CN115650633A - Ultrasonic transducer matching layer composite material with largely adjustable acoustic impedance and preparation method thereof by high-pressure thermal curing method - Google Patents
Ultrasonic transducer matching layer composite material with largely adjustable acoustic impedance and preparation method thereof by high-pressure thermal curing method Download PDFInfo
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Abstract
The invention discloses a composite material for an ultrasonic transducer matching layer with greatly adjustable acoustic impedance and a method for preparing the composite material by a high-pressure thermal curing method, and belongs to the field of ultrasonic transducers. The invention aims to solve the problem that the acoustic impedance adjustable range of the resin and solid powder composite material prepared by the existing method is less than 6MRayls. When the liquid resin is used, after the liquid resin and the solid powder are fully mixed, applying pressure of several megapascals to dozens of megapascals to extrude partial liquid, and then heating and curing; for solid resin, the uniformly mixed powder material is heated to a melting point under low pressure, then the pressure is increased to extrude bubbles, and the temperature is reduced under the pressure to cure. The high-pressure heat curing method can enable the acoustic impedance of the composite material to be accurately regulated and controlled within 2-15MRayls, and the obtained composite material has low acoustic attenuation and meets the requirements of a matching layer material. The composite material obtained by the method can be used as a matching layer of an ultrasonic transducer, particularly a multilayer matching design, and can be applied to ultrasonic transducers and ultrasonic transducer arrays of all frequencies.
Description
Technical Field
The invention belongs to the field of ultrasonic transducers, and particularly relates to a matching layer composite material with greatly adjustable acoustic impedance and a preparation method thereof by a high-pressure thermal curing method.
Background
An ultrasonic transducer (commonly called an ultrasonic probe) based on a piezoelectric material is the most core device of medical ultrasonic and nondestructive testing ultrasonic equipment. However, in either piezoelectric single crystal or piezoelectric ceramic, the acoustic impedance is extremely mismatched with the acoustic impedance of the detection medium (e.g., human body). For example, the acoustic impedance of PZT piezo ceramic is about 34MRayls, while the acoustic impedance of the human body is about 1.6MRayls. One solution to this problem is to add a single or multiple layers of matching material between the piezoelectric wafer and the detection medium to ensure that the acoustic waves can effectively enter the detection medium. Theoretically, the thickness of each layer of matching material is 1/4 wavelength, in order to increase the bandwidth, the existing ultrasonic transducer is often matched by 2 layers, 3 layers or 4 layers, and the acoustic impedance (the product of density and sound velocity) of each layer of matching material has certain requirements, generally ranging from 2MRayls to 15 MRayls. If the properties of the matching materials cannot meet the design requirements, the sensitivity and bandwidth of the transducer are greatly influenced, and the transducer with the optimal design cannot be realized.
In reality, the quantity of the simple substances is limited, the performance is fixed, and the acoustic impedance of the simple substances is not adjustable, so that the matching materials are generally composite materials. Most commonly, the composite material is made of epoxy resin and ceramic powder or epoxy resin and metal powder, but the acoustic impedance of the composite material made by the conventional method is generally difficult to exceed 6MRayls.
The acoustic impedance of a material is defined as z = ρ × v, where ρ is the density and v is the propagation velocity of the acoustic wave. When acoustic energy is transferred from one substance to another, it is only effectively propagated by acoustic impedance matching, but it is reflected back at the interface. Since the acoustic impedance difference between the piezoelectric material and the detection medium is too large, the acoustic wave cannot be effectively transmitted to the medium, so that the ultrasonic transducer needs to place a matching layer in front of the piezoelectric wafer, and the acoustic impedance of the matching layer is between the acoustic impedances of the piezoelectric material and the medium. The one-dimensional simplified acoustic propagation theory gives the following requirements for a single-frequency matching material: thickness = wavelength/4, acoustic impedance z = z p 1/2 z m 1/2 Wherein z is p Acoustic impedance of piezoelectric material, z m The acoustic impedance of the medium. The acoustic impedance thus calculated is a fixed value, for example, in the case of the above-mentioned piezoelectric ceramics and human body, the acoustic impedance of the matching layer needs z = (34 x 1.6) 1/2 =7.38MRayls. However, the number of elementary substances present in nature is limited, and the acoustic impedance of each substance is fixed and cannot be adjusted. When multiple layers are used for matching, each layer has special acoustic impedance requirements, and the acoustic impedance requirements of matching layer materials cannot be metA lattice of ultrasound transducers.
