Ultrasonic attenuation materials

• US 7,808,157 B2
• Filed: 03/30/2007
• Issued: 10/05/2010
• Est. Priority Date: 03/30/2007
• Status: Active Grant

• Current Assignee: W. L. Gore & Associates (W.L. Gore & Associates)
• Original Assignee: Gore Enterprise Holdings Incorporated (W.L. Gore and Associates)
• Inventors: Scholz, Hermann, Oakley, Clyde Gerald, Shepard, Michael J., Zipparo, Michael J.
• Primary Examiner(s): BUDD, MARK OSBORNE
• Application Number:
  US11/694,499
• Publication Number:
  US 20080242984A1
• Time in Patent Office: 1,285 Days
• Field of Search: 310/326, 310/327, 310/322, 310/324
• US Class Current: 310/334
• CPC Class Codes: G10K 11/002 Devices for damping, suppressing, obstructing or conducting sound in acoustic devices G10K1/06 - G10K1/10 take precedence; for electro-mechanical transducers for communication H04R3/002

Abstract

Improved acoustic attenuation materials and applications are provided. An improved acoustic attenuation material may include a woven layer of fibers made of porous polymers, such as porous polytetrafluoroethylene (PTFE), that include interstitial space. An improved acoustic attenuation material may include sheets of porous polymers interleaved with layers of epoxy. The sheets of porous polymers may include through holes. An embodiment of an ultrasonic transducer that includes a backing with woven layers of porous PTFE fibers is provided. The ultrasonic transducer that includes a backing with woven layers of porous PTFE fibers may be used in a three-dimensional ultrasound imaging apparatus. An embodiment of an ultrasonic transducer that includes a plurality of sheets of porous PTFE interleaved with layers of epoxy is provided. The ultrasonic transducer that includes a plurality of sheets of porous PTFE may be used in an ultrasonic imaging catheter.

Claims

1. An ultrasound transducer system comprising:

an active layer with an acoustic face and a rear face, wherein said active layer comprises at least one ultrasonic transducer element, wherein said rear face is on an opposite side of said active layer from said acoustic face; and

an acoustic attenuation layer interconnected to said rear face, wherein said acoustic attenuation layer comprises;

(a) fibrous polymer having porosity; and

(b) reinforcing material.

2. The ultrasound transducer system of claim 1, wherein said acoustic attenuation layer comprises porous polymeric fibers

3. The ultrasound transducer system of claim 1, wherein said acoustic attenuation layer has an acoustic attenuation greater than 25 dB/cm at 1 MHz.

4. The ultrasound transducer system of claim 1, wherein said polymer is selected from a group consisting of PTFE, urethane, polystyrene, fluoropolymer, silicone and polyolefin.

5. The ultrasound transducer system of claim 4, wherein said polymer is PTFE.

6. The ultrasound transducer system of claim 1, wherein said at least one ultrasonic transducer element is operable to perform at least one of transmitting an ultrasonic signal and receiving an ultrasonic signal.

7. The ultrasound transducer system of claim 6, wherein said at least one ultrasonic transducer element is operable to transmit and receive an ultrasonic signal.

8. The ultrasound transducer system of claim 1, wherein at least one of said at least one ultrasonic transducer elements is planar.

9. The ultrasound transducer system of claim 1, wherein at least one of said at least one ultrasonic transducer elements is curved.

10. The ultrasound transducer system of claim 1, wherein said reinforcing material is one or more of a thermoplastic material and a thermoset material.

11. The ultrasound transducer system of claim 10, wherein said reinforcing material is selected from a group consisting of THV, FEP, PTFE, PES, EFEP, PET, PEEK, PEI, PC and LCP.

12. The ultrasound transducer system of claim 10, wherein said porosity is partially filled with said reinforcing material.

13. The ultrasound transducer system of claim 1, further comprising a intermediate layer disposed between said rear face and said acoustic attenuation layer, wherein said intermediate layer comprises a material selected from a group consisting of epoxy, silicon rubber, tungsten, aluminum oxide, mica, and microspheres.

