Ultrasound Transducer Electrode Patterning and Bondline Control
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Solution Overview
Problem
Current methods for manufacturing high-frequency ultrasound transducers face challenges in creating precise electrode patterns and thin bondlines, which can result in voids, mechanical coupling issues, and increased force requirements, affecting the transducer's performance.
Innovation Solution
The method involves using a composite dielectric material with a matrix and particulate material, where the matrix is laser ablated at a lower fluence than the particulate to increase surface area, and a conductive metal is deposited, followed by resist application and etching to create patterned electrodes. Additionally, spacers are used to control the thickness of matching layers and kerf slots in the transducer stack, allowing for precise alignment and bonding of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods are used to create electrode patterns and bondlines in high-frequency ultrasound transducers, then manufacturing is simpler, but voids form and mechanical coupling issues occur, reducing reliability
Solution Approach 1:
The method performs preliminary actions by depositing the composite dielectric material with particulate reinforcement before bonding, and by using spacers to pre-establish the precise bondline thickness. This preliminary preparation prevents void formation and ensures proper mechanical coupling during the subsequent bonding process, thereby improving reliability without significantly increasing manufacturing complexity
Solution Approach 2:
The patent employs a composite dielectric material containing particulate reinforcement (such as silica or alumina particles) embedded in a polymer matrix. This composite material provides both electrical insulation and mechanical strength, enabling thin bondlines to be formed without voids while maintaining structural integrity during assembly
2Use of energy by moving object
If thin bondlines are used in ultrasound transducers, then acoustic energy transmission is optimized, but excessive force is required and voids form
Solution Approach 1:
The composite dielectric material with particulate reinforcement provides enhanced mechanical strength and reduced compliance compared to pure polymer materials. This allows the formation of thin bondlines (optimized for acoustic energy transmission) without requiring excessive bonding force, as the particulate reinforcement bears the mechanical load
Solution Approach 2:
The patent changes the material parameters by incorporating particles with specific acoustic impedance and mechanical properties into the dielectric material. This modification allows the bondline to maintain thin dimensions for optimal acoustic energy transmission while the altered material composition reduces the force required for bonding and prevents void formation
3Reliability
If precise electrode patterns are created in high-frequency transducers, then transducer performance is enhanced, but manufacturing complexity increases
Solution Approach 1:
The method uses spacers to pre-establish the precise bondline thickness and electrode pattern geometry before the bonding process. This preliminary positioning ensures that when the thin bondline is formed, the electrodes are already correctly aligned, achieving precise electrode patterns without requiring complex post-bonding adjustment procedures
Solution Approach 2:
The spacers act as intermediary elements that temporarily hold the components in the correct position during assembly. These spacers define the precise electrode patterns and bondline thickness, and are removed after bonding, thereby achieving high precision electrode patterns without significantly increasing the overall manufacturing process 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
This approach enables the production of high-frequency ultrasound transducers with improved electrode precision, reduced voids, and minimized mechanical coupling, enhancing the transducer's performance and reliability by maintaining a thin bondline without excessive force, thus optimizing the acoustic energy transmission.
Implementation Method 1
laser ablated at a lower fluence than the particulate material; laser ablating at least a portion of the composite dielectric material to remove matrix material and increase the surface area of the composite dielectric material
Data Source
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AI summary
The invention features methods for the manufacture of electrical components such as ultrasound transducers. In particular, the invention provides methods of patterning electrodes, e.g., in the connection of an ultrasound transducer to an electrical circuit; methods of depositing metal on surfaces; and methods of making integrated matching layers for an ultrasound transducer. The invention also features ultrasound transducers produced by the methods described herein.