Non-Rectangular Ultrasound Array Sealing for Rib-Space Maneuverability
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Solution Overview
Problem
Rectangular ultrasound transducer arrays pose challenges in cardiac imaging due to restricted movement and patient discomfort, as they may not align easily between ribs and can cause pain.
Innovation Solution
The development of non-rectangular ultrasound transducer arrays with ergonomic designs, featuring a sealing material around the perimeter to stabilize acoustic elements and improve maneuverability, coupled with a non-perpendicular processor chip and housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If rectangular transducer arrays are used, then manufacturing and assembly are simplified, but patient comfort and maneuverability deteriorate due to restricted movement and difficulty aligning between ribs
Solution Approach 1:
The patent applies asymmetry by transitioning from traditional rectangular transducer arrays to non-rectangular configurations. The array geometry is modified to eliminate right angles and straight edges, adopting curved or organic shapes that better conform to the anatomical contours of the patient's body, particularly the intercostal spaces between ribs. This asymmetric redesign improves maneuverability and patient comfort while maintaining manufacturing feasibility through adapted fabrication processes.
Solution Approach 2:
The patent implements curvature by replacing the rectangular perimeter with curved boundaries. The transducer array is designed with rounded edges and curved perimeters that follow the natural contours of the patient's anatomy. This spherical or curved geometry eliminates the sharp corners of rectangular arrays, allowing easier positioning between ribs and improved patient comfort during cardiac imaging procedures.
2Ease of operation
If non-rectangular arrays are used, then patient comfort and maneuverability improve, but structural integrity deteriorates due to less stable acoustic elements at the perimeter
Solution Approach 1:
The patent employs flexible sealing materials as thin film structures that conform to the non-rectangular perimeter of the transducer array. These sealing films wrap around the curved or organic-shaped boundaries, providing structural support and stabilization to the acoustic elements at the perimeter without rigidly constraining the overall flexible or adaptable geometry of the array. The sealing material acts as a flexible shell that maintains integrity while allowing the non-rectangular configuration.
Solution Approach 2:
The patent utilizes composite material structures combining the piezoelectric acoustic elements with supporting sealing materials and housing structures. The sealing materials form a composite system with the acoustic elements, where the sealing material provides mechanical support and stability to the vulnerable perimeter regions. This composite approach allows the non-rectangular array to maintain structural integrity through the synergistic combination of different materials with complementary properties.
3Productivity
If non-rectangular arrays are used, then operator workflow and alignment ease improve, but device complexity increases due to additional sealing materials and manufacturing steps
Solution Approach 1:
The patent applies preliminary action by incorporating the sealing materials during the array fabrication process itself, rather than as a separate post-assembly step. The sealing materials are applied to the acoustic stack before or during the kerfing process, allowing the structural support to be built in advance. This preliminary integration of sealing materials simplifies the overall manufacturing workflow and reduces the number of discrete assembly steps required.
Solution Approach 2:
The patent merges multiple functions into integrated components. The sealing materials serve dual purposes: they provide structural support to stabilize perimeter acoustic elements and simultaneously define the non-rectangular geometric shape of the array. This merging of support and shaping functions into a single integrated sealing structure reduces overall device complexity by eliminating the need for separate support structures and geometric definition elements.
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
Enhances patient comfort and operator workflow by allowing easier probe alignment and maneuverability, while maintaining structural integrity and reducing discomfort during imaging procedures.
Implementation Method 1
one or more sealing materials around a perimeter of the array that forms an edge seal to provide structural integrity to less stable acoustic elements at or near the perimeter of the array
Implementation Method 2
Such transducer arrays may include various layers, including some with piezoelectric materials, which vibrate in response to an applied voltage to produce the desired pressure waves
Implementation Method 3
These transducers may be used to transmit and receive ultrasonic pressure waves through the various tissues of the body
Data Source
AI summary
The present disclosure advantageously describes a method for manufacturing ultrasound imaging arrays that comprise ergonomic, non-rectangular shapes, as well as associated systems and methods. Non-rectangular transducer arrays allow for ergonomic probe shapes that improve patient comfort, maneuverability of the ultrasound device, and operator workflow. For example, an ultrasound imaging device can include an array of acoustic elements comprising a non-rectangular perimeter. The array includes a plurality of active elements configured to emit ultrasound energy and receive echoes corresponding to the emitted ultrasound energy, and a plurality of buffer elements surrounding the plurality of active elements at the non-rectangular perimeter of the array of acoustic elements. An edge seal comprising a sealing material is positioned at least partially around the plurality of buffer elements, and a buffer element of the plurality of buffer elements is spaced from at least one other buffer element by the sealing material of the edge seal.