Planar Linear Array Ultrasound Transducer with Non-Metallic Frame
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Solution Overview
Problem
Conventional ultrasound transducers face challenges with complex 3D structures and high production costs due to intricate electrical connections and the need for skilled assembly, which complicates manufacturing and increases the risk of malfunctions.
Innovation Solution
A planar linear array stack design featuring a non-metallic frame surrounding a piezoelectric material, oriented parallel to an acoustic lens, with integrated flex circuits and a simplified structure to reduce complexity and enhance manufacturing ease.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multi-row arrays are used to improve elevational resolution, then image resolution is improved, but device complexity and manufacturing cost increase due to complicated electrical interconnections
Solution Approach 1:
The patent divides the array into multiple independent rows that can be controlled separately, allowing each row to function as an independent unit. This segmentation enables elevational resolution improvement through controlled multi-row operation while reducing the complexity of interconnections by allowing simpler, row-independent electrical pathways.
Solution Approach 2:
The patent introduces a third dimension of control by enabling independent control of multiple rows in addition to the traditional single-row linear array. This dimensional expansion allows elevational focusing and resolution improvement without requiring complex inter-row electrical connections, as each row can be independently driven.
2Measurement precision
If multi-row arrays are used to improve elevational resolution, then image resolution is improved, but the cost of building arrays increases due to complicated electrical interconnections
Solution Approach 1:
By segmenting the array into independently controllable rows, the patent simplifies the manufacturing process. Each row can be manufactured and tested independently, reducing the overall complexity and cost of assembly. The electrical interconnections between rows are minimized, leading to lower manufacturing costs while maintaining improved elevational resolution.
3Adaptability or versatility
If complex 3D structures with angled mounting are used to preserve lateral space and create electrical paths, then functionality is improved, but assembly difficulty increases
Solution Approach 1:
Instead of angling components to preserve lateral space, the patent uses a planar, orthogonal arrangement where components are mounted perpendicular to the array surface. This inverted approach maintains lateral space while dramatically simplifying assembly, as right-angle mounting is far easier to manufacture and assemble than angled mounting.
4Strength
If conventional arrays with metal tapered support structures are used, then mechanical strength is improved, but device complexity increases due to angled mounting requirements
Solution Approach 1:
The patent applies local quality by providing mechanical support only where needed through localized mounting structures rather than requiring complex tapered support structures throughout. The planar array design allows for simpler, more localized support elements that maintain mechanical strength without increasing overall structural complexity.
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 simplifies the manufacturing process, reduces dependency on skilled operators, decreases production costs, and maintains acoustic quality, making the transducers more reliable and cost-effective.
Implementation Method 1
arrays are used as an interface to convert electrical signal into ultrasound waves and reconvert the received, reflected ultrasound from a tissue structure to an electrical signal
Implementation Method 2
Certain arrays utilize a fixed acoustic lens, such as a convex RTV (room-temperature-vulcanizing silicone) lens, in the elevation direction to focus the ultrasound beam to improve image resolution or image slice thickness
Data Source
AI summary
Examples herein include piezoelectric layers of an ultrasound transducer, ultrasound transducers, methods of manufacturing the transducers, and methods of manufacturing the piezoelectric layers of an ultrasound transducer. In one example, a piezoelectric layer of an ultrasound transducer include a non-metallic frame and a piezoelectric material. The non-metallic frame surrounds the piezoelectric material on at least two sides and is coupled to a lens support structure with a structure such that an acoustic lens and the piezoelectric material are oriented substantially parallel to each other. The piezoelectric material is sized to span an area greater than or equal to an active surface of the acoustic lens.