Transducer array having a temperature sensor isolation layer between a temperature sensor and external environment
A transducer array, tumor treating field system, and method are herein disclosed. The transducer array comprises an electrode having a first side and a second side; a transfer layer covering the first side of the electrode and configured to transfer TTFields into a patient; a temperature sensor in contact with the second side of the at least one electrode; and an isolation layer covering the temperature sensor and at least a portion of the at least one electrode such that the temperature sensor is positioned between the isolation layer and the second side of the electrode, the isolation layer resisting at least one of heat flow and fluid flow through the isolation layer.
1 . A transducer array, comprising:
a transfer layer configured to transfer Tumor Treating Fields (TTFields) into a patient;
an electrode configured to emanate the TTFields, the electrode having a first side covered by the transfer layer and a second side opposite the first side and having a first portion and a second portion;
a temperature sensor in contact with the first portion of the second side of the electrode; and
an isolation layer covering the temperature sensor and the first portion of the second side of the electrode but not disposed over the second portion of the second side of the electrode, such that the temperature sensor is positioned between the isolation layer and the first portion of the second side of the electrode, the isolation layer resisting heat flow through the isolation layer.
2 . The transducer array of claim 1 , wherein the isolation layer has an isolation thickness, the transducer array further comprising a top-coat layer disposed over the isolation layer and the second portion of the second side of the electrode not in contact with the temperature sensor and the isolation layer, the top-coat layer having a top-coat thickness that is thinner than the isolation thickness of the isolation layer.
3 . The transducer array of claim 2 , wherein the isolation thickness of the isolation layer is in a range of 2-6 times thicker than the top-coat thickness of the top-coat layer.
4 . The transducer array of claim 2 , wherein the isolation layer comprises a thermally insulating matrix material, the thermally insulating matrix material configured to resist heat flow from an atmosphere outside of the isolation layer to the temperature sensor, the isolation layer being more thermally insulating than the top-coat layer.
5 . The transducer array of claim 1 , wherein the isolation layer is a thermal insulator.
6 . The transducer array of claim 1 , wherein the isolation layer comprises a liquid resistant matrix material, the liquid resistant matrix material configured to resist a liquid flow through the isolation layer.
7 . The transducer array of claim 6 , wherein the isolation layer is hydrophobic.
8 . The transducer array of claim 1 , wherein the isolation layer is in contact with less than 20% of the second side of the electrode.
9 . The transducer array of claim 1 , wherein the isolation layer comprises at least one of an epoxy material, a thermally insulating foam material, and a hydrophobic material.
10 . The transducer array of claim 1 , wherein the isolation layer is non-conducting.
11 . The transducer array of claim 1 , wherein the isolation layer has a first insulation value, and wherein the electrode has an outer perimeter, and further comprising a non-conductive top-coat layer disposed on the isolation layer, the non-conductive top-coat layer extending within the outer perimeter and beyond the outer perimeter of the electrode, the non-conductive top-coat layer having a second insulation value less than the first insulation value.
12 . The transducer array of claim 1 , wherein the temperature sensor has a contact portion that is in contact with the first portion of the second side of the electrode and has an exposed portion not in contact with the second side of the electrode, and wherein the isolation layer surrounds the exposed portion of the temperature sensor and extends to the first portion of the second side of the electrode without contacting the second portion of the second side of the electrode.
13 . A tumor treating field system, comprising:
an electric field generator configured to generate an electrical signal having an alternating current waveform at a frequency in a range from 50 kHz to 1 MHz;
a first conductive lead electrically coupled to the electric field generator, the first conductive lead configured to carry the electrical signal;
a first transducer array coupled to the first conductive lead, the first transducer array comprising:
an electrode layer having a first surface, a second surface opposite the first surface and having a first portion and a second portion, and an outer perimeter, the electrode layer comprising at least one electrode configured to receive the electrical signal from the electric field generator;
a transfer layer in contact with the first surface of the electrode layer;
a temperature sensor in contact with the first portion of the second surface of the electrode layer; and
an isolation layer disposed over the temperature sensor and the first portion of the second surface of the electrode layer but not disposed over the second portion of the second surface of the electrode layer, the isolation layer resisting heat flow through the isolation layer;
a second conductive lead electrically coupled to the electric field generator; and
a second transducer array coupled to the second conductive lead, the second transducer array receiving the electrical signal from the second conductive lead, and, in conjunction with the first transducer array, forming a tumor treating field.
14 . The tumor treating field system of claim 13 , wherein the isolation layer has an isolation thickness, wherein the first transducer array further comprises a top-coat layer disposed over the isolation layer and the second portion of the second surface of the electrode layer not in contact with the temperature sensor and the isolation layer, the top-coat layer having a top-coat thickness that is thinner than the isolation thickness of the isolation layer.
15 . The tumor treating field system of claim 14 , wherein the isolation layer comprises a thermally insulating matrix material, the thermally insulating matrix material configured to resist the heat flow from the temperature sensor to an atmosphere outside of the isolation layer more than that of the top-coat layer.
16 . The tumor treating field system of claim 13 , wherein the isolation layer has a first insulation value, and wherein the first transducer array further comprises a non-conductive top-coat layer disposed on the isolation layer, the non-conductive top-coat layer extending within the outer perimeter and beyond the outer perimeter of the electrode layer, the non-conductive top-coat layer having a second insulation value less than the first insulation value.
17 . The tumor treating field system of claim 13 , wherein the transfer layer is a non-conductive, thin-film polymer layer.
18 . The tumor treating field system of claim 13 , wherein the electrode layer of the first transducer array comprises a plurality of electrodes and a plurality of temperature sensors, each electrode comprising a first electrode surface and a second electrode surface opposite the first electrode surface, the second electrode surface having a first electrode portion and a second electrode portion larger than the first electrode portion, each electrode having a respective temperature sensor in contact with the first portion of the second electrode surface, and wherein the isolation layer includes a plurality of isolation sections with at least some of the isolation sections disposed over respective ones of the temperature sensors and the first portion of the second electrode surface of each electrode, but not disposed over the second portion of the second electrode surface.
19 . The tumor treating field system of claim 13 , wherein the isolation layer comprises a liquid resistant matrix material, the liquid resistant matrix material configured to resist a liquid flow through the isolation layer.
20 . The tumor treating field system of claim 13 , wherein the isolation layer is non-conducting.