14. An ultrasound transducer system comprising:

an active layer with an acoustic face and a rear face, wherein said active layer comprises at least one ultrasonic transducer element, wherein said rear face is on an opposite side of said active layer from said acoustic face; and

a backing interconnected to said rear face, said backing including a woven layer, wherein said woven layer is comprised of a plurality of fibers, said plurality of fibers comprised of a polymer, wherein said woven layer defines woven layer void space between said plurality of fibers, wherein at least a portion of said woven layer void space is filled with a reinforcing material.

15. The ultrasound transducer system of claim 14, wherein said plurality of fibers are comprised of PTFE, wherein said reinforcing material is comprised of THV.

16. The ultrasound transducer system of claim 14, further comprising:

a second woven layer, wherein said second woven layer is comprised of a second plurality of fibers, said second plurality of fibers comprised of said polymer, said second plurality of fibers having said fiber porosity; and

a layer of adhesive between said woven layer and said second woven layer, wherein said layer of adhesive binds said woven layer to said second woven layer.

17. The ultrasound transducer system of claim 14, wherein said backing further comprises an intermediate layer disposed between said rear face and said woven layer, wherein said intermediate layer comprises a material selected from a group consisting of epoxy, silicon rubber, tungsten, aluminum oxide, mica, and microspheres.

18. The ultrasound transducer system of claim 17, wherein said intermediate layer comprises epoxy.

19. The ultrasound transducer system of claim 14, further comprising an electrical connection member, wherein said electrical connection member is comprised of an insulating material and a plurality of independent electrically conductive pathways, wherein each of said plurality of electrically conductive pathways is disposed transverse to and in electrical contact with a corresponding one of said at least one ultrasonic transducer element.

20. The ultrasound transducer system of claim 14, further comprising a plurality of continuous pathways through said backing, wherein said plurality of continuous pathways are at least partially filled with an electrically conductive material, wherein each of said plurality of continuous pathways is operable to provide an electrically conductive path through said backing.

21. The ultrasound transducer system of claim 14, wherein said plurality of fibers comprise porous fibers.

22. The ultrasound transducer system of claim 21, wherein said porous fibers have a porosity of less than about 85 percent.

23. The ultrasound transducer system of claim 21, wherein said porous fibers have a porosity of at least about 5 percent.

24. Acoustic attenuation material operable to attenuate acoustic energy incident upon said material, said material comprising:

a woven layer,

wherein said woven layer is comprised of a plurality of fibers, said plurality of fibers having a fiber porosity,

wherein said woven layer is comprised of PTFE, and said woven layer defines woven layer void space between said plurality of fibers, and wherein at least a portion of said woven layer void space is filled with THV.

25. The acoustic attenuation material of claim 24, further comprising a second woven layer,

wherein said second woven layer is comprised of a second plurality of fibers, said second plurality of fibers having said fiber porosity, and wherein said second woven layer is comprised of PTFE.

26. The acoustic attenuation material of claim 24, wherein a frequency of said acoustic energy is between 100 kHz and 100 MHz.

27. The acoustic attenuation material of claim 24, wherein said acoustic attenuation material has an acoustic attenuation of at least 25 dB/cm at 1 MHz. further comprising a plurality of continuous pathways through said acoustic attenuation material.

28. The acoustic attenuation material of claim 24, wherein said plurality of continuous pathways are at least partially filled with an electrically conductive material, wherein each of said plurality of continuous pathways is operable to provide an electrically conductive path through said acoustic attenuation material.

29. A method of reducing acoustic energy incident on a back face of an ultrasound transducer, said method comprising:

providing a layer of material comprising a porous polymer, wherein said layer of material has a front surface and a rear surface;

locating said layer of material adjacent to said back face of said ultrasound transducer, wherein said front surface is in face to face contact with said back face, wherein said back surface is in contact with a fluid;

absorbing acoustic energy emanating from said back face within said layer of material; and

absorbing acoustic energy incident upon said rear surface within said layer of material.