Disclosure of Invention
The composite material of the epoxy resin and the solid powder can accurately regulate and control acoustic impedance and has small acoustic attenuation, and is suitable for being used as a matching material, but has the defect of small adjustable range which is generally between 2 and 6MRayls. The solid powder here may be an oxide, glass, ceramic or metal. Because the multilayer matching broadband ultrasonic transducer has strict requirement on the acoustic impedance of a matching layer material and often needs the acoustic impedance to be more than 10MRayls, the traditional epoxy resin + solid powder composite material prepared under normal pressure is generally in a 0-3 structure, and the acoustic impedance is below 6MRayls and cannot meet the requirement. Although the density can be adjusted greatly by increasing the proportion of solid powder with large specific gravity, the sound velocity is reduced by the 0-3 structure composite material with the density, so the acoustic impedance is not changed greatly as the product of the two. Therefore, the traditional method for preparing the composite material cannot meet the requirement of the ultrasonic transducer on the optimal design of the matching material. The acoustic impedance of the material can be adjusted and controlled by another method to be made into porous materials, such as porous ceramics, porous metals and the like. Although the adjustable range of acoustic impedance of the porous material is large, the acoustic attenuation of the porous material is extremely increased along with the porosity, which greatly reduces the sensitivity of the ultrasonic transducer. The matching material is also generally not a porous material. In addition, the process of sintering the porous material is very difficult to control, and the required acoustic impedance material cannot be accurately obtained.
In order to solve the technical problems, the composite material with greatly adjustable performance is prepared by a high-pressure thermosetting method, the acoustic impedance of the prepared composite material can be continuously and accurately adjusted from 2MRayls to 15MRayls, the acoustic attenuation is low, and the requirements of various ultrasonic transducer designs on multilayer matching materials at present can be completely met.
The invention aims to prepare a 0-3 or 3-3 type composite material of resin and powder by adopting a high-pressure thermosetting method to increase the adjustable range of acoustic impedance. The resin here may be vinyl resin, acrylic resin, epoxy resin, phenolic resin, etc.; the solid powder may be an oxide, ceramic, glass or metal. And a plurality of different solid powder materials can be added simultaneously to further accurately regulate and control the density and the sound velocity of the composite material.
The invention adopts different high-pressure thermosetting preparation methods aiming at liquid and solid resins: for liquid resin, after the liquid resin and solid powder are fully mixed, applying pressure with the range of several megapascals to dozens of megapascals to extrude partial liquid, and then heating and curing the liquid; for solid resin, the uniformly mixed material is heated to a melting point under low pressure, then the pressure is increased to extrude bubbles, and the bubbles are cooled and solidified under the pressure. The high-pressure heat curing method can enable the acoustic impedance of the composite material to be accurately regulated and controlled within 2-15MRayls, and the obtained composite material has low acoustic attenuation and meets the requirements of matching layer materials.
For liquid resin, the method for preparing the ultrasonic transducer matching layer composite material with the largely adjustable acoustic impedance by the high-pressure thermosetting method is realized by the following steps:
step 1, fully and uniformly mixing the liquid resin and the solid powder by using a stirring, centrifuging or rotating mechanical mixing mode;
step 2, putting the mixture into a mould to pressurize, and keeping the pressure for a certain time;
step 3, demolding, heating and curing to obtain the composite material;
wherein, the particle size of the solid powder is less than 5 microns, and the solid powder is one or the mixture of several of oxide, ceramic, glass or metal.
For liquid resin, pressure can be used to adjust the acoustic impedance of the composite material, and the higher the pressure is, the higher the solid particle content in the finished product is, and the acoustic impedance of the finished composite material is greater.
Further defined, the mass ratio of liquid resin to solid powder in step 1 is generally not more than 1:1, but to ensure that each solid particle is encapsulated by the liquid resin.
Further, the liquid resin in step 1 is one of or a mixture of several of vinyl resin, acrylic resin and epoxy resin in any ratio.
In the step 1, the solid powder is one or a mixture of more of aluminum oxide, tungsten carbide, glass, silicon oxide, lead zirconate titanate ceramic, glass and metal in any ratio.
Further defined, the pressure in step 2 is 5 to 65 mpa, the pressure can be used for adjusting the acoustic impedance of the composite material, and the higher the pressure is, the larger the proportion of solid particles in the finished product is, and the acoustic impedance of the finished composite material is higher.
