Stretchable Ultrasonic Transducer Array for Nonplanar Surface Coupling

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Solution Overview

Problem

Existing ultrasonic probes struggle with achieving solid interfacial contact and reliable coupling on irregular nonplanar surfaces, leading to acoustic energy reflections, wave distortions, and significant transmission loss, while flexible probes face limitations in conforming to complex surfaces and maintaining mechanical integrity during repeated use.

Innovation Solution

Development of stretchable ultrasound probes using piezoelectric materials and advanced microfabrication techniques, such as transfer printing thin layers of patterned metal electrodes and polymer encapsulation on a biocompatible silicone membrane, allowing for a 10×10 array of high-performance 1-3 piezoelectric composite transducers with an 'island-bridge' layout encapsulated by compliant silicone elastomers, enabling over 50% stretchability and conformability on complex surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If rigid ultrasonic probes are used, then manufacturing precision and structural integrity are improved, but adaptability to nonplanar surfaces deteriorates

Engineering Contradiction:

Improveinterfacial contact qualityVSAvoidconformability to complex surfaces

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent employs a flexible substrate made of elastomeric material that can deform to match the curvature of nonplanar surfaces. This flexible substrate supports the piezoelectric transducer elements while allowing the probe to conform to complex geometries, resolving the contradiction between maintaining manufacturing precision and adapting to varied surface shapes.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The probe integrates composite structures combining rigid piezoelectric transducer elements with a flexible elastomeric substrate. This composite design allows the rigid elements to maintain their manufacturing precision and acoustic performance while the flexible substrate provides adaptability to nonplanar surfaces.

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If flexible ultrasonic probes are used, then adaptability to nonplanar surfaces is improved, but mechanical integrity during repeated use deteriorates

Engineering Contradiction:

Improveconformability to complex surfacesVSAvoidmechanical integrity under repeated deformation

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The elastomeric substrate is specifically selected for its flexibility and ability to undergo repeated deformation without failure. This flexible substrate maintains mechanical integrity during repeated use while still allowing the probe to conform to complex surfaces.

Inventive Principle:

Principle #30Flexible shells and thin films

3Manufacturing precision

If abundant ultrasonic couplant is used, then interfacial contact quality is improved, but energy transmission loss increases

Engineering Contradiction:

Improveacoustic coupling qualityVSAvoidacoustic energy transmission loss

Core Design Contradiction:

Manufacturing precisionVSLoss of energy

Solution Approach 1:

The patent extracts and eliminates the need for external ultrasonic couplant by integrating the coupling function directly into the probe structure. The flexible substrate and piezoelectric elements are designed to provide acoustic coupling without requiring additional couplant material, thereby preventing energy transmission loss while maintaining good interfacial contact.

Inventive Principle:

Principle #2Taking out (Extraction)

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 probes achieve excellent electromechanical coupling, minimal cross-talk, high signal-to-noise ratio, wide bandwidth, and high spatial resolution, allowing for accurate 3D imaging of defects on nonplanar surfaces with minimal mechanical loading, and can be integrated seamlessly with the human body for healthcare applications.

Implementation Method 1

a 10×10 array of high-performance 1-3 piezoelectric composite transducers

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Implementation Method 2

Ultrasound imaging technologies have been widely used to visualize internal discontinuities in objects

Methodology Applied

Scientific EffectUltrasonic wave propagation: Ultrasound

Data Source

PatentUS20250352166A1Stretchable ultrasonic transducer devices

Publication Date: 2025.11.20 RGT UNIV OF CALIFORNIA

AI summary

A conformable piezoelectric transducer array for performing ultrasound or the like includes a silicone elastomer substrate and a silicone elastomer superstrate. A plurality of piezoelectric transducer elements are disposed between the substrate and superstrate. A first electrical interconnect layer electrically interconnects a first surface of the transducer elements adjacent to the substrate and a second electrical interconnect layer electrically interconnecting a second surface of the transducer elements adjacent to the superstrate.