Flexible large-area ultrasound arrays for medical applications made using embossed polymer structures.

With the huge progress in micro-electronics and artificial intelligence, the ultrasound probe has become the bottleneck in further adoption of ultrasound beyond the clinical setting (e.g. home and monitoring applications). Today, ultrasound transducers have a small aperture, are bulky, contain lead and are expensive to fabricate. Furthermore, they are rigid, which limits their integration into flexible skin patches. New ways to fabricate flexible ultrasound patches have therefore attracted much attention recently. First prototypes typically use the same lead-containing piezo-electric materials, and are made using micro-assembly of rigid active components on plastic or rubber-like substrates. We present an ultrasound transducer-on-foil technology based on thermal embossing of a piezoelectric polymer. High-quality two-dimensional ultrasound images of a tissue mimicking phantom are obtained. Mechanical flexibility and effective area scalability of the transducer are demonstrated by functional integration into an endoscope probe with a small radius of 3 mm and a large area (91.2×14 mm2) non-invasive blood pressure sensor.

Algorithm to Correct Measurement Offsets Introduced by Inactive Elements of Transducer Arrays in Ultrasonic Flow Metering.

Ultrasonic flow meters (UFMs) based on transducer arrays offer several advantages. With electronic beam steering, it is possible to tune the steering angle of the beam for optimal signal-tonoise ratio (SNR) upon reception. Moreover, multiple beams can be generated to propagate through different travel paths, covering a wider section of the flow profile. Furthermore, in a clamp-on configuration, UFMs based on transducer arrays can perform self-calibration. In this manner, userinput is minimized and measurement repeatability is increased. In practice, transducer array elements may break down. This could happen due to aging, exposure to rough environments, and/or rough mechanical contact. As a consequence of inactive array elements, the measured transit time difference contains two offsets. One offset originates from non-uniform spatial sampling of the generated wavefield. Another offset originates from the ill-defined beam propagating through a travel path different from the intended one. In this paper, an algorithm is proposed that corrects for both of these offsets. The algorithm also performs a filtering operation in the frequency-wavenumber domain of all spurious (i.e., flow-insensitive) wave modes. The advantage of implementing the proposed algorithm is demonstrated on simulations and measurements, showing improved accuracy and precision of the transit time differences compared to the values obtained when the algorithm is not applied. The proposed algorithm can be implemented in both in-line and clamp-on configuration of UFMs based on transducer arrays.

Measurement of Pipe and Liquid Parameters Using the Beam Steering Capabilities of Array-Based Clamp-On Ultrasonic Flow Meters.

Clamp-on ultrasonic flow meters (UFMs) are installed on the outside of the pipe wall. Typically, they consist of two single-element transducers mounted on angled wedges, which are acoustically coupled to the pipe wall. Before flow metering, the transducers are placed at the correct axial position by manually moving one transducer along the pipe wall until the maximum amplitude of the relevant acoustic pulse is obtained. This process is time-consuming and operator-dependent. Next to this, at least five parameters of the pipe and the liquid need to be provided manually to compute the flow speed. In this work, a method is proposed to obtain the five parameters of the pipe and the liquid required to compute the flow speed. The method consists of obtaining the optimal angles for different wave travel paths by varying the steering angle of the emitted acoustic beam systematically. Based on these optimal angles, a system of equations is built and solved to extract the desired parameters. The proposed method was tested experimentally with a custom-made clamp-on UFM consisting of two linear arrays placed on a water-filled stainless steel pipe. The obtained parameters of the pipe and the liquid correspond very well with the expected (nominal) values. Furthermore, the performed experiment also demonstrates that a clamp-on UFM based on transducer arrays can achieve self-alignment without the need to manually move the transducers.

Design and Proof-of-Concept of a Matrix Transducer Array for Clamp-On Ultrasonic Flow Measurements.

Common clamp-on ultrasonic flow meters consist of two single-element transducers placed on the pipe wall. Flow speed is measured noninvasively, i.e., without interrupting the flow and without perforating the pipe wall, which also minimizes safety risks and avoids pressure drops inside the pipe. However, before metering, the transducers have to be carefully positioned along the pipe axis to correctly align the acoustic beams and obtain a well-calibrated flowmeter. This process is done manually, is dependent on the properties of the pipe and the liquid, does not account for pipe imperfections, and becomes troublesome on pipelines with an intricate shape. Matrix transducer arrays are suitable to dynamically steer acoustic beams and realize self-alignment upon reception, without user input. In this work, the design of a broadband 37×17 matrix array (center frequency of 1 MHz) to perform clamp-on ultrasonic flow measurements over a wide range of liquids ( c=1000-2000 m/s, α ≤ 1 dB/MHz · cm) and pipe sizes is presented. Three critical aspects were assessed: efficiency, electronic beam steering, and wave mode conversion in the pipe wall. A prototype of a proof-of-concept flowmeter consisting of two 36-element linear arrays (center frequency of 1.1 MHz) was fabricated and placed on a 1-mm-thick, 40-mm inner diameter stainless steel pipe in a custom-made flow loop filled with water. At resonance, simulated and measured efficiencies in water of the linear arrays compared well: 0.88 and 0.81 kPa/V, respectively. Mean flow measurements were achieved by electronic beam steering of the acoustic beams and using both compressional and shear waves generated in the pipe wall. Correlation coefficients of between measured and reference flow speeds were obtained, thus showing the operational concept of an array-based clamp-on ultrasonic flowmeter.

