Patent Description:
<CIT> discloses an ultrasound probe with thermal and drop impact management.

<CIT> discloses an ultrasonic probe capable of emitting heat generated by a transducer outside the ultrasonic probe using a heat radiation plate. The ultrasonic probe includes a transducer configured to generate an ultrasonic wave, a heat spreader provided on a surface of the transducer, the heat spreader being configured to absorb heat generated by the transducer, at least one heat radiation plate which contacts at least one side of the heat spreader, and at least one board installed on the at least one heat radiation plate so as to transfer heat generated by the at least one board to the at least one heat radiation plate.

External ultrasound imaging probes have become indispensable diagnostic tools in modern day medical care due to their non-invasive nature and ever-increasing resolution. In a conventional ultrasound imaging probe, an acoustic stack and printed circuit boards are fixedly secured to an internal frame, which is fixedly secured to a heat spreader and an external housing. All these components have to fit with one another with tight tolerances in order to achieve a high-quality ultrasound imaging probe with an exterior surface that is free of gaps. Gaps, if present, not only are unsightly to customers but also can trap contaminants. What can make things worse is the variation or inconsistency between gaps on a single device or across different devices. While gaps are undesirable, it can be costly and challenging to rid conventional ultrasound imaging probes of them.

Embodiments of the method of the present invention provide a substantially gapless ultrasound imaging probe with large manufacturing tolerance. An exemplary ultrasound probe manufactured according to the present disclosure includes a housing, a chassis, an ultrasound transducer assembly fixedly secured to the chassis, a plurality of heat spreader members positioned around the chassis, and a cable strain relief. The plurality of heat spreader members is movably coupled to the chassis and the cable strain relief. The movable coupling allows the plurality of heat spreader members to move in more than one dimension with respect to the cable strain relief and/or the chassis while a portion of the cable strain relief, the plurality of heat spreader members and the chassis are being enclosed by the housing. Advantageously, the movable coupling allows for manufacture of high-quality external ultrasound probes that have only small exterior seams that have consistent width within a single device and across different devices. A filling material, such as room-temperature-vulcanizing (RTV) rubber, can be positioned in the space between the housing members and/or the heat spread members.

According to an exemplary embodiment, an ultrasound imaging probe is provided. The probe includes an ultrasound transducer assembly configured to obtain imaging data associated with a body of a patient; a chassis fixedly secured to the ultrasound transducer assembly; a plurality of heat spreader members positioned around the chassis and configured to provide a thermal path for heat generated by the ultrasound transducer assembly while obtaining the imaging data, wherein the plurality of heat spreader members is movably coupled to the chassis; and a housing positioned around the plurality of heat spreader members, wherein the plurality of heat spreader members is configured to move relative to the chassis when the housing is positioned around the plurality of heat spreader members.

In some embodiments, the probe further includes a retention clip positioned around proximal ends of the plurality of heat spreader members. In some embodiments, the housing comprises a nosepiece sized and shaped to receive the ultrasound transducer assembly. The plurality of heat spreader members is movably coupled to the chassis by two shoulder screws and the plurality of heat spreader members is configured to move in more than one dimension relative to the chassis. In some embodiments, the ultrasound transducer assembly comprises: a lens; a transducer array; and a backing block. In some embodiments, the probe further includes a plurality of printed circuit boards to the chassis, wherein the plurality of printed circuit boards is in communication with the ultrasound transducer assembly. In some embodiments, the probe further includes a filling material disposed between the housing and the plurality of heat spreader members. In some embodiments, the filling material is formed of a room-temperature-vulcanizing rubber. In some embodiments, the probe further includes a cable strain relief movably coupled to the plurality of heat spreader members, wherein the plurality of heat spreader members is configured to move in more than one dimension relative to the cable strain relief. In some embodiments, the probe further includes an elastic ring member, wherein the cable strain relief comprises a distal lip adjacent a distal end of the cable strain relief and a proximal lip proximal to the distal lip, wherein the distal lip of the cable strain relief is sized and shaped to engage a shoulder defined at proximal portions of the plurality of heat spreader members, and wherein when the distal lip engages the shoulder, the elastic ring member is disposed between the proximal lip and proximal ends of the plurality of heat spreader members. In some embodiments, the elastic ring member is formed of a thermally conductive elastomer. In some embodiments, the probe further includes a thermally-conductive gap pad disposed between the chassis and at least one of the plurality of heat spreader members.

