Patent ID: 8316518

Claim:
A method for producing electrodes in a pattern, comprising: (a) providing an ultrasound array transducer stack comprising a plurality of ultrasonic array elements; (b) placing a connector having an electrical connection for each of the plurality of ultrasonic array elements in proximity to the ultrasound array transducer stack; (c) depositing a composite dielectric material comprising a matrix material and a particulate material on the ultrasound array transducer stack and the connector, wherein the matrix material is laser ablatable at a lower fluence than the particulate material; (d) laser ablating the composite dielectric material to substantially expose the plurality of ultrasonic array elements and to form a plurality of trenches in the composite dielectric material, each of the plurality of trenches extending from one of the ultrasonic array elements to an electrical connection of the connector, wherein laser ablating the composite dielectric material includes removing matrix material and increasing a surface area of the composite dielectric material; (e) depositing a conductive metal on the plurality of ultrasonic array elements and the plurality of trenches after laser ablating the composite dielectric material; (f) depositing a resist on the conductive metal, such that the resist is thicker over each ultrasonic array element and each trench compared to areas between the ultrasonic array elements; (g) removing a portion of the resist to expose a portion of the conductive metal in a pattern that is a negative of a desired pattern of electrodes; and (h) removing the exposed portion of the conductive.