Abstract:
A method for constructing a connection assembly for use in a multiple aperture ultrasonic tranducer including an array of elements for transmitting or receiving signals, wherein each element is comprised of a plurality of segments, and the connection assembly for interconnecting the segments of each elements and for connecting the segments to transmit/receive circuitsto form the aperatures of the array. An isolating layer is superimposed on the segments of the array and a plurality of via openings are formed through the isolating layer. At least one via opening being assocated with each segment of the array and each via opening exposing an area of an assocated segment. A conductive layer is superimposed on the isolating layer, the conductive layer having conduxtive paths interconnecting the segments and connecting the segments to the transmit/receive circuits to form the apertures of the array.

Description:
CROSS REFERENCE TO RELATED APPLICATION(S) 
     This is a divisional of application Ser. No. 08/935,744 filed on Sep. 23, 1997 now U.S. Pat. No. 5,990,598. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to a design and the method of constructing ultrasonic transducers and, in particular, a design and method for interconnecting elements in multiple elevation transducers. 
     BACKGROUND OF THE INVENTION 
     Ultrasonic transducers are used in many medical applications and, in particular, for the non-invasive acquisition of images of organs and conditions within a patient, typical examples being the ultrasound imaging of fetuses and the heart. The ultrasonic transducers used in such applications are generally hand held, and must meet stringent dimensional constraints in order to acquire the desired images. For example, it is frequently necessary that the transducer be able to obtain high resolution images of significant portions of a patient&#39;s chest cavity through the gap between two ribs when used for cardiac diagnostic purposes, thereby severely limiting the physical dimensions of the transducer. 
     As a consequence, and because of the relatively small aperture between human ribs and similar constraints upon transducer positioning when attempting to gain images of other parts of the human body, there has been significant development of linear or phased array transducers comprising multiple transmitting and receiving elements, with the associated electronics and switching circuits, to provide relatively narrowly focused and “steerable” transmitting and receiving “beams”. The most common of such transducers comprises a one element wide by multiple element long linear array of transmitting and receiving elements arranged in line along a flat plane or, preferably, along a concave or convex arc, thereby providing a greater scanning arc. 
     The transmitting and receiving beams of such transducers are formed and steered by selecting individual transducers elements or groups of transducer elements to transmit or receive ultrasonic energy, wherein each such individual transducer element or group of transducers elements forms an “aperture” of the transducer array. Such an array is thereby formed of a single row of apertures extending along the face of the array and such transducers are consequently referred to as “single aperture” transducers. 
     While such azimuth scanning single aperture arrays are advantageous for many applications, single aperture transducers have the disadvantage that they can scan only along the single plane of the transducer elements. As a consequence, there have been many attempts to construct transducers that are also capable of steering or focusing in elevation as well as azimuth, that is, along the axis at right angles to the azimuth plane along which the elements are arrayed as well as along the azimuth plane. 
     As is well understood, the formation and steering and/or focusing of the transmitting and receiving beams of a transducer are controlled by selection and use of the various separate physical divisions or areas of transducer material comprising the transducer array, which, as described above, are referred to as “apertures”. In contrast to “single aperture” transducers, however, in which each aperture is formed by an element or group of elements extending across the face of the array as a single unitary area or division or the array, each corresponding element in a transducer capable of scanning in elevation is divided into multiple sub-elements, or segments. For this reason, and because each element position along such an array can form multiple apertures, that is, using different combinations of the sub-elements or segments of each of the transducer elements, such transducers are consequently referred to as “multiple aperture” transducers. 
     The shape, focus and direction of the transmitting and receiving beams of a multiple aperture transducer are again controlled by selection of the apertures of the array. In a multiple aperture array, however, each aperture is formed by one or more of the sub-elements, or segments, of the transducer elements, so that the apertures of a multiple aperture array can be used to steer and focus the transducer scan beam along the elevation axis as well as along the azimuth axis and can define multiple azimuthal scan planes, each being at a different angle of elevation. 
     It should be noted that in both single aperture transducers and in multiple aperture transducers the apertures may be either driven actively, or simply de-activated to reduce the size of the acoustic aperture, thereby controlling the shape, direction and focus of the transmitting and receiving beams formed by the transducer array. 
     The transducer elements of both single aperture and multiple aperture transducers are generally made of a piezoelectric material and the array of elements or sub-elements is generally mounted onto a body made of a backing material. Connections between the individual transducer elements and the associated electronics and switching elements are usually provided through various arrangements and combinations of thick and thin film circuits, flexible printed circuits and wires, which are generally located on the back of the array, between the array and the body, with leads running along the body to the transducer electronics. One or more layers of impedance matching material, generally considered to be a part of the elements themselves, is often superimposed upon the transducer elements to match the acoustic impedance of the transducer to the body or material being scanned, and a lens comprised of a suitable material may be additionally superimposed upon the impedance matching material to shape or focus the beams generated by the transducer elements. In some implementations, the impedance matching layers may have suitable acoustic characteristics and may be shaped to operate as an acoustic lens. 