A method of manufacturing an ultrasound imaging probe includes obtaining an ultrasound transducer assembly fixedly secured to a chassis; movably coupling the chassis to a plurality of heat spreader members; and enclosing the plurality of heat spreader members, the chassis and the ultrasound transducer assembly in a housing while moving the plurality of heat spreader members relative to the chassis.

Movably coupling the chassis to the plurality of heat spreader members comprises coupling the chassis to the plurality of heat spreader members by two shoulder screws. In some embodiments, the method further includes coupling a thermally-conductive gap pad to the chassis and/or at least one of the plurality of heat spreader members, such that the thermally-conductive gap pad is positioned between the chassis and the at least one of the plurality of heat spreader members. Moving the plurality of heat spreader members relative to the chassis comprises moving the plurality of heat spreader members about the two shoulder screws in more than one dimension. In some embodiments, the method further includes movably coupling a cable strain relief to proximal ends of the plurality of heat spreader members. In some embodiments, movably coupling the cable strain relief to the proximal ends of the plurality of heat spreader members comprises coupling the cable strain relief to the proximal ends of the two heat spreader halves with an elastic ring member. In some embodiments, enclosing the plurality of heat spreader members, the chassis and the ultrasound transducer assembly in the housing comprises moving the plurality of heat spreader members relative to the cable strain relief. In some embodiments, moving the plurality of heat spreader members relative to the cable strain relief comprises pivoting the plurality of heat spreader members relative to the cable strain relief.

Any alterations and further modifications to the described devices, and any further application of the principles of the present disclosure are fully contemplated and included within the present disclosure as would normally occur to one skilled in the art to which the disclosure relates.

<FIG> is a diagrammatic perspective view of an ultrasound imaging system <NUM>. Ultrasound imaging system <NUM> includes a console <NUM> and an ultrasound imaging probe <NUM>. The ultrasound imaging probe <NUM> is connected to a cable <NUM> that is coupled to a connector <NUM>. The ultrasound imaging probe <NUM> can be brought into communication with the console <NUM> by connecting the connector <NUM> to a connector receptacle <NUM> on the console <NUM>. The console <NUM> includes a control interface <NUM> and a display device <NUM>. In embodiments represented in <FIG>, the console <NUM> can include a plurality of wheels such that the console <NUM> can roll around on the floor.

The probe <NUM> can be sized and shaped, structurally arranged, and/or otherwise configured for handheld use by a user. During use, the ultrasound imaging probe <NUM> can be placed on or near the anatomy of a subject to obtain imaging data. In some instances, the subject can be a patient. In some other instances, the subject can be an animal other than a human being. The ultrasound imaging probe <NUM> may be placed directly on the body of the subject and/or adjacent the body of the subject. For example, the ultrasound imaging probe <NUM> may be put in contact with the body of the subject while obtaining imaging data. In some embodiments, the ultrasound imaging probe <NUM> can include an ultrasound transducer array of a plurality of ultrasound transducer elements configured to obtain imaging data of the patient anatomy.

Electrical signals representative of the imaging data can be transmitted from the ultrasound imaging probe <NUM> to the connector <NUM> along electrical conductors of the cable <NUM>. With the connector <NUM> coupled to the connector receptacle <NUM> on the console <NUM>, the electrical signals can be transmitted to the console <NUM>. The console <NUM> includes one or more processors that can process the electrical signals and output a graphical representation of the imaging data to the display device <NUM>. A sonographer can control imaging data acquisition of the ultrasound imaging probe <NUM> via the control interface <NUM> of the console <NUM>. In some implementations, the connector <NUM> includes one or more male or female zero insertion force (ZIF) connectors, one or more low insertion force (LIF) connectors, flat flexible connectors (FFCs), ribbon cable connectors, and serial advanced technology attachment (SATA) connectors. In the some embodiments, instead of the console <NUM>, the ultrasound imaging system <NUM> can include a mobile device, such as a tablet computer, a smart phone, a laptop, or a personal data assistant (PDA). For example, in an embodiment where a tablet computer is used instead of the console <NUM>, the touch screen serves as the control interface and the display device. In these embodiments, the connector <NUM> can be a Universal Serial Bus (USB) connector of any version or a mini-USB of any version.