The composite material prepared by the method has a communication structure of 0-3 type or 3-3 type.
For solid resin, the method for preparing the composite material with greatly adjustable performance by high-pressure thermosetting is realized by the following steps:
step 1), fully and uniformly mixing solid resin powder and solid powder, and fully and uniformly mixing the powder by using mechanical equipment such as ball milling, vibration milling or a stirrer;
step 2), putting the mixture obtained in the step 1 into a mold for pressurization, starting heating under the condition of pressure preservation to melt the phenolic resin, and then, after the pressure is increased, preserving heat and maintaining pressure for a certain time;
step 3), cooling and curing under the condition of pressure maintaining, removing pressure when the temperature is reduced to below 50 ℃, continuously cooling to room temperature, and then demoulding to obtain the product;
wherein, the grain diameter of the solid powder is less than 5 microns, and the solid powder is one or the mixture of several of oxide, ceramic, glass or metal.
Further, the mass ratio of the solid resin to the solid powder in step 1) is set according to the acoustic impedance requirement, and the acoustic impedance of the solid resin and the solid powder does not change along with pressure.
Further defined, the solid resin in step 1) is a phenolic resin.
Further, the solid powder in the step 1) is one of aluminum oxide, tungsten carbide, glass, silicon oxide, lead zirconate titanate, ceramic and metal or a mixture of several of the aluminum oxide, the tungsten carbide, the glass, the silicon oxide, the lead zirconate titanate, the ceramic and the metal in any ratio.
Further defined, the heating in step 2) is at a temperature to melt the solid resin at a pressure of from 5 mpa to 20 mpa.
The invention provides a composite material prepared by the method, and the communicating structure is 0-3 type or 3-3 type.
Further, the mold may be a cylinder, a rectangular parallelepiped, or the like.
When the solid phenolic resin is used, the acoustic impedance depends on the proportion of the original resin and the solid powder.
The particle size of the solid powder in the present invention should generally be less than 5 μm, and particularly when the proportion of the solid powder is small, the smaller the particles, the more uniform the mixing.
Compared with the prior art, the invention has the following beneficial effects:
the acoustic impedance of the composite material prepared by the high-pressure thermosetting method can be accurately regulated and controlled in a wide range from 2MRrayls to 15MRayls, the acoustic attenuation is low, and various requirements of various ultrasonic transducers on matching materials are completely met.
The sound attenuation range of the composite material obtained by the method is 5dB/cm-50dB/cm when the frequency is 3 MHz.
The composite material obtained by the method is mainly used as a matching material of an ultrasonic transducer, in particular to an ultrasonic transducer matching layer with a multi-layer matching design. The applied ultrasonic transducers include various medical ultrasonic array transducers and unit ultrasonic transducers, various nondestructive inspection ultrasonic transducers and various underwater acoustic transducers. Ultrasonic transducers and ultrasonic arrays at all frequencies can be used.
Detailed Description
The invention will be better understood by reference to the following examples. The invention is not limited to what has been described in the detailed description.
Example 1: in this example, a composite material was prepared using a liquid epoxy resin and alumina powder as raw materials.
The method for preparing the composite material with the acoustic impedance being greatly adjustable by the liquid epoxy resin and the alumina powder at room temperature through high-pressure thermosetting is realized through the following steps:
step 1, stirring the epoxy resin and alpha-phase alumina powder to be fully and uniformly mixed, wherein the mass ratio of the epoxy resin to the alumina powder is 0.8:1.
step 2, putting the mixed material into a stainless steel mold, pressurizing to 62 MPa, and maintaining the pressure at 62 MPa for 12 hours to extrude bubbles and part of liquid resin in the mixture;
and 3, after demolding, putting the obtained product into a 65 ℃ oven, preserving heat for 12 hours to solidify the epoxy resin, wherein the acoustic impedance of the finally obtained composite material is 8.5Mrayls.