     Single aperture transducers are generally constructed from a single piece of transducer material having a width equal to the length of one element and a length equal to the widths of the total number of elements plus spaces between the elements. One or more thin or thick film circuits or flexible printed circuits having connections and paths for the individual elements, or the like implemented in any of several other ways, are bonded to one side of the piece of transducer material and a layer or layers of matching material may be bonded to the radiating and receiving side of the transducer material to form a “stack” of the transducer material, circuits and matching layers. A temporary or permanent layer of backing material of some form, such as a flexible material, may also be bonded to the back of the stack to aid in handling the stack during manufacture. 
     Successive cuts are then made across the width of the transducer stack on the radiating/receiving side of the stack and at intervals corresponding to the widths of the elements and the spacing between the elements to divide the single piece of material into the individual elements. This operation is generally referred to as “dicing” and is usually done with a device referred to as a dicing saw, but may be done with other techniques, such as lasers. These cuts may extend only through the transducer and matching material layers, or partly or completely through the circuit layer, or through the circuit layer and at least a part of any backing layers, depending upon the detailed design and implementation of the circuit layers. 
     The assembly of individual transducer elements with the circuit and matching layers are then bonded to the backing body, which may have a flat, concave or convex face, as described above, with any temporary backing layers being removed as necessary. It should be noted that in certain instances the dicing may be done after the assembly of transducer elements, matching materials, and circuits is bonded to the backing material and that the dicing cuts may extend into the layers of backing material or even into the backing body. 
     Connections between the thin or thick film circuits connecting to the transducer elements and wires or printed circuits, such as flexible circuits, which in turn connect to the electronics and switching elements may made before or after the transducer assembly is bonded to the backing body, again depending on the detailed design and implementation of these connections. 
     While methods for the construction of multiple aperture transducer are well known, and similar to those used in construction of single aperture arrays, multiple aperture arrays present greater difficulties than do single aperture arrays. For example, a particular application may require that each element be comprised of three segments, or apertures, that is, two outer segments and a middle segment. This may be achieved, for example, by constructing the transducer elements from three elongated pieces of transducer material, that is, two outer pieces and a middle piece, and then dicing the pieces across the face of the array as was described with regard to single aperture arrays, or by additional cuts along the transducer stack in the longitudinal direction to divide the two outer segments from the middle segment. 
     A primary problem in constructing transducers, however, is in achieving the electrical connections to the elements and sub-elements, or segments, as the number of elements or sub-element segments increases. That is, the physical dimensions of an array, especially for medical use, is generally constrained, for example, by the need to scan the cardiac structures through the space between patient&#39;s ribs to avoid interference by the ribs. At the same time, there is a need and trend to increase the number of elements or sub-elements to achieve every finer scan resolution to achieve increasingly detailed images of the cardiac structures. 
     While this problem exists even with single aperture transducers, the problem is particularly severe with multiple aperture transducers because the number of electrical connections to each element, each of which may be comprised of three or more segments, or sub-elements, is greatly increased while the space in which to make the connections does not increase. For example, in a single aperture array each element is made of a single segment while in a three aperture array each element is divided into three segments. As a result, while each element of a single aperture array requires a single connection to the single segment that comprises the element, a three aperture array requires, for each element, two separate connections to the two outer segments and a third connection to the middle segment, thereby tripling the number of connections per element, and possibly requiring additional connections to each possible pair of segments. In addition, each middle segment is bounded ore both ends by the outer segments of the element and on either side by the two adjacent elements, so that the middle segments are not readily accessible for connections. It is therefore apparent that the space available to make connections to the segments of a multiple aperture array and to run the leads from the segments to the points of connection to the transducer electronics is extremely constrained and that the problem compounds very rapidly as the number of elements in the transducer or the number of segments in each element increases. 
     Considering a specific example, the Hewlett-Packard Model 21215 transducer provides two sizes of elevation apertures and is constructed generally as described above, that is, of a linear array of separate or separated elements wherein each element is comprised of three separate segments, two outer segments and a middle segment. In this design, the elements are arranged in a straight plane, rather than a concave or convex arc, and the middle segment of each element is connected to a transmit/receive circuit while the two outer segments of the element are connected together and then to a second transmit/receive circuit or through a switch to the same transmit/receive circuit as the middle segment. 
     Connections to the segments are made through flex circuits, that is, circuits etched onto thin, flexible circuit boards, wherein an individual flex circuit is used for each set of elevation segment connections and wherein each flex circuit contains all of the connections for the corresponding segments of each of the elements along the array. The transducer therefore requires three flex circuits, one for each out row of segments and one for the middle row of segments. The two flex circuits connecting to the outer segments of each element of the outer segments and are then connected by a flex circuit having jumper connections, or by a circuit board. The third flex circuit connects to the middle segments of the elements, and thus must make connection at the middle of the back side of the piezoelectric array. 
     It is therefore apparent that a three aperture array like the Hewlett-Packard Model 21215 requires three times as many connections to the piezoelectric segments themselves and twice as many flex circuits as in a single aperture array, and two additional flex circuit to flex circuit connections through flex jumper connections or through a printed circuit board for each element. These connections result in higher cost and lower manufacturing yield. In addition, assembly is more complex in that the flex circuit to the middle segments must be carefully aligned with the flex circuits to the outer segments. This factor alone makes it difficult, if not impossible, to manufacture a curved array and the presence of the middle segment flex circuit requires the use of either a poured backing body material or complex molding or machining to manufacture the backing body. 
