Abstract:
An ultrasonic transducer includes a piezoelectric layer for generating an ultrasonic by using a power received from outside, a ground electrode attached to a first surface of the piezoelectric layer, a signal electrode attached to a second surface of the piezoelectric layer, and circuit boards connected to the ground electrode and the signal electrode. A part of the ground electrode and a part of the signal electrode are directly connected to the circuit boards, each of the ground electrode and the signal electrode includes flexible material, and the circuit boards include rigid material. The circuit boards may be provided on both sides of the ground electrode and the signal electrode. This structure provides a direct connection of the ground electrode or the signal electrode and the circuit boards to improve issues of cost increase for manufacturing socket connector ultrasonic transducers socket volume increase, socket designing challenges and socket failures.

Description:
TECHNICAL FIELD 
       [0001]    The present disclosure, in some embodiments, relates to an ultrasonic transducer, and more particularly, to an ultrasonic transducer which improves issues with socket connector transducers, such as manufacturing cost increase, socket volume increase, socket designing challenges and socket failures. 
       BACKGROUND 
       [0002]    The statements in this section merely provide background information related to the present disclosure and do not necessarily constitute prior art. 
         [0003]    An ultrasonic transducer is a device for transmitting an ultrasonic signal to a treatment region and receiving an ultrasonic echo signal reflected from the treatment region, to acquire an ultrasonic image of the treatment region. 
         [0004]    The ultrasonic transducer is applicable to various industry fields. In particular, the ultrasonic transducer can be mainly used in the medical apparatus field such as an ultrasonic diagnosis apparatus that acquires a tomographic image of a soft tissue or an image of blood flow in a noninvasive manner by transmitting an ultrasonic signal from a body surface of a target object to a treatment region inside the body and receiving an echo signal reflected from the treatment region. 
         [0005]    The principle of transmitting and receiving the ultrasonic by the transducer is to utilize the characteristics of a piezoelectric member. The piezoelectric member is material that converts electrical energy into mechanical energy and vice versa. For example, a piezoelectric member in an ultrasonic transducer is formed with top and bottom electrodes and is applied therethrough with electric power, when it serves to oscillate and interconvert an electrical signal and an acoustic signal. 
         [0006]      FIGS. 1 and 2  are partial schematic diagrams of a typical ultrasonic transducer. 
         [0007]    The ultrasonic transducer generally includes a body  100  for transmitting an ultrasonic wave or receiving an image signal that is back-reflected from the treatment region, an electrode assembly  130  connected to the body  100 , and a circuit board  110  for processing power or image. 
         [0008]    The electrode assembly  130  and the circuit board  110  are electrically connected to each other with a connection socket  120 . However, the structure in which the electrode assembly  130  and the circuit board  110  are interconnected with the connection socket  120  causes a substantial cost increase in manufacturing the connection socket  120  and for attaching the connection socket  120  to the electrode assembly  130 . 
         [0009]    Further, with this structure, an ultrasonic transducer with a plurality of piezoelectric members installed needs to have a channel for the electrode assembly  130  to electrically connect to each of the piezoelectric members, and hence, more piezoelectric members installed lead to more voluminous socket and more complicated socket design. 
         [0010]    In addition, the socket connection structure may cause a contact failure leading to an error in an electrical signal or an image signal. 
       DISCLOSURE 
     Technical Problem 