Measurement of Pipe and Fluid Properties With a Matrix Array-Based Ultrasonic Clamp-On Flow Meter.

Current ultrasonic clamp-on flow meters consist of a pair of single-element transducers that are carefully positioned before use. This positioning process consists of manually finding the distance between the transducer elements, along the pipe axis, for which maximum signal-to-noise ratio (SNR) is achieved. This distance depends on the sound speed, thickness, and diameter of the pipe and on the sound speed of the liquid. However, these parameters are either known with low accuracy or completely unknown during positioning, making it a manual and troublesome process. Furthermore, even when sensor positioning is done properly, uncertainty about the mentioned parameters, and therefore on the path of the acoustic beams, limits the final accuracy of flow measurements. In this research, we address these issues using an ultrasonic clamp-on flow meter consisting of two matrix arrays, which enables the measurement of pipe and liquid parameters by the flow meter itself. Automatic parameter extraction, combined with the beam-steering capabilities of transducer arrays, yields a sensor capable of compensating for pipe imperfections. Three parameter extraction procedures are presented. In contrast to similar literature, the procedures proposed here do not require that the medium be submerged nor do they require a priori information about it. First, axial Lamb waves are excited along the pipe wall and recorded with one of the arrays. A dispersion curve-fitting algorithm is used to extract bulk sound speeds and wall thickness of the pipe from the measured dispersion curves. Second, circumferential Lamb waves are excited, measured, and corrected for dispersion to extract the pipe diameter. Third, pulse-echo measurements provide the sound speed of the liquid. The effectiveness of the first two procedures has been evaluated using simulated and measured data of stainless steel and aluminum pipes, and the feasibility of the third procedure has been evaluated using simulated data.

Exploiting nonlinear wave propagation to improve the precision of ultrasonic flow meters.

Acoustic wave propagation in ultrasonic flow measurements is typically assumed to be linear and reciprocal. However, if the transmitting transducer generates a sufficiently high pressure, nonlinear wave propagation effects become significant. In flow measurements, this would translate into more information to estimate the flow and therefore a higher precision relative to the linear case. In this work, we investigate how the generated harmonics can be used to measure flow. Measurements in a custom-made flow loop and simulations using the Khokhlov-Zabolotskaya-Kuznetsov (KZK) equation will show that the second harmonic component provides similar transit time differences to those obtained from the fundamental component, their linear combination results in more precise flow measurements compared to the estimations with the fundamental component alone.

On the resolution of subsurface atomic force microscopy and its implications for subsurface feature sizing.

Ultrasound atomic force microscopy (AFM) has received considerable interest due to its subsurface imaging capabilities, particularly for nanostructure imaging. The local contact stiffness variation due to the presence of a subsurface feature is the origin of the imaging contrast. Several research studies have demonstrated subsurface imaging capabilities with promising resolution. However, there is limited literature available about the definition of spatial resolution in subsurface AFM. The changes in contact stiffness and their link to the subsurface resolution are not well understood. We propose a quantitative approach to assess the resolution in subsurface AFM imaging. We have investigated the influences of several parameters of interest on the lateral resolution. The quantification of the subsurface feature size can be based on threshold criteria (full width at half maximum and Rayleigh criteria). Simulations and experimental measurements were compared, revealing that the optimal choice of parameter settings for surface topography AFM is suboptimal for subsurface AFM imaging.

Suppression of Lamb wave excitation via aperture control of a transducer array for ultrasonic clamp-on flow metering.

During ultrasonic clamp-on flow metering, Lamb waves propagating in the pipe wall may limit the measurement accuracy by introducing absolute errors in the flow estimates. Upon reception, these waves can interfere with the up and downstream waves refracting from the liquid, and disturb the measurement of the transit time difference that is used to obtain the flow speed. Thus, suppression of the generation of Lamb waves might directly increase the accuracy of a clamp-on flow meter. Existing techniques apply to flow meters with single element transducers. This paper considers the application of transducer arrays and presents a method to achieve a predefined amount of suppression of these spurious Lamb waves based on appropriate amplitude weightings of the transducer elements. Finite element simulations of an ultrasonic clamp-on flow measurement setting will be presented to show the effect of array aperture control on the suppression of the Lamb waves in a 1-mm-thick stainless steel pipe wall. Furthermore, a proof-of-principle experiment will be shown that demonstrates a good agreement with the simulations.