     To further compound the problem of achieving a large number of connections and leads to the transducer elements and segments in a small area, the connections to the segments must be made in such a manner as not to interfere with the acoustic characteristics of the transducer. That is it has been described above that the connections to the transducer elements and segments are generally made through thin or thick film circuits or flex circuits bonded to the back side of the transducer elements. The number of leads and connections, however, generally results in a connection and lead layer or layers having significant thickness and effect, in terms of the acoustic characteristics of the array, thereby distorting or interfering with the acoustic characteristics of the array. In addition, the lead and connection layer or layers and other layers interposed between, such as insulating layers, do not provide smooth surfaces, or planes, because of the raised or depressed areas of the layers forming the leads and connections. As such, it is difficult to reliably bond the layers together without significant additional layers of bonding materials and the unevenness of the surfaces tend to trap bonding material and air between the layers, thereby providing an acoustically non-homogenous “body” bonded to the “back” face of the transducer elements that further interferes with the acoustic characteristics of the transducer array. 
     The methods used in the prior art to construct multiple aperture arrays include the use of multiple flex circuits, as described just above, connections embedded in the backing body, the use very thin film or deposited circuits to form the connections and leads to the transducer elements and segments, and even the use of electrostrictive rather than piezoelectric materials for the transducer elements. 
     Each of these methods, however, provides its own difficulties and problems. For example, the disadvantages of multiple flex circuits have been discussed above, and the disadvantages of connections embedded in the backing body are comparable. 
     An alternative is the use of a multi-layer thick film ceramic hybrid circuit which also serves as the backing body. The laminated layers with embedded connection circuits results in leads which run vertically, that is, perpendicularly, between the segments and an interface circuit to which the connections are made, but also results in leads with very small cross sections that are attached at both ends by butt joints, which lack reliability. The use of a multi-layer thick film circuit, in turn, can provide much stronger and more reliable connections, but the acoustic characteristics of the ceramic material may degrade the acoustic performance of the transducer. Both approaches, moreover, may have the disadvantage of requiring multiple steps to make the connections to the piezoelectric elements and may result in added cost from not using standard printed or hybrid circuit manufacturing techniques. 
     Yet other approaches use thin film or very thin film circuits for the connections and leads, thereby providing connection and lead layers that are acoustically thin and thereby cause less interference with the acoustic characteristics of the transducer. Thin film circuits, however, are difficult to work with in manufacture, often being relatively fragile, and generally require “wet” manufacturing processes that result in potentially undesirable materials to be disposed of. 
     In addition, thin film circuits, like thick film circuits and flexible circuits, require connections between layers, for example, between the layer forming contacts to the elements and segments and the layer providing the interconnecting leads, and these interlayer connections, commonly called “vias” are difficult to form in the thicknesses typical of thin film circuits. Certain of the prior art approaches to thin film circuits, for example, while recognizing the advantages of thin film circuits for the actual contacts to the transducer elements and segments and for the interconnecting leads, have required the use of additional, vertically oriented circuit boards or very thin, free standing wires to accomplish the necessary connections. 
     The present invention provides a solution to these and other problems of the prior art. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a connection assembly for use in a multiple aperture ultrasonic transducer including an array of elements for transmitting or receiving signals that is capable of steering and/or focusing in elevation as well as azimuth and wherein each element is comprised of a plurality of segments and wherein the connection assembly interconnects the segments of each element and connects the segments to transmit/receive circuits to form the apertures of the array, and to a method for constructing such a connection assembly. 
     According to the present invention, the connection assembly includes an isolating layer and a conductive layer. The isolating layer is superimposed on the segments of the array and has at least one via opening corresponding to and located within the area of each segment of the array. Each via opening exposes a corresponding area of a segment. The conductive layer is superimposed on the isolating layer and has conductive paths interconnecting the segments and connecting the segments to the transmit/receive circuits to form the apertures of the array. 
     In a presently preferred embodiment, the conductive layer forms a continuous layer covering the isolating layer, the interior surfaces of the via openings and the areas of the segments exposed through the via openings and is scribed to divide the conductive layer into conductive paths interconnecting the segments and connecting the segments to the transmit/receive circuits to form the apertures of the array. 
     Further according to the present invention, the conductive paths associated with each element are separated from the conductive paths associated with neighboring elements by dicing cuts that divide the portion of the isolating layer and the conductive layer superimposed on the element from the portions of the isolating layer and the conductive layer superimposed on the neighboring elements. 
     Further according to the present invention, the conductive layer is a deposited conductive layer, and is deposited by a sputtering process. 
