Single Element Ultrasound Transducer Mass Production via Laminate Dicing
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Solution Overview
Problem
Traditional single element ultrasound transducers are labor-intensive to produce and not well-suited for high volume manufacturing due to their complex assembly process, which involves a cylindrical housing and manual attachment of electrodes.
Innovation Solution
The process involves mass processing of piezo ceramic into a bulk laminate, which is then diced into individual transducers and insulated with parylene coating or epoxy, allowing for surface mounting on a flexible circuit for efficient electrical termination, eliminating the need for a transducer housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional single element transducers are produced with cylindrical housing and manual electrode attachment, then the transducer structure is complete and functional, but the manufacturing process becomes labor intensive and unsuitable for high volume production
Solution Approach 1:
The patent divides the bulk laminate into multiple individual transducer elements through dicing, allowing parallel processing and mass production. Each element is separated but maintains its functional integrity, enabling high-volume manufacturing while reducing manual assembly requirements.
Solution Approach 2:
The patent eliminates the traditional cylindrical housing by mounting transducer elements directly onto a flexible circuit board. This extraction of the housing component simplifies the overall structure and enables automated surface mounting processes, dramatically improving productivity.
Solution Approach 3:
The patent combines multiple transducer elements onto a single flexible circuit board, integrating electrical connections and mechanical support into one structure. This merging reduces the number of separate components and assembly steps, making the manufacturing process more suitable for high-volume production.
2Ease of manufacture
If manual attachment of electrodes and casting of acoustic layers is used, then the transducer achieves proper acoustic and electrical functionality, but the manufacturing process becomes labor intensive
Solution Approach 1:
The patent applies electrodes and acoustic layers to the bulk laminate before dicing into individual elements. This preliminary action allows these components to be processed in bulk, and after dicing, each element already has its electrodes and acoustic layers in place, eliminating time-consuming manual attachment steps for each individual transducer.
Solution Approach 2:
The patent replaces manual mechanical assembly with automated surface mounting technology. The flexible circuit board with pre-mounted elements can be automatically attached to the ultrasound probe housing, reducing labor intensity and assembly time while maintaining proper functionality.
3Adaptability or versatility
If traditional transducer architecture with housing is used, then the transducer is mechanically protected, but the manufacturing cost increases and scalability decreases
Solution Approach 1:
The flexible circuit board serves multiple functions: it provides mechanical support for the transducer elements, electrical connections for signal transmission, and a mounting platform that can be adapted to different probe configurations. This multi-functionality reduces the need for separate housing structures, simplifying the overall device while improving adaptability.
Solution Approach 2:
The patent uses a flexible circuit board instead of a rigid cylindrical housing. This flexible substrate provides the necessary mechanical support and protection while allowing the transducer array to be configured in different geometries and mounted in various applications, reducing structural complexity and increasing adaptability.
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 low-cost, high-volume manufacturing of single element ultrasound transducers, facilitating efficient electrical connection and reducing production complexity, thereby improving manufacturing efficiency and scalability.
Implementation Method 1
Single element transducers for an ultrasound system transmit acoustic ultrasonic energy from an emitting (front) face of the transducer element and/or receive ultrasonic energy and convert it into electrical signals for processing
Implementation Method 2
an acoustic impedance matching layer is cast on the patient face of the disc
Implementation Method 3
an acoustic backing is cast on the rear side of the transducer to absorb undesired acoustic energy emanating from the rear face of the ceramic
Implementation Method 4
a parylene coating for insulation
Data Source
AI summary
A single element ultrasound transducer is fabricated from a laminate plate which produces multiple transducer elements simultaneously. The laminate plate includes the piezo ceramic, matching layer, and backing layer with rear electrode. The laminate plate is diced while mounted on nitto tape to retain the individual elements in position after dicing. The sides of the elements are covered with an insulating coating, which permits the transducer elements to be surface mounted on flex circuit by bonding the rear electrode to a signal conductor of the flex circuit and the matching layer to a return conductor by metallically coating the mounted transducer element and return conductor on the flex circuit.