Flexi-PCB Mounting for Ultrasonic Transducer Conformability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing ultrasound transducer arrays face challenges in conforming to complex 3D surfaces and ensuring even exposure due to limitations in flexibility and electrical connectivity, leading to inconsistent treatment and potential overheating or underexposure during therapeutic applications.
Innovation Solution
A flexible printed circuit board (flexi-PCB) configured to bend about non-parallel axes, with cut-out portions defining fingers or lands, allows for mounting of ultrasound transducers to conform to complex surfaces and includes an elastomeric matrix for tension, enabling doubly-curved surface molding and robust electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional rigid PCB is used to mount transducers, then electrical connections are stable, but the device cannot conform to complex 3D surfaces
Solution Approach 1:
The patent employs a flexible printed circuit board (flexi-PCB) instead of a rigid PCB to mount the transducer array. The flexi-PCB can bend and conform to complex 3D body surfaces while maintaining electrical connections between transducers and control electronics, thus resolving the contradiction between adaptability to complex surfaces and electrical connection stability.
Solution Approach 2:
The flexi-PCB is designed with segmented or modular structures that allow differential bending about non-parallel axes. This segmentation enables each region of the PCB to independently conform to the curvature of complex surfaces while maintaining overall electrical connectivity, addressing both adaptability and connection complexity requirements.
2Adaptability or versatility
If a single continuous sheet of flexi-PCB is used, then manufacturing is simple, but it cannot bend about non-parallel axes to conform to doubly curved surfaces
Solution Approach 1:
The patent divides the flexi-PCB into multiple segments or regions that can independently bend. This segmentation allows the PCB to conform to doubly curved surfaces by enabling differential bending about non-parallel axes in different regions, while maintaining manufacturing feasibility through modular construction.
Solution Approach 2:
The flexi-PCB design incorporates multi-directional bending capabilities by introducing curvature in multiple dimensions. The PCB structure allows bending about non-parallel axes, transitioning from single-plane flexibility to three-dimensional conformability, enabling adaptation to complex body geometries.
3Ease of operation
If manual movement of hand-held transducer probes is used, then device simplicity is maintained, but uneven exposure and operator fatigue occur
Solution Approach 1:
The patent implements an electronic movement system where the flexi-PCB with mounted transducers can be autonomously positioned and moved across the treatment area. The system eliminates the need for manual manipulation by incorporating electronic actuation mechanisms that automatically achieve even exposure patterns, thereby improving ease of operation while accepting increased device complexity.
4Adaptability or versatility
If transducers are mounted on a flexible substrate, then conformability to body surfaces is improved, but electrical connections may fail during frequent flexing
Solution Approach 1:
The patent uses a flexi-PCB with flexible electrical traces and connections designed to withstand repeated bending and flexing. The flexible substrate and trace design maintain electrical connectivity during movement, ensuring reliability while preserving conformability to body surfaces.
Solution Approach 2:
The flexi-PCB structure incorporates design features that anticipate and accommodate the stresses of repeated flexing. By designing the electrical connections and substrate to withstand mechanical stress from the outset, the system prevents connection failures during frequent flexing while maintaining surface conformability.
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 enables efficient ultrasound delivery to complex surfaces, reduces operator error, and enhances the depth of penetration by clustering transducers, providing consistent and effective treatment while minimizing the risk of overheating or underexposure.
Implementation Method 1
a flexi-PCB configured so as to be bendable about non-parallel axes
Implementation Method 2
an array of ultrasound transducers mounted on a flexi-PCB
Data Source
AI summary
An ultrasound transducer patch (100) comprises an array of ultrasound transducers (20) mounted to a flexi-PCB (10) containing multiple tracks (12). Each transducer (20), or a sub-group of the transducers is electrically connected to first and second of the multiple tracks. The flexi-PCB (10) is configured, such as by virtue of cut-out portions (114, 414) or by inherent elasticity, to be bendable a out non-parallel axes. The enables the patch (100) to readily conform to a complex 3D surface such as a portion of a patient's face to ensure efficient transmission of ultrasound energy to a desired area of treatment.