     In a further aspect of the present invention, the connections between the segments and flex leads connecting to the circuitry driving the segments are accomplished at the same time and in the same processes as the connection to and between the segments, rather than in a separate process. According to the present invention, a flex circuit having flex leads is assembled to be coplanar with the segments of the array at the time the isolating and conductive layers are superimposed on the elements of the array, so that the isolating layer and the conductive layer are superimposed upon the flex circuit and scribed in the same steps as the superimposing and scribing of the isolating layer and conductive layer on the elements, with via openings provided through the isolating layer in areas of the flex leads to provide connections between the conductive layer and the flex leads. The conductive layer in the area of the flex leads is then scribed to provide connections between the segments and flex leads formed on the flex circuit, and diced to separate the connections to individual segments in the same step in which the elements are diced into segments. 
    
    
     Other features, objects and advantages of the present invention will be understood by those of ordinary skill in the art after reading the following descriptions of a present implementation of the present invention, and after examining the drawings, wherein: 
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1A is an illustration of the segments and connections of a typical two aperture transducer; 
     FIG. 1B is an illustration of the segments and connections of a typical four aperture transducer; 
     FIG. 2 is a cross sectional representation of a typical two aperture transducer; 
     FIGS. 3A,  3 B and  3 C are representations of the electrode layer, insulating layer and connector layer or a typical three aperture transducer; 
     FIG. 4 is a cross sectional illustration of a typical via; 
     FIG. 5A is a cross sectional illustration of a connection assembly of the present invention; 
     FIG. 5B is a diagrammatic cross section view of the connection assembly of the present invention illustrating the manufacture of the connection of flex leads to the segments of a transducer; 
     FIG. 6 is a diagrammatic view of a connection assembly of the present invention with scribing lines and dicing lines and conductor paths; and, 
     FIGS. 7A,  7 B,  7 C and  7 D are diagrammatic representations of the elements, isolating layer, scribed conductive layer and assembled connection assembly of the present invention. 
    
    
     DETAILED DESCRIPTION 
     The following will first describe the general construction of multi-aperture transducers, and in particular a typical construction of the circuitry layers bonded to the back, or non-radiating and receiving side, of the transducer elements to provide connections between the transducer element segments and the transmit/receive circuitry associated with the transducer. The present invention will then be described in detail, thereby clearly illustrating the differences between the connection circuitry of the present invention and the connection circuitry generally used in transducers. 
     A. General Description of a Multi-Aperture Transducer with Multi-Layer Backplane Interconnections (FIGS.  1 A,  1 B,  2  and  3 A- 3 C and  4 ) 
     Referring to FIG. 1A, therein is shown a diagrammatic representation of a single piezoelectric Element  10  of an exemplary two aperture Transducer  12  and, in outline form, two adjacent Elements  10  of the array of Elements  10  comprising the transmit/receive array of the transducer. As indicated therein, the construction of the transducer as a two aperture transducer requires that each piezoelectric Element  10  be divided into three piezoelectric segments comprised of a single Middle Segment (MS)  14  and two Outer Segments (OSs)  16 . As represented, Middle Segment (MS)  14  is connected through a Circuit Lead  18  to a First Transmit/Receive Circuit (TRC)  20  to form the transmit/receive element of a first aperture and Outer Segments (OSs)  16  are interconnected by an Interconnect Lead  22  to form a single unit to together form the transmit/receive element of the second aperture, and are thereafter connected through a Circuit Lead  24  to a Second Transmit/Receive Circuit (TRC)  26 . In alternate embodiments, Second Transmit/Receive Circuit (TRC)  26  may be replaced by a switch which selectively connects either Middle Segment (MS)  14  or the two Outer Segments (OSs)  16  to the single First Transmit/Receive Circuit (TRC)  20 . It will be noted, as is well understood in the art, that all Elements  10  of the transducer are constructed and interconnected in the same manner as illustrated for the single Element  10  in FIG.  1 A and that the Elements  10  will each have a connection to signal and power ground as indicated in FIG. 1A, usually as a common connection shared by all Elements  10 . 
     It will be recognized by those of ordinary skill in the arts that the element construction and segment connections and interconnections illustrated in FIG. 1A may be extended at will to transducers having larger numbers of apertures. For example, FIG. 1B illustrates a piezoelectric Element  10  of a four aperture transducer. In this transducer, Middle Segment (MS)  14  comprises the transmitting/receiving element for a first aperture, first Outer Segments (OSs)  16 A are interconnected to form the transmit/receive element of a second aperture, second Outer Segments (OSs)  16 B are interconnected to form the transmit/receive element of a third aperture, and third Outer Segments (OSs)  16 C are interconnected to form the transmit/receive element of a fourth aperture. This construction may be expanded indefinitely, adding successive pairs of Outer Segments (OSs)  16  with the Middle Segment (MS)  14  forming one aperture and each successive pair of Outer Segments (OSs)  16  located symmetrically outwards from Middle Segment (MS)  14  forming additional apertures. Again, Middle Segment (MS)  14  and Outer Segments (OSs)  16  will further have a connection to ground. 
