JP3281784B2 - Ultrasonic probe manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing an ultrasonic probe, and more particularly to a method of attaching an acoustic lens.

[0002]

[Prior art]

[Background of the Invention] An ultrasonic probe is used, for example, in a medical ultrasonic diagnostic apparatus as an ultrasonic wave transmitting / receiving unit. For example, strip-shaped piezoelectric elements of minute width are arranged in the width direction, and linear or sector drive is performed in the same direction. In such a device, an acoustic lens is generally provided in the length direction of the piezoelectric element so as to increase the resolution in the same direction.

FIGS. 3 to 5 are views of an array-type probe for explaining a conventional example of this type. FIG. 3 is a schematic front sectional view, and FIG. 4 is a side sectional view. FIG. 5 is a diagram of the acoustic lens. The ultrasonic probe includes a probe main body 1, an acoustic lens 2, and a case 3. The probe main body 1 is formed by arranging strip-shaped piezoelectric elements 5 made of PZT (lead zirconate titanate) on the backing material 4 in the width direction. For example, after the flexible board 6 (ab) is fixed to the backing material 4 with the piezoelectric plate connected to both sides, a cut that reaches the backing material 4 from above the piezoelectric plate at a pitch between conductive paths provided at regular intervals (not shown). And cut. However,
Both main surfaces of the piezoelectric plate (piezoelectric element 5) have electrodes (not shown). Then, a filler is buried in each groove 7, and an acoustic matching layer 8 is formed on the front surface of the piezoelectric element 5. Further, the acoustic matching layer 8,
Protective mold layer 9 on the side of piezoelectric element 5 and backing material 4
Is provided. At this time, the flexible substrate 6 (ab) is embedded and fixed in the protective mold layer 9. That is, the probe main body 1 is a single unitized element, that is, a probe unit.

[0004] The acoustic lens 2 includes a lens portion and a leg portion. The lens portion has a convex curvature in the length direction of the piezoelectric element 5, and the leg portion extends vertically from the outer periphery of the lens. Generally, it is made of silicon resin or the like, and is integrally formed by molding. Then, such an acoustic lens 2 is covered from above the probe main body 1. That is, the lens part is on the probe main body 1 and the leg part is on the side surface of the probe main body 1, and is fixed with an adhesive or the like. For convenience of explanation, the probe main body 1 provided with the acoustic lens 2 is referred to as a probe main body with a lens.

[0005] The case 3 is made of a synthetic resin or the like, and has a thick opening wall surface on the tip side, for example. The opening wall surface matches the outer dimension between the legs of the acoustic lens 2 and has a step from the opening wall surface to make the inner diameter larger than the opening surface. Then, the lens portion of the lens-equipped probe main body is positioned so as to protrude from the opening surface, and a filler (not shown) is provided in the gap between the lens-equipped probe main body and the case 3 to be integrated.

In such a device, the front surface (the acoustic lens 2 side) of the ultrasonic probe is pressed while rubbing against a living body or the like to transmit and receive ultrasonic waves. At this time, since the leg portion of the acoustic lens 2 is also provided on the side surface of the probe main body 1, it is possible to prevent the lens portion from shifting in the lateral direction. That is, the leg portion reinforces the strength of the lens portion by the adhesive, and prevents displacement and peeling. Therefore, good ultrasonic characteristics are maintained.

[0007]

[Problems to be solved by the invention]

"Problems of the prior art" However, in the ultrasonic probe having the above-described configuration, the length of the lens portion is basically made to match that of the piezoelectric element 5, but the inner diameter of the leg portion is not 1 to the outside dimensions. The outer shape of the leg portion is made to match the inner diameter of the case 3. Therefore, even if the length of the piezoelectric element 5 is constant, if the outer shape of the probe main body 1 and the inner diameter of the case 3 are different, the acoustic lens 2 must be formed each time, and the versatility is lacking. There was a problem.

Note that the outer shape and dimensions of the probe main body 1 are basically determined by the use such as for a body surface or a body cavity, the inner diameter shape of the case 3 and the like, and also by the electrode leading-out method. For example, when transmitting and receiving ultrasonic waves from the body surface, the outer shape of the case 3 and the probe main body 1 formed thereby is generally large, and when inserted into a body cavity, the outer shape is set small. Further, when the electrodes are led out of silver foil or the like, the thickness of the protective mold is reduced because the electrodes are not bent more than the flexible substrate. For this reason, the inner and outer diameters or shapes between the legs of the acoustic lens 2 cannot be uniquely determined from the length of the piezoelectric element 5.

[Problem and Object of the Invention] The present invention is to produce an acoustic lens that can be used in common even if the lengths of the piezoelectric elements are equal and the inner diameter of the case 3 and the outer shape of the probe body are different. It is an object of the present invention to provide a method for manufacturing an ultrasonic probe having an acoustic lens with excellent versatility.

[0010]

[Means for Solving the Problems]

"Points of Interest" In the present invention, attention was paid to the point that the legs of the acoustic lens are very thin and have elasticity.

According to the present invention, a sheet-like acoustic lens comprising a lens portion having a curvature and a flat portion extending to the outer periphery is formed, and the lens portion is fixed on the probe main body 1. The solution is that the flat portion is bent to the side surface of the probe.