Referring now to <FIG>, illustrated therein is a flow chart of a method <NUM> of manufacturing an ultrasound imaging probe, such as the ultrasound imaging probe <NUM> in <FIG>. The method <NUM>, as discussed below, can manufacture a substantially gapless ultrasound imaging probe without having to adopt tight engineering tolerances. The method <NUM> is merely an example, and is not intended to limit the present disclosure beyond what is explicitly recited in the claims. Additional operation can be provided before, during, and after the method <NUM>, and some operations can be replaced, eliminated, or moved around for additional embodiments of the method <NUM>. The method <NUM> will be described in conjunction with <FIG>, <FIG>, <FIG>, and <FIG>.

The method <NUM> begins at block <NUM> where an ultrasound transducer assembly <NUM> is fixedly secured to a chassis <NUM> (<FIG>). In some embodiments, the ultrasound transducer assembly <NUM>, which can also be referred to as the ultrasound transducer stack <NUM>, can include a lens, an ultrasound transducer array, and an acoustic backing block.

The ultrasound imaging assembly <NUM> can include one or more acoustic elements. For example, a plurality of acoustic elements can be arranged in an array. For example, an ultrasound transducer array can include any suitable number of individual acoustic elements between <NUM> acoustic elements and <NUM> acoustic elements, including values such as <NUM> acoustic elements, <NUM> acoustic elements, <NUM> acoustic elements, <NUM> acoustic elements, <NUM> acoustic elements, <NUM> acoustic elements, <NUM> acoustic elements, and/or other values both larger and smaller. The ultrasound transducer assembly <NUM> can include suitable configuration, such as a planar array, a linear array, a phased array, a curved array, etc. For example, the ultrasound imaging assembly <NUM> can include a one-dimensional array, <NUM>. x-dimensional array, such as a <NUM>-dimensional array, or a two-dimensional array, in some instances. In that regard, the ultrasound transducer assembly <NUM> can be configured obtain one-dimensional, two-dimensional, and/or three-dimensional images of the anatomy of the patient. The ultrasound transducer assembly <NUM> can include a matrix array, including one or more segments of ultrasound elements (e.g., one or more rows, one or more columns, and/or one or more orientations) that can be uniformly or independently controlled and activated. The ultrasound imaging assembly <NUM> can include any suitable transducer type, including a piezoelectric micromachined ultrasound transducer (PMUT), capacitive micromachined ultrasonic transducer (CMUT), single crystal, lead zirconate titanate (PZT), PZT composite, other suitable transducer type, and/or combinations thereof.

The lens of the ultrasound transducer assembly <NUM> can have an acoustic impedance configured to facilitate transmission of ultrasound energy from the array into the patient's anatomy. The backing block of the ultrasound transducer assembly <NUM> is used to attenuate or absorb acoustic energy not directed to the anatomy of interest. The backing block may be disposed adjacent to and/or in contact with the ultrasound transducer array. The backing block can be formed of any suitable material, such as polymers, graphite, composites, ceramics, metals, or any combination thereof.

In some implementations, the ultrasound transducer assembly <NUM> is fixedly secured to the chassis <NUM> by mechanical fixtures and/or adhesive. For example, a proximal surface of the ultrasound transducer assembly <NUM> can have one or more projections that can be received within one or more grooves on a distal surface of the chassis <NUM>. In the embodiments represented in <FIG>, the ultrasound transducer array of the ultrasound transducer assembly <NUM> is electrically coupled to one or more flexible circuits <NUM> that extend proximally along the chassis <NUM>.