     As represented in the cross section of Transducer  12  illustrated in FIG. 2, the segment interconnections and connections of the exemplary transducer shown therein are typically formed in a multi-layered Connection Assembly  28  that is comprised of an Electrode Layer  30 , an Insulating Layer  32  and a Connector Layer  34  wherein Electrode Layer  30  and Connector Layer  34  may typically be formed of thick or thin film circuits or of flexible circuits. It will be recognized by those of skill in the arts that, although Insulating Layer  32  and Connector Layer  34  are represented in FIG. 2 as single layers for simplicity and clarity of representation and discussion, Insulating Layer  32  and Connector Layer  34  may each or both be comprised of multiple layers and that the layers of Insulating Layer  32  and Connector Layer  34  may be interleaved as necessary to isolate Connection Layers  34  from one another and from Electrode Layer  30 . 
     Electrode Layer  30  is a conductive layer typically comprised of gold with underlying layers of one or more other metals to promote adhesion and defines the electrode areas for the apertures, that is, the connections to the piezoelectric Segments  16  and  14  to form the transmit/receive elements of Transducer  12 . Insulating Layer  32 , in turn, may typically be comprised of such materials as polymide, silica, and a variety of other oxides, nitrides and polymers and insulates Electrode Layer  30  from Connector Layer  34 . Connector Layer  34 , in turn, is typically comprised of another layer of conductive metal or metals similar to Electrode Layer  30  and provides the necessary conductive paths between the electrodes of Electrode Layer  30  to selectively interconnect the piezoelectric segments to form the transmit/receive elements of the apertures, such as between two Outer Segments (OSs)  14 A, and between the Middle Segment-(MS)  12  and Outer Segments (OSs)  14 . Connector Layer  34  also provides the conductive paths necessary to connected the piezoelectric segments of each of the apertures to the Flex Circuits  56   b  connecting to the Transmit/Receive Circuit (TRC)s  20 ,  26 . Connection Assembly  28  typically has a total acoustic thickness of approximately 5 to 10 microns, and thereby does not adversely affect the acoustic characteristics of the transducer assembly. As will be described further below, the electrode areas of Electrode Layer  30  are selectively connected to the connection paths of Connector Layer  34  through conductive paths, referred to as “vias” running between Electrode Layer  30  and Connector Layer  34  through Insulating Layer  32 . 
     Lastly, it will be noted that, as described above, Middle Segment (MS)  14  and Outer Segments (OSs)  16  will have connections to ground, often implemented as a common connection that is shared by all Segments  14 , 16  and that is connected to the faces of Segments  14 , 16  opposite the faces connecting to Electrode Layer  30 . A common method for implementing this ground connection is through a ground plane that may be implemented, for example, as a layer on the faces of Segments  14 , 16  opposite Connection Assembly  28  with the ground layer extending to the edges of Elements  10  for connection to ground. It will be noted that these ground connections are not explicitly illustrated or shown in the following descriptions or the figures referred to therein, for purposes of clarity of presentation and discussion, but are present and, as well understood by those of ordinary skill in the relevant arts, may be implemented using the methods just discussed and other analogous methods. 
     The construction of a Connection Assembly  28  with the three layers thereof is further illustrated in FIGS. 3A through 3C with the Electrode Layer  30 , Insulating Layer  32  and Connector Layer  34  of the Connection Assembly  28  viewed from the “bottom” or “back” side, that is, as viewed from the side of the piezoelectric transducer elements to which the Connection Assembly  28  is bonded. FIGS. 3A through 3C illustrate a three aperture Transducer  12  having five segments, the exemplary transducer shown in FIGS,  3 A through  3 C having been expanded from the two aperture transducer of FIG. 2 to more thoroughly illustrate the connections and conductive paths of Electrode Layer  30 , Insulating Layer  32  and Connector Layer. It will be understood that the components of Construction Assembly  28  as illustrated in FIGS. 3A through 3C and in the following text illustrate the structure and construction of each component thereof in the area of and under a single Element  10  of the exemplary three aperture Transducer  12  and that this structure and construction will be repeated as a single continuous structure extending under each Element  10  of the Transducer  12  and for the entire length of the array comprised of the Elements  10 . 
     The segments of the three aperture Transducer  12  shown in FIGS. 3A through 3C are designated as Segments  36 A through  36 E wherein Segments  36 A and  36 E correspond generally to Outer Segments  16  of FIG.  1 A and Segment  36 C corresponds generally to Middle Segment  14  while Segments  36 B and  36 D are located between Outer Segments  16  and Middle Segment  14  and to either side of Middle Segment  14 . It will be understood that a first aperture is formed by Segment  36 C, a second aperture by Segments  36 B and D and the third aperture by Segments  36 A and  16 E. It will also thereby be understood that the second aperture is formed by connecting together Segments  36 B and  36 D into a first electrical unit and the third aperture by connecting together Segments  36 A and  36 E into a second electrical unit. 
     FIG. 3A illustrates the Electrode Layer  30  of the Connection Assembly  28  and it is shown therein that Electrode Layer  30  includes conductive electrode area under and corresponding to each of Segments  36 A through  36 E. These electrode areas are respectively designated as Electrode Areas  38 A through  38 E and each electrically connect or bond to the corresponding ones of Segments  36 A through  36 E, thereby establishing separate electrical connections to the segments of the Element  10 . Insulating Layer  32 , in turn, is shown in FIG.  3 B and it will be seen therein that Insulating Layer  32  generally covers Electrode Areas  38 A through  38 E, thereby insulating Electrode Areas  38 A through  38 E from the conductive paths of Connector Layer  34 . 
