=5.9 MHz and round trip attenuation is 24 dB, total thickness is 500 um. A third example comprises three elemental layers, 18 um copper, 25 um polyimide and 12 um pressure sensitive adhesive. The calculated values are Z.sub.o=4.8 MRayl, V.sub.o=1253 m/s, =3008/m, with round trip attenuation 29 dB at 6 MHz for N=10, fc=7.25 MHz, and total thickness of 550 um.
(31) An exemplary embodiment of a multilayer absorber for a monolithicPZT platetransducer is also provided. The structure is same as the one shown in
(32) Depending on the design requirements, the total thickness of the multilayer absorber may become too thick, particularly when many layers have to be used for high attenuation or when the multilayer absorber has to be used in a low frequency region where the absorption becomes smaller. Reducing the total number of layers may not yield enough attenuation. In such a case, the boundary of the region of the metallic layer can be graded as shown in
(33) When the elemental layers are as represented by the two layers 11 (metal) and 12 (adhesive) as shown in
(34) In order to increase the attenuation of a multilayer absorber, metal layer 21 on polymer film 22 is subdivided into narrow long strips forming grating 61 as shown in
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(36) The impedance characteristics of the exemplary multilayer absorbers have been calculated using a one dimensional model, which is based on wave analysis with suitable boundary conditions between one layer and another. The result agrees with aforementioned simplified design equations. The impedance seen from one side surface 16 in
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(38) Thus, as shown and described herein, a bonding layer of adhesive and a polymer layer have predictable, stable, reliable, long lasting absorber material behavior. Further, the piezoelectric material may be a uniform plate (non-composite) or PZT-polymer composite material. The inventive device includes a design of metal, polymer, and adhesive layers for desired impedance and absorption. Acoustic impedance and absorption for a structure of a plurality of metal deposited polymer layers bonded by adhesive are analyzed. Design equations to give necessary performance of the absorber structure have been shown. Examples of acoustic impedance and absorption for structures of various metal layers bonded by adhesive are provided. Side boundaries between gross multiple layer regions with metal and without metal make some angles to the surfaces. A layer of periodic narrow strips of metal on each polymer layer is bonded by adhesive. The metal strips on each layer are at a different and not necessarily periodic angles.
(39) With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
(40) Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.