       [0011]    Therefore, the present disclosure has been made in view of the above aspects, and it is an object of at least one embodiment of the present disclosure to provide an ultrasonic transducer which improves issues with socket connector transducers, such as manufacturing cost increase, socket volume increase, socket designing challenges and socket failures, and a method for manufacturing the ultrasonic transducer. 
         [0012]    The technical problem to be solved by the present disclosure is not limited to the above-mentioned, and other technical problems addressed not mentioned herein can be clearly understood by one of ordinary skill in the pertinent art from the following descriptions. 
       SUMMARY 
       [0013]    According to some embodiments, an ultrasonic transducer includes a piezoelectric layer configured to generate an ultrasonic by using a power received from outside, a ground electrode configured to be attached to a first surface of the piezoelectric layer, a signal electrode configured to be attached to a second surface of the piezoelectric layer, and at least one circuit board configured to be connected to the ground electrode and the signal electrode. A part of the ground electrode and a part of the signal electrode are directly connected to the circuit board, each of the ground electrode and the signal electrode includes flexible material, and the circuit board includes rigid material. 
         [0014]    According to another embodiment, an ultrasonic transducer includes a ground electrode configured to be grounded, a signal electrode configured to transfer a signal, a piezoelectric layer configured to be inserted between the ground electrode and the signal electrode, including piezoelectric material, and configured to generate an ultrasonic, at least one circuit board configured to insert each side of the ground electrode and the signal electrode therein, to be integrated with the ground electrode and the signal electrode, and a connector configured to be coupled with the circuit board and to electrically connect the circuit board with a body connecting unit installed between a main body of an ultrasonic diagnosis apparatus and the circuit board. Here, the ground electrode or the signal electrode includes a perforated portion where the piezoelectric layer is to be attached. The ground electrode or the signal electrode includes a plurality of signal channels electrically connected to the body connecting unit. 
         [0015]    According to yet another embodiment, a method for manufacturing an ultrasonic transducer includes manufacturing a ground electrode and a signal electrode each including flexible material, attaching at least one circuit board laterally on both opposite sides of the ground electrode and the signal electrode, and fixedly inserting a piezoelectric layer between and centrally of the ground electrode and the signal electrode. The fixedly inserting of the piezoelectric layer includes forming a plurality of perforations on the ground electrode or the signal electrode where the piezoelectric layer is to be attached, and infusing an adhesive in the perforations. 
       Advantageous Effects 
       [0016]    According to the present disclosure as described above, an ultrasonic transducer and the method of manufacturing the ultrasonic transducer according to some embodiments provide a direct connection of a ground electrode or a signal electrode and a circuit board, and hence improves the issues with socket connector transducers, such as manufacturing cost increase, socket volume increase, socket designing challenges and socket failures. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0017]      FIGS. 1 and 2  are partial schematic diagrams of a typical ultrasonic transducer. 
           [0018]      FIG. 3  is a partial perspective view of an ultrasonic transducer according to some embodiments of the present disclosure. 
           [0019]      FIG. 4  is a side view of an ultrasonic transducer according to some embodiments of the present disclosure. 
           [0020]      FIG. 5  is a flowchart of a method for manufacturing an ultrasonic transducer according to according to some embodiments of the present disclosure. 
       