Example 2 in the present example, the solid phenolic resin, alumina powder, lead zirconate titanate powder and tungsten powder are used as raw materials to prepare the composite material
In the embodiment, the method for preparing the composite material with the acoustic impedance being greatly adjustable by the solid phenolic resin, the alumina powder, the lead zirconate titanate powder and the tungsten powder at room temperature through high-pressure thermosetting is realized by the following steps:
step 1, stirring phenolic resin powder, alumina powder, lead zirconate titanate powder and tungsten powder until the materials are fully and uniformly mixed, wherein the phenolic resin powder: alumina powder: lead zirconate titanate powder: the mass ratio of the tungsten powder is 0.15: 0.5525;
and 2, putting the uniformly mixed powder into a cylindrical stainless steel mold, pressurizing to 5 MPa, starting heating to 120 ℃ under the pressure maintaining condition to melt the phenolic resin, and then increasing the pressure to 12 MPa, and maintaining the temperature and the pressure for 2 hours.
And 3, maintaining the pressure, cooling to solidify, removing the pressure when the temperature is reduced to 50 ℃, continuously cooling to room temperature, and then demolding to obtain the connected structure 3-3.
The properties of the composite material obtained in this example were as follows: density ρ =3.38g/cm 3 Acoustic speed v =4004m/s and acoustic impedance z =13.53MRayls.
It should be understood that the above examples are only for clarity of illustration and are not intended to limit the embodiments. Other variations and modifications will be apparent to persons skilled in the art in light of the above description. This need not be, nor should it be exhaustive of all embodiments. And obvious variations or modifications derived therefrom are intended to be within the scope of the invention.
Claims (10)
1. The method for preparing the ultrasonic transducer matching layer composite material with greatly adjustable acoustic impedance by a high-pressure thermosetting method has the following acoustic impedance which can be changed by pressure: the method is characterized by comprising the following steps:
step 1, fully and uniformly mixing liquid resin and solid powder according to a design proportion, wherein the design proportion ensures that each solid particle is wrapped by the liquid resin;
step 2, putting the mixture into a mold, pressurizing at room temperature, and maintaining the pressure for a certain time;
step 3, demolding, heating and curing to obtain the composite material;
wherein, the grain diameter of the solid powder is less than 5 microns, and the solid powder is one or the mixture of several of oxide, ceramic, glass or metal.
2. The method according to claim 1, wherein the mass ratio of liquid resin to solid powder in step 1 is less than 1:1.
3. the method according to claim 1, wherein in step 1, the liquid resin is one or a mixture of several of vinyl resin, acrylic resin and epoxy resin, and the solid powder is one or a mixture of several of aluminum oxide, tungsten carbide, glass, silicon oxide, lead zirconate titanate, ceramic and metal.
4. The method of claim 1, wherein the pressure in step 2 is between 5 mpa and 65 mpa to extrude a portion of the liquid resin to achieve the acoustic impedance requirements of the composite material.
5. A liquid resin + solid powder composite material prepared by the method of any one of claims 1 to 4, wherein the interconnected structure of the composite material is of type 0 to 3 or 3 to 3.
6. The method for preparing the ultrasonic transducer matching layer composite material with the largely adjustable acoustic impedance by a high-pressure heat curing method is characterized in that the method is realized by the following steps:
step 1, sufficiently and uniformly mixing phenolic resin powder and solid powder according to a designed proportion;
step 2, putting the mixture obtained in the step 1 into a mold for pressurization, starting heating under the condition of pressure preservation to melt the phenolic resin, increasing the pressure, and preserving the heat and the pressure for a certain time;
step 3, cooling and solidifying under the pressure-keeping condition, removing pressure when the temperature is reduced to below 50 ℃, continuously cooling to room temperature, and then demoulding;
wherein, the particle size of the solid powder is less than 5 microns, and the solid powder is one or the mixture of several of oxide, ceramic, glass alumina, glass or metal.
7. The method according to claim 6, wherein the mass ratio of the solid resin to the solid powder in step 1 of claim 6 is set in accordance with the acoustic impedance requirement.
8. The method according to claim 6, wherein the solid resin in step 1 of claim 6 is phenolic resin powder, and the solid powder is one or more of aluminum oxide, tungsten carbide, glass, silicon oxide, lead zirconate titanate and metal, and is mixed in any ratio.
9. The method of claim 6, wherein the heating in step 2 is at a temperature to melt the solid resin at a pressure of from 5 MPa to 20 MPa.
10. A solid resin powder + solid powder composite material prepared by the method of any one of claims 6 to 9, the interconnected structure being of type 0-3 or 3-3.
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| CN116985500A (en) * | 2023-09-25 | 2023-11-03 | 之江实验室 | Acoustic emission sensor and method for manufacturing same |
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