[0012]

According to the present invention, since the acoustic lens is formed into a sheet shape and the lens portion is fixed, and then the flat portion is bent, there is no need to previously form the leg portion of the acoustic lens. Less than,
An embodiment of the present invention will be described.

[0013]

FIG. 1 is a partial sectional view of an ultrasonic probe for explaining one embodiment (manufacturing method) of the present invention. The same parts as those in the prior art are denoted by the same reference numerals and description thereof will be omitted. The ultrasonic probe includes the probe main body 1, the acoustic lens 2, and the case 3 as described above (see FIGS. 3 and 4). The probe body 1 has the piezoelectric element 5 and the acoustic matching layer laminated on the backing material 4 in the same manner as described above, and the flexible substrate 6 (ab) extends from both sides to form the protective mold layer 9.
Is provided with the probe main body 1.

In this embodiment, the acoustic lens 2
Is first formed in a sheet shape including a lens portion 2a and a flat portion 2c. However, the acoustic lens 2 is made of the same silicon material as before, and is formed by molding or the like. The lens portion 2a has a curvature corresponding to the length of the piezoelectric element 5, and the flat portion 2c is provided on the outer surface of the lens portion 2a on a plane. Then, the lens portion 2a is made to coincide with the piezoelectric element 5 and is fixed on the probe main body 1 to form a probe main body with a lens. Then, for example, the flat portion 2c is bent and fixed to the side surface of the probe main body 1 by its elasticity.

Thereafter, as described above, the lens portion 2a of the lens-equipped probe main body is positioned so as to protrude from the opening surface of the case 3. Then, a filler is provided in the gap between the probe main body with lens and the case 3 to be integrated.

With such a configuration (manufacturing method), the acoustic lens 2 is formed into a sheet shape, and the flat portion 2c is bent after the lens portion 2a is fixed.
Need not be formed in advance by molding. Therefore, even if the external shape and dimensions of the probe main body 1 are different depending on the case 3 or the electrode deriving method, if the length of the piezoelectric element 5 is substantially constant, the sheet-shaped acoustic lens 2 having the same shape can be used. Can be shared.

[0017]

In the above embodiment, the flat portion 2c of the acoustic lens 2 is bent and fixed to the side surface of the lens-equipped probe main body, and is housed in the case 3. However, the present invention is not limited to this.
For example, the probe body with lens is inserted from the rear end side of the case 3 or the like, and the flat portion 2c is bent by the pressing force from the opening wall surface when the lens portion 2a is projected from the opening surface. After that, a filler may be provided between the probe body with lens and the case 3. Note that the flat portion 2c has a small thickness (for example, 0.5 mm or less) and has a strong rubber property, so that twisting at the time of bending does not cause any particular problem.

Also, the protective mold layer 9 provided on the side surface of the probe body 1 is not provided in advance, but the probe body with lens without the protective mold layer 9 is accommodated in the case 3 and then the filler is provided. It may be formed integrally by Although the electrodes are led out by the flexible substrate 6 (ab), the electrodes are not limited to this and may be silver foil or the like.

Further, notches or cuts may be provided at the corners of the flat portion 2c of the acoustic lens 2 so as to make the bending easier, and the present invention is appropriately performed without departing from the spirit of the present invention. The ultrasonic probe manufactured by fixing the lens portion 2a of the sheet-shaped acoustic lens 2 and then bending the flat portion 2c is within the technical scope of the present invention.

[0020]

According to the present invention, a sheet-like acoustic lens comprising a lens portion having a curvature and a flat portion extending to the outer periphery is formed, and after fixing the lens portion on the probe main body, the flat portion is formed. Since the probe is bent on the side surface of the probe main body, a method for manufacturing an ultrasonic probe having an acoustic lens with excellent versatility can be provided, and the practical advantage is great.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of an ultrasonic probe (probe main body with lens) for explaining a manufacturing method of the present invention.

FIG. 2 is a diagram of an acoustic lens employed in the present invention.

FIG. 3 is a partial front sectional view of an ultrasonic probe illustrating a conventional example.

FIG. 4 is a partial side sectional view of an ultrasonic probe explaining a conventional example.

FIG. 5 is a diagram of an acoustic lens for explaining a conventional example.

[Explanation of symbols]

1 probe body, 2 acoustic lens, 3 case, 4 backing material, 5 piezoelectric element, 6 flexible substrate, 7
Groove, 8 acoustic matching layer, 9 protective mold layer.

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int. Cl. ⁷ , DB name) H04R 17/00 332 A61B 8/00 G01N 29/24 H04R 1/34 330

Claims (1)

(57) [Claims] 1. A probe body formed by arranging a plurality of piezoelectric elements on a backing material in a width direction, and a lens having a curvature in a longitudinal direction of the piezoelectric element in contact with a front surface of the probe body. In the method of manufacturing an ultrasonic probe comprising a portion and an acoustic lens composed of a leg portion abutting on a side surface of the probe main body, the acoustic lens includes a lens portion and a flat portion extending around the outer periphery of the lens portion. An ultrasonic lens, wherein after fixing the lens portion of the acoustic lens on the probe main body, the flat portion is bent to a side surface of the probe main body. Contactor manufacturing method.