Mapping buried nanostructures using subsurface ultrasonic resonance force microscopy.

Nondestructive subsurface nanoimaging of buried nanostructures is considered to be extremely challenging and is essential for the reliable manufacturing of nanotechnology products such as three-dimensional (3D) transistors, 3D NAND memory, and future quantum electronics. In scanning probe microscopy (SPM), a microcantilever with a sharp tip can measure the properties of a surface with nanometer resolution. SPM combined with ultrasound excitation, known as ultrasound SPM, has shown the capability to image buried nanoscale features. In this paper, the development of a modified type of ultrasound SPM called subsurface ultrasonic resonance force microscopy (SSURFM) is reported. The capability and versatility of this method is demonstrated by the subsurface imaging of various samples including rigid structures buried under a soft matrix (aluminum under a polymer), rigid structures buried under multiple layers (aluminum under a polymer and titanium layer), and rigid structures under a rigid matrix (aluminum under silicon oxide). Furthermore, tuning and optimization of the image contrast are reported. The experimental results provide possible new industrial metrology and inspection solutions for nanostructures buried below the surface.

F-k Domain Imaging for Synthetic Aperture Sequential Beamforming.

Spatial resolution in medical ultrasound images is a key component in image quality and an important factor for clinical diagnosis. In early systems, the lateral resolution was optimal in the focus but rapidly decreased outside the focal region. Improvements have been found in, e.g., dynamic-receive beamforming, in which the entire image is focused in receive, but this requires complex processing of element data and is not applicable for mechanical scanning of single-element images. This paper exploits the concept of two-stage beamforming based on virtual source-receivers, which reduces the front-end computational load while maintaining a similar data rate and frame rate compared to dynamic-receive beamforming. We introduce frequency-wavenumber domain data processing to obtain fast second-stage data processing while having similarly high lateral resolution as dynamic-receive beamforming and processing in time-space domain. The technique is very suitable in combination with emerging technologies such as application-specific integrated circuits (ASICs), hand-held devices, and wireless data transfer. The suggested method consists of three steps. In the first step, single-focused RF line data are shifted in time to relocate the focal point to a new origin t' = 0, z' = 0. This new origin is considered as an array of virtual source/receiver pairs, as has been suggested previously in literature. In the second step, the dataset is efficiently processed in the wavenumber-frequency domain to form an image that is in focus throughout its entire depth. In the third step, the data shift is undone to obtain a correct depth axis in the image. The method has been tested first with a single-element scanning system and second in a tissue-mimicking phantom using a linear array. In both setups, the method resulted in a −6-dB lateral point spread function (PSF) which was constant over the entire depth range, and similar to dynamic-receive beamforming and synthetic aperture sequential beamforming. The signal-to-noise ratio increased by 6 dB in both the near field and far field. These results show that the second-stage processing algorithm effectively produces a focused image over the entire depth range from a single-focused ultrasound field.

Mode vibrations of a matrix transducer for three-dimensional second harmonic transesophageal echocardiography.

Transesophageal echocardiography (TEE) uses the esophagus as an imaging window to the heart. This enables cardiac imaging without interference from the ribs or lungs and allows for higher frequency ultrasound to be used compared with transthoracic echocardiography (TTE). TEE facilitates the successful imaging of obese or elderly patients, where TTE may be unable to produce images of satisfactory quality. Recently, three-dimensional (3-D) TEE has been introduced, which greatly improves the image quality and diagnostic value of TEE by adding an extra dimension. Further improvement could be achieved by optimizing 3-D TEE for harmonic imaging. This article describes the optimal geometry and element configuration for a matrix probe for 3-D second harmonic TEE. The array concept features separated transmit and receive subarrays. The element geometry was studied using finite element modeling and a transmit subarray prototype was examined both acoustically and with laser interferometry. The transmit subarray is suitable for its role, with a 3 MHz resonance frequency, a 40%-50% -3 dB bandwidth and crosstalk levels <-27 dB. The proposed concept for the receive subarray has a 5.6 MHz center frequency and a 50% -3 dB bandwidth.

Comparison of fundamental, second harmonic, and superharmonic imaging: a simulation study.

