Miniature Ultrasound Transducer Capillary Shaping
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Solution Overview
Problem
Conventional methods for fabricating ultrasound transducers for intravascular ultrasound imaging do not efficiently shape thin polymer films into concave, lens-like geometries, leading to suboptimal performance in forming high-resolution images within the human body.
Innovation Solution
A method involving the use of a substrate with a piezoelectric polymer film, where a well is formed on the back side and a backing material is dispensed to create a capillary effect, allowing the film to be deflected into a concave shape using air pressure, and then cured to maintain the shape, within a transducer shaping chamber that controls pressure and temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional fabrication methods are used to shape thin polymer films into transducer membranes, then the manufacturing process is simple, but the transducer cannot achieve the required concave, lens-like geometry for high-resolution imaging
Solution Approach 1:
The patent applies preliminary action by forming a well in the substrate before depositing the polymer film, and by pre-positioning the polymer material in the well. This preliminary structuring enables the film to be shaped into the required concave geometry during subsequent processing steps, resolving the contradiction between achieving precise geometry and maintaining fabrication simplicity
Solution Approach 2:
The patent utilizes parameter changes by controlling the deposition conditions of the polymer film, the curing process of the epoxy, and the application of air pressure during shaping. These parameter adjustments enable the transformation of the polymer film from a flat state to a precisely shaped concave lens geometry, achieving high manufacturing precision through controlled physical and chemical changes
2Manufacturing precision
If automated processes are implemented to shape transducer membranes, then manufacturing precision improves, but the ease of manufacture decreases
Solution Approach 1:
The patent applies self-service by utilizing the capillary effect to automatically draw epoxy material into the well and fill it to the appropriate level without requiring complex automated dispensing systems. This self-filling mechanism maintains manufacturing precision while simplifying the fabrication process and improving ease of manufacture
3Reliability
If the transducer membrane is deflected into a concave shape, then ultrasound focusing capability improves, but the structural stability of the membrane decreases
Solution Approach 1:
The patent applies composite materials by combining the polymer film with epoxy material filled in the well. The epoxy acts as a structural support that maintains the membrane's concave shape and provides mechanical stability, while the polymer film maintains its piezoelectric properties for ultrasound generation. This composite structure resolves the contradiction between achieving the required concave geometry for focusing and maintaining structural stability
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
This approach enables the fabrication of miniature ultrasound transducers with improved resolution and depth penetration, capable of generating focused ultrasound signals for detailed vessel morphology imaging, overcoming the limitations of conventional methods.
Implementation Method 1
the transducer membrane including a piezoelectric component
Implementation Method 2
dispensing a backing material onto a first sidewall of the well in a manner so as to create a capillary effect that causes the backing material to wick down the sidewall
Implementation Method 3
applying air pressure to the transducer membrane from the first side to deflect a portion of the transducer membrane towards the second side
Implementation Method 4
curing the epoxy material by heat during the applying the air pressure
Data Source
AI summary
The present disclosure provides methods and apparatus of fabricating a transducer for use in ultrasound imaging. A substrate is provided. The substrate may be a silicon substrate having a first side and a second side opposite the first side. A transducer membrane is formed over the first side of the substrate. The transducer membrane includes a piezoelectric component. A well is formed in the substrate from the second side. A backing material is dispensed onto a first sidewall of the well in a manner so as to create a capillary effect that causes the backing material to wick down the sidewall, across the back side of the substrate exposed by the well, and up a second sidewall of the well. The transducer membrane is deflected so that the transducer membrane has a concave shape.