Ultrasound Transducer Array Interconnection for Dynamic Elevation Aperture
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional ultrasound diagnostic imaging systems using 1D arrays face challenges in achieving both high resolution and deep penetration depth due to fixed apertures and complex electrical interconnections, which increase production costs and risk malfunctions.
Innovation Solution
A method for fabricating transducers with signal and ground-return flexes inside a backing block, forming stack configurations with adjustable gaps and multiple rows, and using matching layers to improve beam patterns, allowing for multi-dimensional and multi-frequency arrays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a fixed aperture with an acoustic lens is used in 1D arrays, then image resolution is improved, but penetration depth is limited
Solution Approach 1:
The patent implements dynamic aperture control by enabling independent activation of different row groups (e.g., first row group for near field, second row group for far field) through electronic switching. This allows the aperture size to be dynamically adjusted based on imaging depth requirements, resolving the contradiction between fixed aperture resolution and variable penetration depth needs.
Solution Approach 2:
The transducer array is segmented into multiple row groups (e.g., first row group and second row group) that can be independently controlled. This segmentation enables selective activation of specific row groups for different imaging scenarios, allowing optimization of both resolution and penetration depth for different clinical applications.
2Measurement precision
If multi-row arrays are used for elevation aperture adjustment, then elevational resolution is improved, but production cost increases
Solution Approach 1:
The patent merges multiple row groups into a single integrated transducer assembly with shared backing block, matching layers, and acoustic lens. This consolidation reduces manufacturing complexity and costs compared to separate multi-row arrays, while maintaining the ability to electronically control elevation aperture through row group selection.
Solution Approach 2:
The multi-row array structure serves multiple functions: it provides both high resolution imaging (when all rows are activated) and deep penetration imaging (when specific row groups are selected), while also enabling flexible aperture control. This multi-functionality justifies the enhanced manufacturing capability.
3Measurement precision
If multi-row arrays are used for elevation aperture adjustment, then elevational resolution is improved, but device reliability decreases
Solution Approach 1:
The patent implements local quality by providing independent electrical connections for different row groups through separate signal flexes and ground-return flexes. This localized electrical architecture allows independent control and monitoring of each row group, improving reliability by isolating potential failures to specific segments while maintaining overall system functionality.
4Measurement precision
If multi-row arrays are used for elevation aperture adjustment, then elevational resolution is improved, but all rows must operate at the same center frequency
Solution Approach 1:
The patent applies local quality by enabling different row groups to operate at different center frequencies through independent electrical connections and selective activation. This allows the first row group to be optimized for one frequency range while the second row group operates at another frequency range, providing frequency flexibility while maintaining elevational resolution 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 solution enhances elevational beam patterns, broadens frequency ranges, and improves image quality by enabling flexible design for both near and far fields, reducing production costs and minimizing malfunctions.
Implementation Method 1
one-dimensional (1D) 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
1D 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
Implementation Method 3
forming stacks by bonding one or more matching layers to the piezoelectric layer portions by utilizing a conductive surface of a first matching layer of the one or more matching layers
Data Source
AI summary
A method of fabricating a transducer includes embedding signal flexes and ground-return flexes inside a backing block. The method includes forming stack configurations with a height in elevation and a width perpendicular to the height. The forming includes: dicing a piezoelectric layer in the elevation into rows (separating the piezoelectric layer into portions); defining a beam pattern for the transducer by aligning the portions on the backing block; and forming gaps in-between each piezoelectric layer portion and each adjacently aligned piezoelectric layer portion. The method includes forming stacks by bonding one or more matching layers to the piezoelectric layer portions by utilizing a conductive surface of a first matching layer of the one or more matching layers. The method also includes forming cavities in the one or more matching layers in elevation, dicing the stacks along an elevation direction into multiple elements, and filling the cavities with a material.