The method <NUM> proceeds to block <NUM> (<FIG>) where at least one printed circuit board (PCB) <NUM> is coupled to the ultrasound transducer assembly <NUM> and the chassis <NUM> (<FIG>). In some embodiments, the at least one PCB <NUM> includes a plurality of electrical contacts that are configured to engage a plurality of electrical contacts on the one or more flexible circuits <NUM>. By electrically connecting the at least one PCB <NUM> to the one or more flexible circuits <NUM> coupled to the ultrasound transducer assembly <NUM>, the at least one PCB <NUM> can be electrically coupled to and/or in communication with the ultrasound transducer array in the ultrasound transducer assembly <NUM>. In some implementations, the at least one PCB <NUM> can be fixedly secured to the chassis <NUM> by a fastener or a screw. In embodiments represented in <FIG>, the at least one PCB <NUM> includes two PCBs <NUM> that are both mechanically coupled to the chassis <NUM> by a screw and pressed on a portion of the flexible circuit <NUM>. In these embodiments, proximal portions of the two PCBs <NUM> are secured to a spacer tube <NUM> by at least one screw <NUM>. The spacer tube <NUM> maintains spacing between the two PCBs <NUM>.

The method <NUM> proceeds to block <NUM> (<FIG>) where a cable strain relief <NUM> is movably coupled to a plurality of heat spreader members <NUM>, <NUM> (<FIG>). The cable strain relief <NUM> reduces strain exerted on a cable that includes electrical conductors in electrical communication with the PCBs <NUM>. In some embodiments, the cable strain relief <NUM> includes a distal lip <NUM> at a distal end of the cable strain relief <NUM> and a proximal lip <NUM> proximal to the distal lip <NUM>. In the embodiments represented in <FIG>, the cable strain relief <NUM> is cylindrical in shape and each of the distal lip <NUM> and the proximal lip <NUM> is annular in shape. In some embodiments represented in <FIG>, the plurality of heat spreader members includes two heat spreader members <NUM> and <NUM>. In some other embodiments, the plurality of heat spreader members can include three, four, or more heat spreader members. The heat spreader members <NUM> and <NUM> are configured to provide a thermal path for heat generated by the ultrasound transducer assembly <NUM>. The plurality of heat spreader members can be made of thermally conductive materials, such as silver, copper, gold, aluminum, iron, zinc, alloys, graphite, and/or combinations thereof. In the embodiments represented in <FIG>, each of heat spreader members <NUM> and <NUM> includes a shoulder, such as the shoulder <NUM>. In some implementations, a cable with a plurality of electrical conductor, such as the cable <NUM> in <FIG>, can extend distally through a lumen within the cable strain relief <NUM> such that the plurality of electrical conductors can be electrically coupled to the PCBs <NUM>. For the ease of manufacturing, the plurality of electrical conductors of the cable is electrically coupled to the PCBs <NUM> before the cable strain relief <NUM> is movably coupled to the plurality of heat spreader members <NUM> and <NUM>.

