Hybrid multi/single layer array transducers for increased signal-to-noise ratio

Fabrication and Characterization of a Miniaturized 15-MHz Side-Looking Phased-Array Transducer Catheter

This paper describes the development of a miniaturized 15-MHz side-looking phased-array transducer catheter. The array features a 2-2 linear composite with 64 piezoelectric elements mechanically diced into a piece of PMN-30%PT single crystal and separated by non-conductive epoxy kerfs at a 50-μm pitch, yielding a total active aperture of 3.2 mm in the azimuth direction and 1.8 mm in the elevation direction, with an elevation natural focal depth of 8.1 mm. The array includes non-conductive epoxy backing and two front matching layers. A custom flexible circuit connects the array piezoelectric elements to a bundle of 64 individual 48-AWG micro-coaxial cables enclosed within a 1.5-m long 10F catheter. Performance characterization was evaluated via finite element analysis simulations and afterwards compared against obtained measurement results, which showed an average center frequency of 17.7 MHz, an average bandwidth of 52.2% at -6 dB, and crosstalk less than -30 dB. Imaging of a tungsten fine-wire phantom resulted in axial and lateral spatial resolutions of approximately 90 μm and 420 ìm, respectively. The imaging capability was further evaluated with colorectal tissue-mimicking phantoms, demonstrating the potential suitability of the proposed phased-array transducer for the intraoperative assessment of surgical margins during minimally invasive colorectal surgery procedures.

Imaging arrays with improved transmit power capability

Bonded multilayer ceramics and composites incorporating low-loss piezoceramics have been applied to arrays for ultrasound imaging to improve acoustic transmit power levels and to reduce internal heating. Commercially available hard PZT from multiple vendors has been characterized for microstructure, ability to be processed, and electroacoustic properties. Multilayers using the best materials demonstrate the tradeoffs compared with the softer PZT5-H typically used for imaging arrays. Three-layer PZT4 composites exhibit an effective dielectric constant that is three times that of single layer PZT5H, a 50% higher mechanical Q, a 30% lower acoustic impedance, and only a 10% lower coupling coefficient. Application of low-loss multilayers to linear phased and large curved arrays results in equivalent or better element performance. A 3-layer PZT4 composite array achieved the same transmit intensity at 40% lower transmit voltage and with a 35% lower face temperature increase than the PZT-5 control. Although B-mode images show similar quality, acoustic radiation force impulse (ARFI) images show increased displacement for a given drive voltage. An increased failure rate for the multilayers following extended operation indicates that further development of the bond process will be necessary. In conclusion, bonded multilayer ceramics and composites allow additional design freedom to optimize arrays and improve the overall performance for increased acoustic output while maintaining image quality.

Ultrasonic imaging using a 5-MHz multilayer/single-layer hybrid array for increased signal-to-noise ratio

Conventional diagnostic ultrasound scanners are bulky and require significant amounts of electrical power during operation. Reducing the size, weight, and consumption of electrical power is made easier through the use of highly integrated compact transmit and receive electronics that may be incorporated in the transducer handle. This necessitates the use of low voltage transmitters and low power receive preamplifiers. Conventional scanners typically use approximately 100-V pulses during transmit; therefore, decreasing the transmit voltage to 15 V decreases the transmit sensitivity. Conventional receive electronics that are located at the scanner degrade the received signal-to-noise ratio (SNR) because the array element cannot efficiently drive the coaxial cable. Transmit sensitivity and received SNR can be radically improved using a multilayer/single-layer hybrid array making integration of electronics into the transducer handle more feasible. In this paper, we discuss the design, fabrication, and testing of a 5-MHz hybrid linear array. The hybrid array included 16 multilayer transmit elements (10 Omega impedance) and 24 single-layer receive elements at a half wavelength element pitch. Low voltage transmitters with an output resistance of 7 Omega and high impedance JFET preamplifiers using 15 V for biasing were located adjacent to the hybrid array in the transducer handle. The transmit sensitivity and received SNR of the hybrid array were compared with a conventional array using 50-Omega transmitters and receive preamplifiers at the scanner. The transmit sensitivity improved by 12.8 dB, and the received SNR improved by 7.8 dB, yielding an overall improvement of 20.6 dB, which compared well with predictions from the KLM model. Images of phantoms and in vivo images of the kidney obtained with the Siemens Model 1200 phased array system showed the increased SNR using the hybrid array. Estimates of penetration in tissue mimicking phantoms (alpha=0.5 dB/(cm MHz)) improved by 7 cm compared with the control.

Multi-layered PZT/polymer composites to increase signal-to-noise ratio and resolution for medical ultrasound transducers

Increasing transducer bandwidth and signal-to-noise ratio (SNR) is fundamental to improving the quality of medical ultrasound images. In previous work, the authors have proposed the use of multi-layer 1-3 PZT/epoxy composites to increase both but have encountered significant fabrication challenges. These difficulties include making the bond thickness between the layers extremely small relative to the ultrasound wavelength and aligning the posts of the composite to increase the coupling coefficient. The authors have routinely achieved a bond thickness of less than 5 mum but aligning the posts is more complicated. Finite element (PZFlex; Weidlinger, Assoc., New York, NY and Los Altos, CA) simulations show that the pulse-echo SNR and bandwidth degrade significantly with misalignment of the posts. Alignment of greater than 90% of the post pitch (i.e., tolerance of 10 to 20 mum) is required to obtain significant increases in SNR and bandwidth relative to conventional transducer arrays. This will be a difficult tolerance for large-scale production. Thus, the authors have developed a multi-layer composite hybrid array that will not require post alignment. This structure consists of a layer of 5 MHz 1-3 composite material on top of conventional 5 MHz PZT, which will provide greater SNR relative to conventional composites and increased bandwidth over multi-layer PZT. PZFlex simulations show that for a 2 MHz linear array element, the 2 layer hybrid structure increases the pulse-echo SNR by 7.5 dB over that from a single layer PZT element. Even without a matching layer, an increase in the -6 dB pulse-echo fractional bandwidth from 22% for the PZT element to 35% for the hybrid element was also predicted. Experimentally, in a 32 element array, the authors achieved an increase of 5.2 dB in SNR and an increased -6 dB bandwidth from 23 to 30%. In vitro and in vivo images showed corresponding improvements.

Characterizing ultrasonic transducers using radiation efficiency and reception noise figure

Transducer performance is considered separately for transmission and reception operations. The transmission operation is traditionally characterized by its traditional transfer function. Using a Thevenin source, the transfer function may be scaled to become the absolute radiation efficiency. Transmission lines are accurately modeled, and a matched impedance design is recommended. The reception operation also is characterized by its traditional transfer function. However, reception sensitivity is defined as the signal-to-noise ratio achieved by the combined transducer, transmission line, and preamplifier. The thermal noise arises from the media and other noise sources contributed by the transducer, transmission line, and preamplifier. An absolute sensitivity measure is defined as the acoustic noise figure, which is the sum of individual transducer and preamplifier noise figures. The transducer noise figure is independent of the receiver load impedance and depends critically on dissipative loss. Preamplifier noise figure performance requires noise matching to the transducer. High performance design methods are presented that incorporate transmission lines, which include loss. Modeled examples are used to demonstrate performance.