    
    
     REFERENCE NUMERALS 
       [0021]      
         [0000]    
       
         
               
               
               
             
           
               
                   
                   
               
             
             
               
                   
                 100: Body 
                 110: Circuit Board 
               
               
                   
                 120: Connection Socket 
                 130: Electrode Assembly 
               
               
                   
                 310: Piezoelectric Layer 
                 320: Ground Electrode 
               
               
                   
                 321: Perforated Portion 
                 322: Perforation 
               
               
                   
                 330: Signal Electrode 
                 340: Circuit Board 
               
               
                   
                 341: Upper Board Portion 
                 342: Lower Board Portion 
               
               
                   
                 343: Integrated Circuit 
                 410: Acoustic Lens 
               
               
                   
                 420: Matching Layer 
                 430: Sound-absorbing Layer 
               
               
                   
                 440: Body Coupler 
                 450: Connector 
               
               
                   
                   
               
             
          
         
       
     
       DETAILED DESCRIPTION 
       [0022]    Hereinafter, at least one embodiment of the present disclosure will be described in detail with reference to the accompanying drawings. The present disclosure contemplates various changes and modifications to be made, although they are illustrated through some exemplary embodiments. The present disclosure should not be limited to these embodiments but various changes and modifications are made by one ordinarily skilled in the art within the subject matter, the idea and scope of the present disclosure as hereinafter claimed. In the following description, like reference numerals designate like elements, although the elements are shown in different drawings. In the accompanying drawings, structures are exaggerated to emphasize some embodiments of the disclosure or reduced to facilitate the comprehension thereof. 
         [0023]    Terms such as first and second, which may be used to describe various components, should not be interpreted as limiting said components. The above terms are used only to distinguish one of the components from the others. For example, and without departing from the scope of the present disclosure, the first component can be designated as the second component, and vice versa. On the other hand, unless defined otherwise, all terms, including technical or scientific terms used herein have the same meaning as are generally understood by persons of skill in the art to which this disclosure pertains. The terms, such as those commonly used as in lexical definition, should be interpreted as having a meaning consistent with the meaning that has the context of the relevant art, and unless expressly defined in this application, they shall not be interpreted too ideally or impractically unless the present disclosure expressly defines them so. 
         [0024]      FIG. 3  is a partial perspective view of an ultrasonic transducer according to some embodiments of the present disclosure. 
         [0025]    A piezoelectric layer  310  generates an ultrasonic by using a piezoelectric effect, and the ultrasonic generated by the piezoelectric layer  310  is emitted through an acoustic lens  410  (see  FIG. 4 ). In some embodiments, the piezoelectric layer  310  has a single-layer structure, and in some embodiments, the piezoelectric layer  310  has a multilayer structure including a plurality of laminated piezoelectric layers  310 . 
         [0026]    A ground electrode  320  is attached to a first surface of the piezoelectric layer  310 , and a signal electrode  330  is attached to a second surface of the piezoelectric layer  310 . The signal electrode  330  is a pathway for inputting a power for generating the ultrasonic to the piezoelectric layer  310 , and at the same time, it transfers an image signal on a treatment region, which is obtained from an ultrasonic back-reflected to the piezoelectric layer  310 , to a main body (not shown) of an ultrasonic treatment apparatus. 
         [0027]    The ground electrode  320  and the signal electrode  330  are integrations of channels respectively connected to a plurality of piezoelectric members included in the piezoelectric layer  310 , and each of the channels is a pathway for transferring the power or the image signal. 
         [0028]    The ground electrode  320  and the signal electrode  330  are directly connected to at least one circuit board  340  with the above-mentioned structure, which eliminates the connection socket shown in  FIGS. 1 and 2 . 
         [0029]    Various modes can be used for inserting the ground electrode  320  and the signal electrode  330  into the circuit board  340 . In some embodiments, the ground electrode  320  and the signal electrode  330  are first laminated on a lower board portion  342 , and an upper board portion  341  is subsequently laminated on top. 
         [0030]    A process of integrating the circuit board  340 , the ground electrode  320 , and the signal electrode  330  in the above laminating manner is as follows. 
