Tubular Ultrasound Probe Substrate Layout for Low-Noise Assembly
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Solution Overview
Problem
Existing intracavitary insertion type ultrasound probes face challenges in assembly complexity and electrical noise interference due to the layout of flexible substrates and wiring patterns, which hinder efficient operation and functionality.
Innovation Solution
A flexible substrate design with a tubular shape and functional tab array, featuring separated wiring line systems and ground lines to reduce electrical crosstalk and noise, along with a simplified assembly process by allowing tabs to be easily bent during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the flexible substrate is rolled into a tubular shape with electronic components and transducer array, then the probe achieves compact structure and flexibility for intracavitary insertion, but the wiring pattern becomes complex and assembly becomes difficult
Solution Approach 1:
The substrate is divided into multiple tabs extending from the tubular body, with each tab containing separate wiring lines. This segmentation allows wiring lines to be grouped and routed independently, reducing overall wiring complexity while maintaining the compact tubular structure necessary for intracavitary insertion.
Solution Approach 2:
The wiring pattern transitions from a two-dimensional planar layout to a three-dimensional configuration using tabs that extend outward from the tubular substrate. This dimensional change allows wiring lines to be separated and organized in space, reducing crossover and connection complexity while preserving the compact probe form factor.
2Reliability
If multiple wiring line systems cross electronic components on the flexible substrate, then electrical connections are established, but electrical crosstalk and noise increase
Solution Approach 1:
Multiple wiring line systems are separated onto different tabs, physically isolating them from each other. This segmentation reduces electromagnetic interference and crosstalk between adjacent wiring lines while maintaining reliable electrical connections to the electronic components and transducer array.
Solution Approach 2:
Ground lines are introduced as intermediary elements between signal-carrying wiring lines on the tabs. These ground lines act as shields and reference planes, reducing electrical noise and crosstalk while maintaining signal integrity for reliable electrical connections.
3Reliability
If the flexible substrate uses traditional wiring layout, then connections are made, but assembly work becomes time-consuming and complex
Solution Approach 1:
The substrate is divided into modular tabs, each containing specific wiring lines and connections. This modular segmentation allows assembly workers to handle and connect individual tabs separately, simplifying the assembly process while ensuring reliable connections through organized wiring groups.
Solution Approach 2:
Wiring lines are pre-organized and grouped on the tabs during substrate manufacturing, with connection points prepared in advance. This preliminary organization of wiring patterns reduces the complexity of assembly operations and enables faster, more reliable connection-making during the assembly process.
Data Source
AI summary
A practically valuable flexible substrate can be provided for an intracavitary insertion type ultrasound probe. A flexible substrate includes a substrate main body and a plurality of tabs. The substrate main body is provided with a transducer array and a plurality of electronic components (ICs). In a state where the flexible substrate is rolled into a tubular shape, one end and the other end of the substrate main body in a circumferential direction come into contact with each other or come close to each other. A first tab is provided with a first connection to which a first cable group is connected. A second tab is provided with a second connection to which a second cable group is connected.