In some implementations, the cable strain relief <NUM> is movably coupled to the plurality of heat spreader members <NUM> and <NUM> by a retention clip <NUM>. The heat spreader members <NUM> and <NUM> can include a semi-annular groove <NUM> and <NUM>, respectively. The semi-annular grooves <NUM> and <NUM> are configured to form an annular groove when the heat spreader members <NUM> and <NUM> are positioned adjacent, near, and/or in contact with one another. The retention clip <NUM> can be switched between an open configuration with a first inner diameter and a closed configuration with a second inner diameter smaller than the first diameter (the closed configuration shown in <FIG>). To couple the cable strain relief <NUM> to the heat spreader members <NUM> and <NUM>, the cable strain relief is moved into the space between the heat spreader members <NUM>, <NUM>. The distal lip <NUM> can be an area of increased diameter that positioned distally past the shoulder <NUM>. Accordingly, when the heat spreader members <NUM> are closed around the strain relief <NUM>, the proximal portion of the lip <NUM> can contact the shoulder <NUM> such that the shoulder <NUM> limits proximal movement of the strain relief <NUM> relative to the heat spreader members <NUM>, <NUM>. The proximal lip <NUM> can be an area of increased diameter that positioned proximal of the proximal end of the heat spreader members <NUM>, <NUM>. Accordingly, when the heat spreader members <NUM> are closed around the strain relief <NUM>, the lip <NUM> limits distal movement of the strain relief <NUM> relative to the heat spreader members <NUM>, <NUM>. The retention clip <NUM>, which go around the semi-annular grooves <NUM> and <NUM> in the open configuration, can be closed to engage the semi-annular grooves <NUM> and <NUM>, thereby bringing the heat spreader members <NUM> and <NUM> toward one another. When received in the annular groove and in the closed position, the retention clip <NUM> can limit the relative movement between the heat spreader member <NUM> and the heat spreader member <NUM>. The retention clip does not eliminate movement entirely, such as occurs when fixedly securing the components. That is, while coupling components such as the retention clip <NUM> are used to limit movement of the components, the heat spreader members <NUM>, <NUM> and the strain relief <NUM> are moveable relative to one another while the retention clip <NUM> is in place. Also, when the closed retention clip <NUM> engages the annular groove, the shoulders of the heat spreader members <NUM> and <NUM> can limit the translational movement of the cable strain relief <NUM> relative to the heat spreader members <NUM> and <NUM> to a difference between a distance separating the distal lip <NUM> and the proximal lip <NUM> and a distance separating the shoulders and the a proximal surface <NUM> of the heat spreader members <NUM> and <NUM>. The relative movement between components can be referred as a play herein. The play can be damped by an elastic ring member <NUM>. In some embodiments, the elastic ring member can be formed of a thermally and/or electrically conductive elastomer, such as an elastomer including a binder and thermally and/or electrically conductive filler particles. Examples of the binder include silicone, fluorosilicone, ethylene propylene diene monomer (EPDM) rubber, fluorocarbon-fluorosilicone, or a combination thereof. Examples of the filler particles include pure silver particles, silver-plated copper particles, silver-plated aluminum particles, silver-plated nickel particles, silver-plated glass particles, nickel-plated graphite particles, nickel-plated aluminum particles, unplated graphite particles, or combinations thereof. The retention clip <NUM> and the elastic ring member <NUM> provide flexibility to the coupling between the cable strain relief <NUM> and the heat spreader members <NUM> and <NUM>.

In some embodiments, the retention clip <NUM>, when closed to engage the annular groove, does not rigidly press the heat spreader members <NUM> and <NUM> together. In those embodiments, the heat spreader members <NUM> and <NUM> can move relative to the cable strain relief <NUM> in more than one dimension (e.g., in the X, Y, and/or Z dimensions) without decoupling from the cable strain relief <NUM>. For example, when the cable strain relief <NUM> is fixed in position, a distal portion of the heat spreader members <NUM> and <NUM> can pivot along the Y-Z plane or along the X-Z plane. Relative to the cable strain relief <NUM>, the heat spreader members <NUM> can be configured for any suitable movement including rotation, pivoting, translation radially (inward/outward), translation longitudinally (proximally/distally), and/or combinations thereof.

The method <NUM> proceeds to block <NUM> (<FIG>) where the chassis <NUM> is movably coupled to the heat spreader members <NUM> and <NUM> (<FIG>). In some embodiments, each of the heat spreader members <NUM> and <NUM> is coupled to the chassis <NUM> by a fixture that allows the heat spreader members <NUM> and <NUM> to move relative to the chassis <NUM>. The heat spreader members <NUM> and <NUM> are coupled to the chassis <NUM> by a shoulder screw <NUM> and a shoulder screw <NUM>, respectively. For example, the shoulder screw <NUM> can extend through a screw hole <NUM> on the heat spreader member <NUM> and thread into the chassis <NUM> at the hole <NUM>. Similarly, the shoulder screw <NUM> can extend through a screw hole on the heat spreader member <NUM> and thread into the chassis <NUM>. Each of the shoulder screws <NUM> and <NUM> includes an unthreaded section adjacent to the screw head and a threaded section away from the screw head. In some embodiments, when the threaded sections of the shoulder screws <NUM> and <NUM> are threaded into the chassis <NUM>, the unthreaded sections that interface the heat spreader members <NUM> and <NUM> can allow the heat spreader members <NUM> and <NUM> to move relative to the chassis <NUM>. For example, the heat spreader members <NUM>, <NUM> can translate or pivot along the Y-Z plane with respect to an axis between the shoulder screws <NUM> and <NUM>. That is, when the ultrasound transducer assembly <NUM> is fixed in position, the heat spreader members <NUM> and <NUM> can pivot along the Y-Z plane with respect to the shoulder screws <NUM> and <NUM>. Movably coupling the heat spreader members <NUM>, <NUM> to the chassis <NUM> using the shoulder screws <NUM>, <NUM> allows the heat spreader members <NUM> and <NUM> to move relative to the chassis <NUM> in more than one dimension (e.g., in the X, Y, and/or Z dimensions) without decoupling from the chassis <NUM>. Relative to the chassis <NUM>, the heat spreader members <NUM> can be configured for any suitable movement including rotation, pivoting, translation radially (inward/outward), translation longitudinally (proximally/distally), and/or combinations thereof.

