Patent ID: 7302866

Claim:
A phased array sensor assembly that can impart ultrasonic waves to a structural surface and receive ultrasonic waves from a structural surface, the sensor assembly comprising: a plurality of piezo-electric disks that are electrically accessible on one side; a plurality of electrically conductive epoxy film adhesive contacts substantially aligned and positioned such that an electrical coupling is formed with the electrically accessible side of the respective plurality of piezo-electric disks; a plurality of piezo transducer flex wire trace circuits aligned to be electrically coupled respectively with the plurality of electrically conductive epoxy film adhesive contacts on one end and including a plurality of wire trace electrical contact pads on the other end; a flexible polyimide layer including a plurality of laser ablated areas for exposing the plurality of wire trace electrical contact pads through a side of the sensor assembly such that the plurality of wire trace electrical contact pads can be electrically coupled with an external device; and a filler layer comprised of non-conductive adhesive for bonding the plurality of piezo-electric disks, plurality of electrically conductive epoxy film adhesive contacts, plurality of piezo transducer flex wire trace circuits, and the polyimide layer together to form a thin profile, flexible sensor assembly capable of being permanently mounted to a structural surface.