Methods and systems for a modified backing
Various methods and systems are provided for a probe for a medical device. In one example, the probe includes an additively manufactured backing having a porous matrix and one or more thermal management structures. The porous matrix may attenuate acoustic energy and the one or more thermal management structures may enable a transfer of heat from a front of the probe to a rear of the probe.
1 . An ultrasound probe, comprising:
an additively manufactured ultrasound probe backing having a porous matrix, the porous matrix at least partially filled with at least one filler, and one or more thermal management structures, wherein the additively manufactured ultrasound probe backing attenuates acoustic energy and enables a transfer of heat from a front of the probe to a rear of the ultrasound probe, wherein the one or more thermal management structures includes at least one support structure continuous and contiguous with the porous matrix, and wherein the at least one support structure and the porous matrix form a single integrated unit.
2 . The ultrasound probe of claim 1 , wherein the porous matrix has a nonhomogeneous structure, and wherein a uniformity, size, shape, and spacing of pores of the porous matrix is modified by varying one or more of a laser pass power, a print speed, a print direction, a print angle, a print hatching, and a print orientation during fabrication of the porous matrix.
3 . The ultrasound probe of claim 1 , wherein the at least one filler includes one or more of a lossy epoxy, a silicone, scattering particles, and a phase change material, and wherein the at least one filler modifies one or more of an acoustic attenuation and a thermal conductivity of the porous matrix.
4 . The ultrasound probe of claim 3 , wherein the phase change material transitions between a solid and a liquid, and wherein a phase change temperature of the phase change material is in a range of 30° C. to 50° C.
5 . The ultrasound probe of claim 1 , wherein the one or more thermal management structures includes pores of the porous matrix, and wherein varying one or more of a pore shape, a pore size, a pore density, and a total porosity of the porous matrix varies a thermal conductivity of the porous matrix.
6 . The ultrasound probe of claim 1 , wherein the one or more support structure includes an external wall, the external wall having a higher density and lower porosity than the porous matrix, and wherein the external wall is positioned between an acoustic stack and the porous matrix.
7 . The ultrasound probe of claim 1 , wherein the at least one support structure includes one or more of an external wall, internal inclusions, and a heat sink, and wherein the at least one support structure is formed of a material with high thermal conductivity.
8 . The ultrasound probe of claim 7 , wherein the internal inclusions are embedded in the porous matrix, and wherein the internal inclusions modify both an acoustic attenuation and a thermal conductivity of the porous matrix.
9 . The ultrasound probe of claim 1 , wherein the porous matrix is formed of one of more of aluminum, aluminum nitride, copper, titanium, tungsten, a metal alloy, and stainless steel.
10 . The ultrasound probe of claim 1 , wherein the additively manufactured ultrasound probe backing is formed as a near-net shape, and wherein machining and/or grinding of the additively manufactured ultrasound probe backing is minimized to achieve a net, final shape when the additively manufactured ultrasound probe backing is formed as the near-net shape.