In some implementations, because the shoulder screws <NUM> and <NUM> are made of thermally and/or electrically conductive materials, such as steel, silver, copper, gold, aluminum, iron, zinc, or an alloy thereof, the shoulder screws <NUM> and <NUM> create heat paths from the chassis <NUM> to the heat spreader members <NUM> and <NUM>. In some embodiments, to further improve the thermal conduction between the chassis <NUM> and the heat spreader members <NUM> and <NUM>, a plurality of gap pads, such as a gap pad <NUM> in <FIG>, can be positioned between surfaces of the chassis <NUM> and surfaces of the heat spreader members <NUM> and <NUM>. The gap pad <NUM> can be in direct contact with the chassis <NUM> and with the heat spreader members <NUM> and <NUM>, even if the chassis <NUM> and the heat spreader members <NUM> and <NUM> do not directly contact one another. The gap pad <NUM> can be coupled (e.g., thermally conductive adhesive, mechanical attachment, etc.) to the chassis <NUM> and/or the heat spreader members <NUM> such that a thermal path extends between the chassis <NUM> to the heat spreader members <NUM>, <NUM> via the gap pad <NUM>. In some instances, the gap pad <NUM> can be formed of an elastomer including a binder and thermally and/or electrically conductive filler particles. Examples of the binder include silicone, fluorosilicone, ethylene propylene diene monomer (EPDM) rubber, fluorocarbon-fluorosilicone, or a combination thereof. Examples of the filler particles include pure silver particles, silver-plated copper particles, silver-plated aluminum particles, silver-plated nickel particles, silver-plated glass particles, nickel-plated graphite particles, nickel-plated aluminum particles, unplated graphite particles, or combinations thereof. In some implementations, the elastomer can be applied to surfaces of the chassis <NUM> because the elastomer is cure and before the heat spreader members <NUM> and <NUM> are coupled to the chassis <NUM> by the shoulder screws <NUM> and <NUM>.

In some embodiment, the heat spreader members <NUM> and <NUM> are sized and shaped to enclose the ultrasound transducer assembly <NUM>, the chassis <NUM>, and the PCBs <NUM>. In those embodiments, the heat spreader members <NUM> and <NUM> include a plurality of cutoffs to accommodate or allow access to features of the ultrasound transducer assembly <NUM>, the chassis <NUM>, and the PCBs <NUM>. For example, a cutoff <NUM> on the heat spreader member <NUM> and a cutoff <NUM> on the heat spreader member <NUM> can form an opening that provides access to the screw <NUM>. For another example, a cutoff <NUM> on the heat spreader member <NUM> and a cutoff <NUM> on the heat spreader member <NUM> can form an opening that provides access to a screw that secures the PCB <NUM> to the chassis <NUM>.

It is noted that operations in blocks <NUM> and <NUM> can be performed sequentially or simultaneously. In some embodiments, operations in block <NUM> can be performed before operations in block <NUM>.