     As shown in FIG. 3C, Connector Layer  34 , in turn, is comprised of conductive Via Areas  40 A through  40 E, each of which corresponds to one of Electrode Areas  38 A through  38 E, a first Aperture Path  42 A running from Via Area  40 A, and thus from Segment  36 A, to the edge of Element  10 , a second Aperture Path  42 B connecting to Via Areas  40 B and  40 D, and thus to Segments  36 B and  36 D, and running to the edge of Element  10 , and a third Aperture Path  42 C is connected to Via Area  40 C and thus to Segments  36 C and runs to the edge of Element  10 . Finally, a fourth Aperture Path  42 D is connecting to Via Area  40 E and thus to Segment  36 E and runs to the edge of Element  10 , with Aperture Paths  42 A and  42 D being connected together through the flex wiring external to the transducer to form the aperture comprised of Segments  36 A and  38 E. 
     Finally, each of Electrode Areas  38 A through  38 E is connected to the corresponding one of Via Areas  40 A through  40 E, thereby interconnecting Segments  36  into the three apertures and to the flex leads to the transmit/receive electronics, by corresponding Vias  44 A through  44 E wherein each Via  44  is a conductive path running between Electrode Layer  30  and Connector Layer  34 . 
     As is well known in the art, and as is generically illustrated in FIG. 4, a Via  44  formed in a three layer connection assembly that includes an Electrode Layer  30 , an Insulating Layer  32  and a Connector Layer  34  is generally constructed by drilling an opening or Hole  46 A between the two conductive layers of the Connection Assembly  28 , that is, between the Electrode Layer  30  and the Connector Layer  34 , wherein the Hole  46 A forms a conductive path between the two conductive layers by means of a layer of Conductive Material  46 B deposited on the inner surface of the Hole  46 A by any of a variety of commonly employed techniques. 
     It will be appreciated by those of ordinary skill in the relevant arts that the reliable manufacture of three layer Connection Assemblies  28  comprised of an Electrode Layer  30 , an Insulating Layer  32  and a Connector Layer  34  with such vias can be difficult. It will also be apparent to those of ordinary skill in the relevant arts that the reliable manufacture of connection assemblies with vias is significantly easier using the methods of the present invention as described below. 
     B. Detailed Description of a Preferred Embodiment (FIGS.  5 ,  6  and  7 ) 
     Having described the general construction of a typical Connection Assembly  28 , the following will now describe a Connection Assembly  28  according to the present invention. 
     Referring to FIG. 5A, therein is illustrated a side sectional view of a Connection Assembly  48  of the present invention. As illustrated therein, and according to the present invention, all three layers of the Connection Assembly  28  described above, that is, Electrode Layer  30 , Insulating Layer  32  and Connector Layer  34 , are replaced with a single Isolating Layer  50  and a single Conductive Layer  54  wherein Isolating Layer  50  is provided with Via Openings  52  therethrough in locations corresponding, for example, to the Vias  44  illustrated in FIGS. 3A through 3C. Conductive Layer  54  is deposited on the lower surface of Isolating Layer  50 , that is, on the side of Isolating Layer  50  opposite Segments  36  of the Elements  10 , and completely covers the lower surface of Isolating Layer  50 , the inner surfaces of Via Openings  54  and the portions of the lower surfaces of Segments  36  of Elements  10  that are exposed through Via Openings  54 . 
     It may therefore be seen that the single Conductive Layer  54  thereby provides both the conductive paths formerly provided by Connector Layer  34  and the connections between the conductive paths and the Elements  10  formerly provided by the Vias  44  of the three layer Connection Assembly  28  illustrated in FIGS. 1 through 4, while the material of Elements  10  itself provided the connections formerly provided by Electrode Layer  30 . It may also be seen that the single Isolating Layer  50  performs all of the functions previously performed by Insulating Layer  32  of the three layer Connection Assembly  28  illustrated in FIGS. 1 through 4. 
     As will be described further below, the area of Conductive Layer  54  on the lower surface of Isolating Layer  50  is then scribed, for example, by a scribing laser, to separate areas of the area of Conductive Layer  54  on the lower surface of Isolating Layer  50  into conductive paths interconnecting the Segments  36  into apertures. 
     In addition to replacing the Electrode Layer  30 , Insulating Layer  32  and Connector Layer  34  of the Connection Assembly  28  discussed above, the single Isolating Layer  50  and Conductive Layer  54  also provides the connections between the apertures, that is, Segments  36 , and Flex Leads  56  that were previously made through extensions to the Connector Layer  34 , referred to as “tab areas”, which were used to provide areas outside of the segments wherein the Flex Leads  56  could be connected to the Connector Layer  34  in the three layer Connection Assembly  28  comprised of an Electrode Layer  30 , Insulating Layer  50  and Conductive Layer  54 . 
