2D Phased Array Ultrasonic Transducer Wiring
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Solution Overview
Problem
The fabrication of high-frequency 2D phased array ultrasonic transducers is challenging due to the difficulty in wiring thousands of elements and the fragility of piezoelectric single crystals, which leads to damage and de-poling during machining, making it difficult to achieve high spatial resolution and real-time 3D imaging.
Innovation Solution
A 2D phased array ultrasound device with a 2D array of piezo crystal elements, conductive electrodes, backing unit, and flexible circuit layers, along with acoustic impedance matching layers, is developed to interconnect the piezo crystal elements efficiently, ensuring high spatial resolution and real-time 3D imaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a large number of piezoelectric elements (256-4096 or more) are used to achieve high resolution and large scanning area, then the imaging resolution and scanning area are improved, but the wiring complexity and fabrication difficulty become extremely difficult
Solution Approach 1:
The patent divides the 2D array into multiple 1D sub-arrays that can be independently wired and controlled. This segmentation reduces the wiring complexity by organizing elements into manageable groups rather than requiring individual wiring for all 256-4096 elements simultaneously
Solution Approach 2:
The patent employs a single-crystal piezoelectric material that serves multiple functions: it provides both the piezoelectric effect for ultrasound generation and the acoustic wave propagation medium. This multi-functionality reduces the need for additional materials and simplifies the overall device structure
2Ease of manufacture
If conventional PZT ceramics are used as the active layer, then the fabrication process is simpler, but the operating frequency is limited to low frequencies
Solution Approach 1:
The patent changes the material parameter from conventional PZT ceramics to single-crystal piezoelectric materials, which have superior piezoelectric coefficients and can operate at high frequencies (20 MHz or higher) while maintaining manufacturability through established single-crystal growth and processing techniques
3Speed
If piezoelectric single crystals are used to achieve high frequency operation, then the operating frequency and imaging resolution are improved, but the elements become fragile and susceptible to damage during machining
Solution Approach 1:
The patent employs protective measures during the fabrication process, including careful handling procedures and protective fixtures during machining operations to prevent damage to the fragile single-crystal elements before they are fully assembled and protected by bonding layers
4Ease of manufacture
If 1D linear array transducers are used to create 3D images through manual wobbling, then the fabrication is easier, but the scanning rate is low and real-time imaging is not achieved
Solution Approach 1:
The patent transitions from 1D linear array to 2D array configuration, enabling electronic beam steering in both azimuth and elevation directions. This dimensional upgrade allows true real-time 3D volumetric imaging without mechanical movement, achieving high scanning rates through electronic control
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 device achieves spatial resolution of less than 90 μm and a center frequency of 25 MHz, enabling real-time 3D imaging of fine structures in human organs, particularly for ocular and cardiovascular diagnostics, with improved axial and lateral resolution and reduced fabrication complexity.
Implementation Method 1
a 2D array of piezo crystal elements formed from the kerfing of a single crystal
Implementation Method 2
a series of front matching layers, having an acoustic impedance matching material, impedance matching the piezo crystal elements to human tissue
Data Source
AI summary
A 2D phased array ultrasound device possessing ultrahigh spatial resolutions (<90 μm) and high centre frequency (25 MHz) including: a 2D array of piezo crystal elements formed from the kerfing of a single crystal; a series of conductive electrodes formed on opposed sides of the piezo crystal elements; a series of front matching layers; and a backing unit comprising backing filler material and a series of flexible circuit layers sandwich together to interconnect the back surface electrodes of the piezo crystal elements.