The method <NUM> then proceeds to block <NUM> (<FIG>) where a filling material <NUM> is positioned over internal surfaces of the housing, such as the housing member <NUM> and the housing member <NUM> (<FIG>). In some embodiments, the filling material <NUM> can include a room-temperature-vulcanizing (RTV) rubber or silicone rubber. The filing material <NUM> can be an elastic material. While rubber is mentioned, any suitable adhesive material, such as epoxy, can be used. Before the rubber/epoxy that forms the filling material <NUM> is cured at block <NUM>, to be described further below, the filling material can be flowable and applied or coated on the internal surfaces of the housing, e.g., by use of an applicator.

As described further herein, the operations in blocks <NUM> and <NUM> can be performed sequentially or simultaneously. In some embodiments, operations in block <NUM> can be performed before operations in block <NUM>.

The method <NUM> proceeds to block <NUM> (<FIG>) where the heat spreader members <NUM> and <NUM> are moved relative to the chassis <NUM> and/or the cable strain relief <NUM> (<FIG>). For example, the movement can occur as a result of block <NUM>. As shown by a curved arrow <NUM>, the heat spreader member <NUM> and <NUM> can be moved relative to the cable strain relief <NUM>. Additionally, as shown by a curved arrow <NUM>, the heat spreader members <NUM> and <NUM> can be moved relative to the chassis <NUM>, e.g., around the shoulder screws <NUM> and <NUM>. That means, the chassis <NUM>, the heat spreader members <NUM> and <NUM>, and the cable strain relief <NUM> act as three segments interlinked by movable coupling, with the chassis <NUM> being a distal segment, the heat spreader members <NUM> and <NUM> being the middle segment, and the cable strain relief <NUM> being a proximal segment. Because the heat spreader members <NUM> and <NUM> (i.e. the middle segment) is movably coupled to and sandwiched between the chassis <NUM> (i.e. the distal segment) and the cable strain relief <NUM> (i.e. the proximal segment), the heat spreader members <NUM> and <NUM> can be said to be floating. In some embodiments of the present disclosure, when the chassis <NUM>, the heat spreader members <NUM> and <NUM>, and the cable strain relief <NUM> are to be enclosed in a housing that includes a housing member <NUM>, a housing member <NUM>, and a nosepiece <NUM>, the three segments can be moved/pivoted relative to one another to compensate for dimensional variations in the housing member <NUM>, the housing member <NUM>, and nosepiece <NUM>, the chassis <NUM>, the heat spreader members <NUM> and <NUM>, and the cable strain relief <NUM>.

The method <NUM> then proceeds to block <NUM> (<FIG>) where the plurality of heat spreader members <NUM> and <NUM>, a portion of the cable strain relief <NUM>, and the chassis <NUM> are enclosed in the housing <NUM>, <NUM> (<FIG>). The enclosing can cause movement described with respect to block <NUM>. With the filling material <NUM> applied to the internal surfaces of the housing and the three segments moved to adapt to the dimensions of the housing, the housing members <NUM> and <NUM> can be pressed against the heat spreader members <NUM> and <NUM> without being strained. This is so because the housing members <NUM> and <NUM> are not pressed onto a rigid structure but a movable one. The engineering variations (e.g., tolerances) can be absorbed and eliminated by the movable coupling between the heat spreader members <NUM> and <NUM> and the cable strain relief <NUM> as well as between the heat spreader members <NUM> and <NUM> and the chassis <NUM>. The filling material <NUM> flows into and fills recesses within the interior space between the housing members <NUM>, <NUM> and/or the heat spreader members <NUM>, <NUM>. In some embodiments, the housing members <NUM> and <NUM> can cover all access openings or screw holes of the heat spreader members <NUM> and <NUM>. In some implementations, the housing members <NUM> and <NUM> can also cover the retention clip <NUM> and the elastic ring member <NUM>. In some embodiments represented in <FIG>, the nosepiece <NUM> of the housing can be secured to the housing members <NUM> and <NUM> by mechanical fixtures or adhesive. In some other embodiments, besides being secured to the housing members <NUM> and <NUM>, the nosepiece <NUM> can also be secured to the chassis <NUM> by mechanical fixtures or adhesive. The nosepiece <NUM> includes an opening that tracks the shape of the ultrasound transducer assembly <NUM>. When secured to the housing members <NUM> and <NUM> and/or the chassis <NUM> and after the filling/rubber material has cured, the nosepiece <NUM> can prevent the ultrasound transducer assembly <NUM> from moving or pivoting relative to the heat spreader members <NUM> and <NUM>. Similarly, when the housing members <NUM> and <NUM> are pressed onto and enclose the heat spreader members <NUM> and <NUM>, and the filling/rubber material has cured, the cable strain relief <NUM> is prevented from movement/pivoting relative to the heat spreader members <NUM> and <NUM>. In some embodiments, when enclosed in the housing and after the filling/rubber material has cured, the pliable three segments no longer move relative to one another.

