System and method for manufacturing an ultrasound probe lens

Patent metadata

Field	Value
Publication number	US-2016185056-A1
Application number	US-201414587103-A
Country	US
Kind code	A1
Filing date	Dec 31, 2014
Priority date	Dec 31, 2014
Publication date	Jun 30, 2016
Grant date	—

Abstract

A method includes the steps of measuring a surface profile of a first component, determining a profile of a second component, the profile of the second component being configured to correspond to the surface profile of the first component, and manufacturing the second component utilizing additive technology in accordance with the determined profile.

First claim

What is claimed is:

1 . A method for additive manufacturing, comprising the steps of:
measuring a surface profile of a first component; determining a profile of a second component, the profile of the second component being configured to correspond to the surface profile of the first component; and manufacturing the second component utilizing additive technology in accordance with the determined profile.

2 . The method according to claim 1 , wherein:
the first component is a transducer of an ultrasound probe; and the second component is a lens of the ultrasound probe.

3 . The method according to claim 2 , wherein:
the step of determining the profile of the lens includes calculating a curvature of the lens in dependence upon the measured surface profile of the transducer.

4 . The method according to claim 3 , further comprising the steps of:
aligning the transducer within a 3D printer; and manufacturing the lens by printing the lens having the calculated curvature.

5 . The method according to claim 4 , further comprising the step of:
after the lens is printed, verifying the curvature of the lens.

6 . The method according to claim 4 , wherein:
measuring the surface profile of the transducer is carried out utilizing a 3D laser scanning system.

7 . The method according to claim 6 , wherein:
the 3D laser scanning system is configured to capture any variation of the transducer in x, y and z planes and to detect any rotation around the x, y and z axes.

8 . The method according to claim 2 , wherein:
the lens is comprised of a polymeric material.

9 . The method according to claim 2 , further comprising the step of:
prior to measuring the surface profile of the transducer, arranging the transducer within a housing of the ultrasound probe.

10 . A method of manufacturing a lens for an ultrasound probe, comprising the steps of:
measuring a surface profile of an acoustic stack of the probe; calculating a profile for the lens; and printing the lens onto the acoustic stack in accordance with the calculated profile.

11 . The method according to claim 10 , wherein:
the acoustic stack includes an array of transducers.

12 . The method according to claim 11 , wherein:
the step of determining the profile for the lens includes calculating a curvature of the lens in dependence upon the measured surface profile of the acoustic stack.

13 . The method according to claim 12 , further comprising the steps of:
aligning the probe within a 3D printer; and constructing the lens by printing the lens having the calculated curvature.

14 . The method according to claim 13 , further comprising the step of:
verifying the curvature of the lens after the lens is printed.

15 . The method according to claim 14 , wherein:
measuring the surface profile of the transducer is carried out utilizing a laser surface profilometer.

16 . The method according to claim 15 , wherein:
the laser surface profilometer is configured to capture any variation of the acoustic stack in x, y and z planes and to detect any rotation around the x, y and z axes.

17 . The method according to claim 10 , wherein:
the lens is comprised of a polymeric material.

18 . A system for manufacturing an ultrasound probe, comprising:
a laser mapping device configured to measure a surface profile of a transducer of the probe; a data analyzer configured to receive surface profile data from the laser mapping device and to calculate a profile for an acoustic lens in dependence upon the surface profile data; and an additive printing device configured to print an acoustic lens on the transducer in accordance with the calculated profile.

19 . The system of claim 18 , wherein:
the laser mapping device is a laser surface profilometer.

20 . The system of claim 18 , wherein:
the additive printing device is a 3D printer configured for polymer deposition.

21 . A method of manufacturing a lens for an ultrasound probe, comprising the steps of:
mapping a surface profile of a transducer of the ultrasound probe; determining a profile of the lens, the profile of the lens being configured to correspond to the surface profile of the transducer; manufacturing a mold having a mold profile corresponding to the determined profile of the lens; introducing a liquid material into the mold; submerging the transducer of the ultrasound probe in the liquid material; allowing the liquid material to cure to form the lens; and removing the ultrasound probe and lens from the mold.

22 . A method of manufacturing a lens for an ultrasound probe, comprising the steps of:
measuring a surface profile of a transducer of the ultrasound probe; determining a profile of the lens, the profile of the lens being configured to correspond to the surface profile of the transducer; printing the lens on a substrate utilizing additive technology in accordance with the determined profile; removing the substrate from the lens; tacking the lens to the transducer of the ultrasound probe; and over-molding the lens and the transducer with a curable material to bond the lens in place.

Assignees

• Gen Electric

Inventors

• Beacham Jimmie Autrey
• Abraham Jessica Lynn
• Masterson Brian John

Classifications

• B29D11/0099 Primary

  while still attached to the mould · CPC title

• A61B8/4444

  related to the probe · CPC title

• B29D11/00009 Primary

  Production of simple or compound lenses · CPC title

• B33Y50/00

  Data acquisition or data processing for additive manufacturing · CPC title

• B29D11/00961

  using microprocessors or computers · CPC title