     According to the present invention, and as illustrated in FIG. 5B, Flex Leads  56   a  are assembled so that the surface of the Flex Circuit  56   b  having Flex Leads  56   a  is coplanar with the lower surface of Elements  10 . Isolating Layer  50  and Conductive Layer  54  are then deposited upon the Flex Circuit  56   b  having Flex Leads  56   a  in the same process in which Isolating Layer  50  and Conductive Layer  54  are deposited on Elements  10  and as continuous layers with the areas of Isolating Layer  50  and Conductive Layer  54  residing on Elements  10 . The areas of Isolating Layer  50  and Conductive Layer  54  deposited on the Flex Circuit  56   b , identified as Flex Connect Areas  58 , include Via Openings  52 , in the manner described above, for connecting Conductive Layer  54  to Flex Leads  56   a . The Flex Connect Areas  58  of Conductive Layer  54  are scribed in the same process in which the portion of Conductive Layer  54  on the lower surface of Elements  10  is scribed to form the conductive leads between Segments  36  and Flex Leads  56   a . As described further below, the Flex Circuits  56   b  having Flex Leads  56   a  and the associated areas of Isolating Layer  50  and Conductive Layer  54 , including Flex Connect Areas  58 , are subsequently diced in the same process in which Elements  10  are diced into Segments  36 . Then, and as illustrated in FIG. 5C, the Flex Circuits  56   b  having Flex Leads  56   a  are bent “downwards” to connect to the circuitry driving Segments  36 . As a consequence, the connections between Segments  36  and Flex Leads  56   a  are accomplished at the same time and in the same processes as the connections to and between Segments  36 , thereby further reducing the complexity and costs of manufacturing the transducer. 
     According to the present invention, therefore, Isolating Layer  50  performs the general functions performed by Insulating Layer  32  as illustrated in FIGS. 2 and 3A through  3 C, but Conductive Layer  54  now performs all of the functions previously performed by Electrode Areas  38 , Vias  44 , Via Areas  40 , Aperture Paths  42  and Tab Areas  58 . In particular, it will be noted that the “bottoms” of Via Openings  52  are, in fact, areas of the lower surfaces of the Segments  36  of the Elements  10  so that the areas of Conductive Layer  54  that are plated or deposited thereupon make electrical contact and connection with Segments  36  and serve the function previously served by Electrode Areas  38 . Conductive Layer  54  further extends from the “bottoms” of Via Openings  52  and “up” the inner surfaces of Via Openings  52  to continue on the lower surface of Isolating Layer  50 , thereby serving the function previously served by Vias  44 . Finally, and as described, the conductive paths cut or etched into the area of Conductive Layer  54  on the lower surface of Isolating Layer  50  serve the functions previously served by Via Areas  40  and Aperture Paths  42 . 
     Referring now to FIG. 6, therein is illustrated a bottom view of a section of an Isolating Layer  50  with Conductive Layer  54 , that is, a view from the side having Conductive Layer  50 , for a three aperture transducer and showing four Elements  10  wherein each Element  10  is comprised of five Segments  36 . The view presented therein is represented as if Isolating Layer  50  and Conductive Layer  54  were transparent, so as to clearly illustrated the relationships between the elements to be described in the following. It will be understood, however, that Isolating Layer  50  and Conductive Layer  54  are to be understood to be present in FIG.  6 . 
     Assembly of the transducer begins with the bonding of Isolating Layer  50  to the lower surface of the block or blocks of piezoelectric material that will form Elements  10  and Segments  36 . It will be understood that, at this time, there may be a separate block of piezoelectric material for each row of Segments  36 , or that a single block of piezoelectric material may be cut longitudinally into separate blocks corresponding to the rows of Segments  36 . 
     At this point in the process, Isolating layer  50  will be a single, smooth, continuous sheet of dielectric or insulating material, such as polymide, having a thickness in the range of range of 0.5 microns to 20 microns and having a width and length corresponding to the length and width of the Elements  10  of the transducer with the areas for establishing connections to Flex Leads  56   a . In the present example, the transducer has 128 Elements  10 , each being comprised of 5 segments, and a total length and width of 12 mm (millimeter) by 0.17 mm; each Segment  36  is approximately 2.4 mm by 0.17 mm and each Element  10  is separated from the adjacent Elements  10  by 0.035 mm while the Segments  36  in each Element  10  are separated by approximately 0.035 mm and the areas for connection to Flex Leads  56   a  are approximately 0.050 mm wide. 
     An opening will then be drilled through Isolating Layer  50 , for example, by use of a laser, at the location of each Via Opening  52 , thereby forming Via Openings  52 , wherein Via Openings  52  may have a diameter in the range of 25 microns, approximately 0.001 inch, with the piezoelectric material of the Segments  36  exposed in the bottoms of the Via Openings  52  serving in replacement of Electrode Areas  38  of the three layer Connection Assembly  28  illustrated in FIGS. 1 through 4. 