It is noted that the operations in blocks <NUM> and <NUM> can be performed simultaneously or in an alternating fashion. For example, the heat spreader members <NUM> and <NUM> can be moved relative to the cable strain relief <NUM> and/or the chassis <NUM> while the housing members <NUM> and <NUM>, whose internal surfaces are coated with the filling/rubber material <NUM>, are being pressed onto the heat spreader members <NUM> and <NUM>. For another example, after the housing members <NUM> and <NUM> enclose the heat spreader members <NUM> and <NUM> and a portion of the cable strain relief <NUM>, the chassis <NUM> can be moved relatively to the heat spreader members <NUM> and <NUM> around the shoulder screws <NUM> and <NUM> to be received within the nosepiece <NUM>.

The method <NUM> proceeds to block <NUM> (<FIG>) where the filling/rubber material <NUM> is cured (<FIG>). When the housing members <NUM> and <NUM> that are coated with the filling/rubber material <NUM> are pressed onto the heat spreader members <NUM> and <NUM> for enclosure, excess filling/rubber material <NUM> can be squeezed out from gaps and seems of the housing members <NUM> and <NUM>. The excess or overflow of filling/rubber material <NUM> is then removed from the housing. In some embodiments, the filling/rubber material <NUM> can be cured at room temperature (<NUM> - <NUM>) for three (<NUM>) to five (<NUM>) days, depending on the amount, thickness, and/or other properties of the filling/rubber material. In some other embodiments, to accelerate the curing process, the ultrasound imaging probe <NUM> can be placed in a climate-controlled chamber or oven for elevated or decreased temperature and/or humidity. For example, the ultrasound imaging probe <NUM> can be placed in an oven set at <NUM> and <NUM>% relative humidity for one (<NUM>) day to cure the filling/rubber material <NUM>. Referring still to <FIG>, shown therein is the ultrasound imaging probe <NUM> manufactured using the method <NUM> in <FIG>. The ultrasound imaging probe <NUM> includes a seam <NUM> between the nosepiece <NUM> and the housing members <NUM> and <NUM>, a seam <NUM> between the housing members <NUM> and <NUM>, and a seam <NUM> between the cable strain relief <NUM> and the housing members <NUM> and <NUM>. Because the heat spreader members <NUM> and <NUM> are floating between the cable strain relief <NUM> and the chassis <NUM>, the seams <NUM>, <NUM> and <NUM> are minimized or can be controlled at consistent levels. For the same reason, the ultrasound imaging probe <NUM> is substantially free of gaps, and in particular, free of gaps of varying sizes.

Claim 1:
A method (<NUM>) of manufacturing an ultrasound imaging probe (<NUM>), the method comprising:
obtaining (<NUM>) an ultrasound transducer assembly (<NUM>) fixedly secured to a chassis (<NUM>);
movably coupling (<NUM>) the chassis to a plurality of heat spreader members (<NUM>, <NUM>); and
enclosing (<NUM>) the plurality of heat spreader members, the chassis and the ultrasound transducer assembly in a housing (<NUM>, <NUM>, <NUM>),
wherein movably coupling the chassis to the plurality of heat spreader members comprises coupling the chassis to the plurality of heat spreader members by two shoulder screws (<NUM>, <NUM>),
wherein the movable coupling allows the plurality of heat spreader members to move relative to the chassis,
wherein moving the plurality of heat spreader members relative to the chassis comprises moving the plurality of heat spreader members about the two shoulder screws in more than one dimension.