         [0031]    In some embodiments, solidified resin films are respectively arranged between the lower board portion  342  and the signal electrode  330 , between the upper board portion  341  and the ground electrode  320 , and between the ground electrode  320  and the signal electrode  330 , followed by heating and pressurizing the laminated structure of the lower board portion  342 , the ground electrode  320 , the signal electrode  330 , and the upper board portion  341 . Each of the resin films is then melted and works as an adhesive. Thereafter, the resin films are cured to firmly integrate the lower board portion  342 , the ground electrode  320 , the signal electrode  330 , and the upper board portion  341 , when the pressure is released to complete the process of attaching the laminated structure. In some embodiments, a liquid adhesive is applied by using a spray, a brush, or the like on a top surface of the lower board portion  342 , one surface or both surfaces of the ground electrode  320  and the signal electrode  330 , and a bottom surface of the upper board portion  341 , and then a pressure is applied to the laminated structure. When the liquid adhesive is cured to firmly integrate the lower board portion  342 , the ground electrode  320 , the signal electrode  330 , and the upper board portion  341 , the pressure is released to complete the process of attaching the laminated structure. Attaching the laminated structure by using the liquid adhesive is advantageous over the case of using the resin film in that it dispenses with a separate heating device. On the other hand, the case of using the resin film is advantageous over using the liquid adhesive in that it dispenses with a separate process of applying the adhesive. 
         [0032]    The circuit board  340  includes various integrated circuits  343  for processing a power and a signal, and hence it is formed with solid material. However, the ground electrode  320  and the signal electrode  330  are formed with flexible material. Therefore, the ground electrode  320  and the signal electrode  330  are coupled centrally with the solid piezoelectric layer  310  and laterally with the solid circuit board  340  to make the assembly rigid at the center and opposite side portions but flexibly bendable where the piezoelectric layer  310  and the circuit board  340  border each other. 
         [0033]    In some embodiments, a method for coupling the piezoelectric layer  310  between the ground electrode  320  and the signal electrode  330  is as follows. 
         [0034]    In some embodiments, the ground electrode  320  and a first surface of the piezoelectric layer  310  are arranged facing each other and the signal electrode  330  and a second surface of the piezoelectric layer  310  are arranged facing each other, and a perforated portion  321  including a plurality of perforations  322  is formed on each of the ground electrode  320  and the signal electrode  330 . An electrically conductive adhesive is infused into each of the perforations  322 , such that the infused electrically conductive adhesive couples the ground electrode  320  and the piezoelectric layer  310  and couples the signal electrode  330  and the piezoelectric layer  310 . The plurality of perforations  322  is formed at portions of the ground electrode  320  and the signal electrode  330  in which the piezoelectric layer  310  is fixedly inserted, and the adhesive is infused into the perforations  322 , thus attaching the piezoelectric layer  310  between the ground electrode  320  and the signal electrode  330 . 
         [0035]    The perforated portion  321  and the perforations  322  according to some embodiments are shown in  FIG. 3 . Each perforated portion  321  is formed in a manner that the plurality of perforations  322  is arranged at regular intervals in an X-axis direction and a Y-axis direction at the attachment sites of the ground electrode  320  and the piezoelectric layer  310  and at the attachment sites of the signal electrode  330  and the piezoelectric layer  310 . The adhesive penetrates onto the surfaces of the piezoelectric layer  310  through each of the perforations  322 , is dispersed around each of the perforations  322 , where the piezoelectric layer  310  is coupled with the piezoelectric layer  310  and the signal electrode  330 , respectively. 
         [0036]    In the above-mentioned mode, the perforations  322  are formed at regular intervals, and the adhesive penetrates through each of the perforations  322 , and hence the attachment sites of the ground electrode  320  and the signal electrode  330  with the piezoelectric layer  310  are evenly distributed over the piezoelectric layer  310 , resulting in reduced faulty attachment and thus achieving a solid bonding. 
         [0037]    In some embodiments, an electrically conductive adhesive is applied between the ground electrode  320  and a first surface of the piezoelectric layer  310  and between the signal electrode  330  and a second surface of the piezoelectric layer  310 , and the piezoelectric layer  310  is attached between the ground electrode  320  and the signal electrode  330 . The electrically conductive adhesive is used in portions of the ground electrode  320  and the signal electrode  330  in which the piezoelectric layer  310  is fixedly inserted, thus attaching the piezoelectric layer  310  between the ground electrode  320  and the signal electrode  330 . Depending on the polarity of the piezoelectric layer  310 , the ground electrode  320  and the signal electrode  330  can be arranged in an opposite manner. 