30. The method of claim 29, wherein said fluid is a gas.

31. The method of claim 29, wherein said material comprises at least one woven layer of porous polymer fibers, wherein void space within each layer of said at least one woven layer of said porous polymer fibers is at least partially filled with a non-porous polymer.

32. The method of claim 29, wherein said porous polymer is selected from a group consisting of urethane, polystyrene, fluoropolymer, silicone and polyolefin.

33. The method of claim 29, wherein said porous polymer is PTFE.

34. The method of claim 29, wherein a frequency of said acoustic energy is between 100 kHz and 100 MHz.

35. Acoustic attenuation material operable to attenuate acoustic energy incident upon said material, said material comprising a woven layer, wherein said woven layer is comprised of a plurality of fibers, said plurality of fibers having a fiber porosity, wherein said woven layer is comprised of PTFE, wherein said woven layer defines woven layer void space between said plurality of fibers, wherein at least a portion of said woven layer void space is filled with THV.

36. The acoustic attenuation material of claim 35, further comprising a second woven layer, wherein said second woven layer is comprised of a second plurality of fibers, said second plurality of fibers having said fiber porosity, wherein said second woven layer is comprised of PTFE.

37. The acoustic attenuation material of claim 36, further comprising a layer of binding material between said woven layer and said second woven layer.

38. The acoustic attenuation material of claim 37, wherein said layer of binding material is comprised of an adhesive polymer.

39. The acoustic attenuation material of claim 38, wherein said adhesive polymer is comprised of an epoxy.

40. The acoustic attenuation material of claim 35, wherein a frequency of said acoustic energy is between 100 kHz and 100 MHz.

41. The acoustic attenuation material of claim 35, wherein said acoustic attenuation material has an acoustic attenuation of at least 25 dB/cm at 1 MHz.

42. The acoustic attenuation material of claim 35, further comprising a plurality of continuous pathways through said acoustic attenuation material, wherein said plurality of continuous pathways are at least partially filled with an electrically conductive material, wherein each of said plurality of continuous pathways is operable to provide an electrically conductive path through said acoustic attenuation material.

43. The acoustic attenuation material of claim 35, wherein said fiber porosity is at least 5 percent.

44. Acoustic attenuation material comprising:

a first woven layer adapted for use in an ultrasonic transducer apparatus, wherein said first woven layer is operable to attenuate acoustic energy incident upon said first woven layer, wherein said first woven layer is comprised of a first plurality of PTFE fibers, said first plurality of fibers having a first fiber porosity, wherein said first woven layer defines first layer void space between said first plurality of fibers; and

reinforcing material, wherein said first layer void space is at least partially filled with said reinforcing material.

45. The acoustic attenuation material of claim 44, wherein said reinforcing material comprises is a material selected from a group consisting of epoxy, THV, FEP PTFE, PES, EFEP, PET, PEEK, PEI, PC and LCP.

46. An acoustic attenuation device comprising:

acoustic attenuation material operable to attenuate acoustic energy incident upon said material; and

a support structure interconnected to said acoustic attenuation material, wherein said acoustic attenuation material includes a first component comprised of a polymer selected from a group consisting of PTFE, urethane, polystyrene, fluoropolymer, silicone and polyolefin, the polymer having a porosity and a second component comprised of a support material.

47. Acoustic attenuation material operable to attenuate acoustic energy incident upon said material, said material comprising:

a first component comprised of a first polymer selected from a group consisting of PTFE, urethane, polystyrene, fluoropolymer, silicone and polyolefin, said first component having a porosity; and

a second component comprised of a second polymer, wherein said porosity is partially filled with said second component, wherein said first component has a first flexural modulus when said porosity is free from said second component, wherein said first component has a second flexural modulus when said second component is partially disposed within said porosity, wherein said first flexural modulus is lower than said second flexural modulus.

48. The acoustic attenuation material of claim 47, wherein said second polymer is selected from a group consisting of epoxy, THV, FEP PTFE, PES, EFEP, PET, PEEK, PEI, PC and LCP.