     Conductive Layer  54  will then be deposited onto Isolating Layer  50 , and into Via Openings  53 , preferably by a sputtering technique. Conductive layer  54  may, for example, be comprised of gold, will have a thickness in the range of 100 Angstroms to 20,000 Angstroms, and will generally cover the entire surface of Isolating Layer  50 , including the interior surfaces and bottoms of Via Openings  52   
     It will be appreciated from the above description of the present invention that, at this time and before scribing, Conducive Layer  54  will present an smooth, flat, continuous plane of conductive material bonded to Isolating Layer  50 , the only surface feature being possible slight depressions at Via Openings  52 . 
     The material of Conductive Layer  54  is then scribed or cut away, again for example using a laser scribing tool, along Scribing Lines  60  as illustrated in FIG. 6 to divide Conductive Layer  54  within the area of each Element  10 , that is, within the area of the Segments  36  of each Element  10 , into conductive paths interconnecting the Segments  36  of each Element  10  and connecting the Segments  36  to Flex Leads  56   a . In the present implementation of the invention, the width of Scribing Lines  60  is in the range of 12 microns, that is, 0.0005 inch. 
     The piezoelectric material, Isolating Layer  50  and Conductive Layer  54  are then sliced, or “diced”, along the Dicing Line  62  between each column of Segments  36  forming an Element  10 , that is, between Elements  10 , to divide the piezoelectric material into Elements  10  and, at the same time, separating the conductive paths formed in Conductive Layer  54  for the Segments  36  of each Element  10  from the conductive paths formed for the Segments  36  of the adjacent Elements  10 . It will be noted that Scribing Lines  60  and Via Openings  52  are set inwards from the edges of Segments  36 , that is, from Dicing Lines  62 , by approximately 35 microns, that is, 0.0014 inch, in the present implementation, to avoid interference between Scribing Lines  60  and Via Openings  52  and the dicing cuts. 
     A study of FIG. 6 will show that the conductive paths formed by scribed and diced Conductive Layer  54  at this point forms the connections described above to construct a three aperture transducer array wherein each Element  10  is comprised of five Segments  36 . That is, and as described previously, in each Element  10  a first aperture is formed by Segment  36 C, which has a Conductive Layer  54  path to a connection to a Flex Lead  56   a , a second aperture is formed by Segments  36 B and  36 D, which are connected together and to a Flex Lead  56   a  by another Conductive Layer  54  path, and the third aperture is formed by Segments  36 A and  16 E, which are connected together and to a Flex Lead  56   a  by another Conductive Layer  54  path. 
     Referring finally to FIGS. 7A,  7 B,  7 C and  7 D, therein is represented the Segments  36  with Isolating Layer  50  and Conductive Layer  54  after cutting of Scribing Lines  60  and Dicing Lines  62  for an 128 element,  3  aperture transducer. FIG. 7A shows the array of Elements  10  comprised of Segments  36  while FIG. 7B shows Isolating Layer  50  with Via Openings  52  and FIG. 7C shows Conductive Layer  54  with Scribing Lines  60 . Finally, FIG. 7D shows the complete assembly of Segments  36 , Isolating Layer  50  and Conductive Layer  54  after Conductive Layer  54  has been scribed and the assembly has been diced. 
     It therefore apparent from the above that Isolating Layer  50  and the scribed Conductive Layer  54  together comprise an acoustically thin layer forming an essentially flat surface having few or no acoustically significant voids or discontinuities. As a result, the Connection Assembly  48  comprised of Isolating Layer  50  and the scribed Conductive Layer  54  does not interfere with or degrade the acoustic characteristics of the transducer. In addition, it is apparent that a Connection Assembly  48  comprised of an Isolating Layer  50  and a scribed Conductive Layer  54  may be constructed through significantly simpler processes than the multiple layer connection assemblies of the prior art, and at significantly decreased manufacturing costs. In addition, a transducer utilizing the Connection Assembly  48  of the present invention may be manufactured entirely with “dry” processes, thereby eliminating or avoiding the use of “wet” processes and potentially hazardous materials. 
     Lastly, while the invention has been particularly shown and described with reference to preferred embodiments of the apparatus and methods thereof, it will be also understood by those of ordinary skill in the art that various changes, variations and modifications in form, details and implementation may be made therein, as has been discussed herein above, without departing from the spirit and scope of the invention as defined by the appended claims. For example, the number, proportions, dimensions, arrangement and spacing of segments and elements in a transducer may vary widely, as may the number and arrangement of the apertures of the transducer, and the segments and elements need not be of uniform dimensions. Likewise, the materials and dimensions of the isolating and conductive layers and the vias and paths scribed into the conductive layer may vary, and there may be multiple isolating and conductive layers, depending, for example, on the connections to be made to and between the segments. Further, the conductive paths of each element may be separated from the conductive paths of the other elements by scribing, instead of by the dicing cut. In addition, the isolating layer as well as the conductive layer may be deposited, and formed from materials suitable to the functions of the layers, such as polymide, polyester, copper, gold, graphite, and so on, or the isolating layer or the conductive layer, or both, may be plated layers using “wet” processes, if necessary or, in certain circumstances, desirable. Further, electrostrictive materials may be used in place of piezoelectric materials, with corresponding changes in the connections provided through the vias and conductive layer. Therefore, it is the object of the appended claims to cover all such variations and modifications of the invention as come within the true spirit and scope of the invention.