ULTRASOUND PATCH WITH INTEGRATED FLEXIBLE TRANSDUCER ASSEMBLY
A self-contained ultrasound patch assembly for detecting fluid flow in a vessel includes piezo elements that can transmit ultrasonic energy and detect echo signals. A flex module has two support portions connected to respective ones of the elements with a hinged portion coupled to the support portions, allowing them to be positioned angularly relative to each other. Electronics that direct the elements to transmit ultrasonic energy and process detected echo signals are in communication with the elements through the flex module. A transducer frame includes an alignment portion engaging a flex module alignment portion to retain the flex module in an aligned position. The frame supports the elements at a fixed angular position with respect to each other. A housing encloses the electronics and frame, and fixedly retains the frame to position the elements to transmit toward a bottom surface and away from a top surface of the housing.
1 .- 20 . (canceled)
21 . A method of making an ultrasound patch assembly configured for use on the skin of a patient to detect fluid flow in a vessel in the patient, the method comprising:
coupling an ultrasound transducer assembly to a transducer frame, wherein the ultrasound transducer assembly comprises:
two piezoelectric (piezo) elements configured to transmit ultrasonic energy and detect echo signals; and
a flex module comprising first and second support portions connected to a respective one of the piezo elements, the flex module further comprising a hinged portion coupled to the first and second support portions and configured to allow the first and second support portions to be positioned angularly relative to each other, the flex module further comprising a first alignment portion;
the transducer frame comprises a second alignment portion that engages the first alignment portion of the flex module to retain the flex module in an aligned position on the transducer frame, the transducer frame supporting the two piezo elements at a fixed angular position with respect to each other;
coupling electronics of the ultrasound patch assembly to the two piezo elements through the flex module, wherein the electronics are configured to direct the two piezo elements to transmit the ultrasonic energy, the electronics further configured to process the detected echo signals;
positioning the electronics of the ultrasonic patch assembly in a housing and positioning the ultrasound transducer assembly and the transducer frame in the housing, wherein the housing encloses the electronics and the transducer frame within an interior area, the housing having a top surface opposite a bottom surface, the top surface being configured to face away from the skin of the patient and the bottom surface being configured to face toward the skin of the patient during use with the patient, wherein the housing fixedly retains the transducer frame and the flex module to position the two piezo elements to transmit the ultrasonic energy toward the bottom surface and away from the top surface.
22 . The method of claim 21 , further comprising electrically connecting the two piezo elements to the flex module.
23 . The method of claim 21 , further comprising electrically connecting the two piezo elements to the flex module via an anisotropic conductive tape electrically.
24 . The method of claim 21 wherein the two piezo elements each have a length and a width defining surface areas of the two piezo elements, the two piezo elements configured to have acoustically active areas that are a subset of the surface areas, wherein the acoustically active areas are surrounded by acoustically inactive areas that are positioned along outer edges of the surface areas, the flex module further comprising electrodes positioned between the acoustically inactive areas of the two piezo elements and the first and second support portions; and further comprising electrically connecting the two piezo elements to the electrodes via an anisotropic conductive tape.
25 . The method of claim 21 wherein coupling an ultrasound transducer assembly to a transducer frame comprises positioning the two piezo elements on the transducer frame that has fixed angular position that is 180 degrees or less, and wherein the transducer frame further comprises first and second surfaces interfacing with the first and second support portions of the flex module, wherein the first and second surfaces have an angular relationship that holds the two piezo elements at the fixed angular position.
26 . The method of claim 21 , further comprising coupling the ultrasound transducer assembly to the transducer frame before the ultrasound transducer assembly and the transducer frame are positioned in the housing.
27 . The method of claim 21 , further comprising coupling an on/off button to the electronics, wherein the on/off button is on a top side of the housing.
28 . The method of claim 21 , further comprising providing air gaps between acoustically active areas of the two piezo elements and the flex module.
29 . The method of claim 21 , further comprising securing a top shell and a base of the housing to each other after the ultrasound transducer assembly, the transducer, and the electronics are in the housing to substantially fully enclose the ultrasound transducer assembly, the transducer, and the electronics in the housing.
30 . The method of claim 21 wherein the bottom surface of the housing comprises a central portion that protrudes outwardly to form a cavity, and further comprising holding the transducer frame at least partially within the cavity of the housing.
31 . The method of claim 30 , further comprising filling with an acoustic medium at least a portion of the cavity between front surfaces of the two piezo elements and an inner surface of the cavity.
32 . The method of claim 21 wherein the first alignment portion is an opening in the flex module and the second alignment portion is a protrusion extending outwardly from a surface of the transducer frame, and further comprising mating the flex module with the transducer frame with the protrusion extending into at least a portion of the opening.
33 . A method of making transducer assembly for an ultrasound patch assembly configured for use on the skin of a patient to detect fluid flow in a vessel in the patient, the method comprising:
coupling two piezoelectric (piezo) elements to a flex module to form an ultrasound transducer assembly, wherein two piezo elements are configured to transmit ultrasonic energy and detect echo signals, and wherein the flex module comprises first and second support portions connected to a respective one of the piezo elements, the flex module further comprises a hinged portion coupled to the first and second support portions and configured to allow the first and second support portions to be positioned angularly relative to each other, the flex module further comprises a first alignment portion;
supporting the ultrasound transducer assembly on a transducer frame, wherein the transducer frame comprises a second alignment portion that engages the first alignment portion of the flex module to retain the flex module in an aligned position on the transducer frame, the transducer frame supporting the two piezo elements at a fixed angular position with respect to each other;
wherein the ultrasound transducer assembly on a transducer frame are configured as a unit to be positioned in and contained in an interior area housing of the ultrasonic patch assembly with the housing fixedly retains the transducer frame and the flex module to position the two piezo elements to transmit the ultrasonic energy toward a bottom surface of the housing and away from a top surface of housing.
34 . The method of claim 33 , further comprising electrically connecting the two piezo elements to the flex module.
35 . The method of claim 33 , further comprising electrically connecting the two piezo elements to the flex module via an anisotropic conductive tape electrically.
36 . The method of claim 33 wherein the two piezo elements each have a length and a width defining surface areas of the two piezo elements, the two piezo elements configured to have acoustically active areas that are a subset of the surface areas, wherein the acoustically active areas are surrounded by acoustically inactive areas that are positioned along outer edges of the surface areas, the flex module further comprising electrodes positioned between the acoustically inactive areas of the two piezo elements and the first and second support portions; and further comprising electrically connecting the two piezo elements to the electrodes via an anisotropic conductive tape.
37 . The method of claim 33 wherein coupling an ultrasound transducer assembly to a transducer frame comprises positioning the two piezo elements on the transducer frame that has fixed angular position that is 180 degrees or less, and wherein the transducer frame further comprises first and second surfaces interfacing with the first and second support portions of the flex module, wherein the first and second surfaces have an angular relationship that holds the two piezo elements at the fixed angular position.
38 . The method of claim 33 , further comprising coupling the ultrasound transducer assembly to the transducer frame before the ultrasound transducer assembly and the transducer frame are positioned in the housing.
39 . The method of claim 33 , further comprising providing air gaps between acoustically active areas of the two piezo elements and the flex module.
40 . The method of claim 33 wherein the first alignment portion is an opening in the flex module and the second alignment portion is a protrusion extending outwardly from a surface of the transducer frame, and further comprising mating the flex module with the transducer frame with the protrusion extending into at least a portion of the opening.