         [0038]    In some embodiments, a combination of above-described two modes may be used for coupling the piezoelectric layer  310  between the ground electrode  320  and the signal electrode  330 . 
         [0039]      FIG. 4  is a side view of an ultrasonic transducer according to some embodiments of the present disclosure. 
         [0040]    A matching layer  420  is arranged at a front end of the piezoelectric layer  310 , and it serves to match an acoustic impedance of the piezoelectric layer  310  with that of a treatment region where the ultrasonic reaches. In some embodiments, the matching layer  420  includes a plurality of layers. The ultrasonic penetrated through the matching layer  420  passes through the acoustic lens  410 , reflected at the treatment region, and then passes through the acoustic lens  410  and the matching layer  420 , to return to the piezoelectric layer  310 . 
         [0041]    A sound-absorbing layer  430  suppresses a free oscillation of the piezoelectric layer  310 , to reduce a pulse width of the ultrasonic, and blocks the ultrasonic from unnecessarily propagating in a backward direction of the piezoelectric layer  310 , to prevent a distortion of an ultrasonic image. 
         [0042]    The circuit board  340  processes a power received from a power source into a power for supplying to the piezoelectric layer  310  for generating an ultrasonic, or processes an image signal received from the piezoelectric layer  310  and transfers the image signal to a main body of an ultrasonic treatment apparatus. 
         [0043]    Both opposite end portions of the ground electrode  320  and the signal electrode  330  respectively attached to the opposite surfaces of the piezoelectric layer  310  are inserted into the circuit board  340 . A connector  450  is coupled with the circuit board  340  in which portions of the ground electrode  320  and the signal electrode  330  are inserted, and the connector  450  is coupled with a body coupler  440 . Therefore, the power or the image signal is transferred between the piezoelectric layer  310  and the main body of the ultrasonic treatment apparatus via the signal electrode  330 , the circuit board  340 , the connector  450 , and the body coupler  440 . 
         [0044]      FIG. 5  is a flowchart of a method for manufacturing an ultrasonic transducer according to according to some embodiments of the present disclosure. 
         [0045]    A method for manufacturing an ultrasonic transducer includes a first step of manufacturing a ground electrode and a signal electrode (step S 510 ), a second step of respectively attaching circuit board laterally to both opposite sides of the ground electrode and the signal electrode (step S 520 ), and a third step of inserting and attaching a piezoelectric layer between and centrally of the ground electrode and the signal electrode (step S 530 ). 
         [0046]    At the first step (step S 510 ), the ground electrode and the signal electrode are manufactured with flexible material, and particularly, the signal electrode is formed with an integration of channels respectively connected to a plurality of piezoelectric members included in the piezoelectric layer. 
         [0047]    At the second step (step S 520 ), various modes can be used as the method for attaching the ground electrode and the signal electrode to the circuit board. In some embodiments, the ground electrode and the signal electrode are laminated on a lower board portion and then an upper board portion is laminated on the stack thereof. This second step enables the ground electrode and the signal electrode to be electrically connected to the circuit board without using a socket, and hence the manufacturing cost can be reduced compared to the connection structure using a socket, and the socket contact problem can be improved. 
         [0048]    As described above, in some embodiments, the third step (step S 530 ) includes a step of forming a plurality of perforations on a portion of the ground electrode or the signal electrode where the piezoelectric layer is fixedly inserted and a step of infusing an adhesive in the perforations. Further, in some embodiments, the third step includes a step of attaching the piezoelectric layer between the ground electrode and the signal electrode by using an electrically conductive adhesive on a portion of the ground electrode or the signal electrode where the piezoelectric layer is inserted and attached. 
         [0049]    Although exemplary embodiments of the present disclosure have been described for illustrative purposes, those skilled in the art will appreciate that unless technically incompatible, they may be combined in various ways in order to implement other further embodiments. 
       CROSS-REFERENCE TO RELATED APPLICATION 
       [0050]    If applicable, this application claims priority under 35 U.S.C §119(a) of Patent Application No. 10-2013-0022070, filed on Feb. 28, 2013 in Korea, the entire content of which is incorporated herein by reference. In addition, this non-provisional application claims priority in countries, other than the U.S., with the same reason based on the Korean patent application, the entire content of which is hereby incorporated by reference.