High resolution intravascular ultrasound transducer assembly having a flexible substrate

• US 5,857,974 A
• Filed: 01/08/1997
• Issued: 01/12/1999
• Est. Priority Date: 01/08/1997
• Status: Expired due to Term

• Current Assignee: Volcano Corporation (Koninklijke Philips N.V.)
• Original Assignee: Endosonics Corporation (JOMED NV)
• Inventors: Eberle, Michael J., Finsterwald, P. Michael
• Primary Examiner(s): Lateef, Marvin M.
• Assistant Examiner(s): MANTIS MERCADER, ELENI M
• Application Number:
  US08/780,437
• Time in Patent Office: 734 Days
• Field of Search: 600/467, 600/437, 600/459, 600/462, 600/439, 29/25.35
• US Class Current: 600/462
• CPC Class Codes: A61B 1/0011 Manufacturing of endoscope parts
• CPC Class Codes: A61B 8/12 in body cavities or body tracts, e.g. by using catheters catheters per se A61M25/00
• CPC Class Codes: A61B 8/445 Details of catheter construction
• CPC Class Codes: A61B 8/4488 the transducer being a phased array
• CPC Class Codes: B06B 1/0622 on one surface
• CPC Class Codes: B06B 1/0633 Cylindrical array
• CPC Class Codes: H05K 1/189 characterised by the use of a flexible or folded printed circuit H05K3/326 takes precedence
• CPC Class Codes: Y10T 29/42 Piezoelectric device making
• CPC Class Codes: Y10T 29/49005 Acoustic transducer
• CPC Class Codes: Y10T 29/4913 Assembling to base an electrical component, e.g., capacitor, etc.

Abstract

An ultrasound transducer assembly of the present invention includes a flexible circuit to which an ultrasound transducer array and integrated circuitry are attached during fabrication of the ultrasound transducer assembly. Integrated circuitry and transducer elements are attached to the flexible circuit while the flexible circuit is in a substantially flat shape. The contacts of the transducer elements are positioned on substantially the same plane such that electrical contact with signal and ground lines on the flexible circuit is established without the need for conductive bridges to physically remote electrodes. In an embodiment of the invention wherein the transducer elements are arranged in a cylindrical array, gaps are entirely filled with backing material having a relatively low acoustic impedance. Structure integrity is enhanced and a path to ground facilitated by electrically conductive disks attached to the ends of the transducer assembly.

Claims

1. An ultrasound transducer assembly for facilitating providing images from within a cavity, the ultrasound transducer assembly comprising:

integrated circuitry;

an ultrasound transducer array including a set of ultrasound transducer elements, each element comprising transducer material, and a first electrode formed on at least a first surface and a second surface of the transducer material and a second electrode formed on at least the second surface of the transducer material;

a flexible circuit to which the ultrasound transducer array and the integrated circuitry are attached during fabrication of the ultrasound transducer assembly, the flexible circuit comprising;

a flexible substrate, providing a re-shapable platform, to which the integrated circuitry and transducer elements are attached;

transducer signal lines on an inner surface of the flexible substrate, the transducer signal lines facilitating an electrical signal path between the integrated circuitry and the set of transducer elements; and

a ground line connection on the inner surface of the flexible substrate; and

wherein a first contact surface on the first electrode and a second contact surface on the second electrode for each transducer element are arranged upon the second surface of the transducer material and upon substantially a same physical plane as the inner surface of the flexible substrate.

2. The ultrasound transducer assembly of claim 1 wherein the first electrode is a signal electrode and the second electrode is a ground electrode.

3. The ultrasound transducer assembly of claim 1 wherein the transducer elements are covered by a substantially continuous metal layer having first and second notch discontinuities thereby defining the signal electrode and ground electrode.

4. The ultrasound transducer assembly of claim 3 wherein the first discontinuity is located on a surface of each transducer element primarily comprising the signal electrode and the second discontinuity is located on a surface of each transducer element primarily comprising the ground electrode.

5. The ultrasound transducer assembly of claim 1 wherein the transducer elements include a discontinuity on a metal layer on the second surface of the transducer material, the discontinuity electrically isolating the first contact surface on the first electrode from the second electrode.

6. The ultrasound transducer assembly of claim 1 wherein the flexible substrate provides a quarter-wave matching layer for the transducer elements.

7. The ultrasound transducer assembly of claim 1 wherein the flexible substrate provides an acoustic matching layer for the transducer elements.

8. The ultrasound transducer assembly of claim 1 wherein the ultrasound transducer array is substantially cylindrical in shape.

9. The ultrasound transducer assembly of claim 8 wherein the spaces within the ultrasound transducer assembly between a lumen tube, the flex circuit, the transducer array and the integrated circuits are filled with a backing material characterized by relatively low acoustic impedance.

10. The ultrasound transducer assembly of claim 9 further comprising at least a first disc attached to the lumen tube and wherein the outer edges abut the re-shaped flexible substrate thereby enhancing the structural integrity of the ultrasound transducer assembly.

11. The ultrasound transducer assembly of claim 10 wherein the first disc comprises a conductive material and wherein the first disc provides a portion of an electrically conductive path between the ground electrodes and an external ground signal.

12. The ultrasound transducer assembly of claim 10 wherein the first disc is positioned at an end of the transducer assembly housing the transducer array, and a second disc attached to the lumen tube is positioned at an opposite end of the transducer assembly housing the integrated circuitry, and wherein the outer edges abut the re-shaped flexible substrate.

13. The ultrasound transducer assembly of claim 1 wherein the transducer elements are covered by a substantially continuous metal layer having first and second discontinuities thereby defining an active region of each transducer element which terminates before an end of the transducer material.

14. The ultrasound transducer assembly of claim 1 wherein the transducer material comprises a PZT material.

15. The ultrasound transducer assembly of claim 1, having suitable dimensions for providing images of a blood vessel from within a vasculature, and wherein the diameter of the substantially cylindrical ultrasound transducer assembly is on the order of 0.3 to 5.0 millimeters.