In medical ultrasound, fundamental imaging (FI) uses the reflected echoes from the same spectral band as that of the emitted pulse. The transmission frequency determines the trade-off between penetration depth and spatial resolution. Tissue harmonic imaging (THI) employs the second harmonic of the emitted frequency band to construct images. Recently, superharmonic imaging (SHI) has been introduced, which uses the third to the fifth (super) harmonics. The harmonic level is determined by two competing phenomena: nonlinear propagation and frequency dependent attenuation. Thus, the transmission frequency yielding the optimal trade-off between the spatial resolution and the penetration depth differs for THI and SHI. This paper quantitatively compares the concepts of fundamental, second harmonic, and superharmonic echocardiography at their optimal transmission frequencies. Forward propagation is modeled using a 3D-KZK implementation and the iterative nonlinear contrast source (INCS) method. Backpropagation is assumed to be linear. Results show that the fundamental lateral beamwidth is the narrowest at focus, while the superharmonic one is narrower outside the focus. The lateral superharmonic roll-off exceeds the fundamental and second harmonic roll-off. Also, the axial resolution of SHI exceeds that of FI and THI. The far-field pulse-echo superharmonic pressure is lower than that of the fundamental and second harmonic. SHI appears suited for echocardiography and is expected to improve its image quality at the cost of a slight reduction in depth-of-field.

Dual-pulse frequency compounded superharmonic imaging.

Tissue second-harmonic imaging is currently the default mode in commercial diagnostic ultrasound systems. A new modality, superharmonic imaging (SHI), combines the third through fifth harmonics originating from nonlinear wave propagation through tissue. SHI could further improve the resolution and quality of echographic images. The superharmonics have gaps between the harmonics because the transducer has a limited bandwidth of about 70% to 80%. This causes ghost reflection artifacts in the superharmonic echo image. In this work, a new dual-pulse frequency compounding (DPFC) method to eliminate these artifacts is introduced. In the DPFC SHI method, each trace is constructed by summing two firings with slightly different center frequencies. The feasibility of the method was established using a single-element transducer. Its acoustic field was modeled in KZK simulations and compared with the corresponding measurements obtained with a hydrophone apparatus. Subsequently, the method was implemented on and optimized for a setup consisting of an interleaved phased-array transducer (44 elements at 1 MHz and 44 elements at 3.7 MHz, optimized for echocardiography) and a programmable ultrasound system. DPFC SHI effectively suppresses the ghost reflection artifacts associated with imaging using multiple harmonics. Moreover, compared with the single-pulse third harmonic, DPFC SHI improved the axial resolution by 3.1 and 1.6 times at the -6-dB and -20-dB levels, respectively. Hence, DPFC offers the possibility of generating harmonic images of a higher quality at a cost of a moderate frame rate reduction.

Second harmonic inversion for ultrasound contrast harmonic imaging.

Ultrasound contrast agents (UCAs) are small micro-bubbles that behave nonlinearly when exposed to an ultrasound wave. This nonlinear behavior can be observed through the generated higher harmonics in a back-scattered echo. In past years several techniques have been proposed to detect or image harmonics produced by UCAs. In these proposed works, the harmonics generated in the medium during the propagation of the ultrasound wave played an important role, since these harmonics compete with the harmonics generated by the micro-bubbles. We present a method for the reduction of the second harmonic generated during nonlinear-propagation-dubbed second harmonic inversion (SHI). A general expression for the suppression signals is also derived. The SHI technique uses two pulses, p' and p″, of the same frequency f(0) and the same amplitude P(0) to cancel out the second harmonic generated by nonlinearities of the medium. Simulations show that the second harmonic is reduced by 40 dB on a large axial range. Experimental SHI B-mode images, from a tissue-mimicking phantom and UCAs, show an improvement in the agent-to-tissue ratio (ATR) of 20 dB compared to standard second harmonic imaging and 13 dB of improvement in harmonic power Doppler.

Optimization of a phased-array transducer for multiple harmonic imaging in medical applications: frequency and topology.

Second-harmonic imaging is currently one of the standards in commercial echographic systems for diagnosis, because of its high spatial resolution and low sensitivity to clutter and near-field artifacts. The use of nonlinear phenomena mirrors is a great set of solutions to improve echographic image resolution. To further enhance the resolution and image quality, the combination of the 3rd to 5th harmonics--dubbed the superharmonics--could be used. However, this requires a bandwidth exceeding that of conventional transducers. A promising solution features a phased-array design with interleaved low- and high-frequency elements for transmission and reception, respectively. Because the amplitude of the backscattered higher harmonics at the transducer surface is relatively low, it is highly desirable to increase the sensitivity in reception. Therefore, we investigated the optimization of the number of elements in the receiving aperture as well as their arrangement (topology). A variety of configurations was considered, including one transmit element for each receive element (1/2) up to one transmit for 7 receive elements (1/8). The topologies are assessed based on the ratio of the harmonic peak pressures in the main and grating lobes. Further, the higher harmonic level is maximized by optimization of the center frequency of the transmitted pulse. The achievable SNR for a specific application is a compromise between the frequency-dependent attenuation and nonlinearity at a required penetration depth. To calculate the SNR of the complete imaging chain, we use an approach analogous to the sonar equation used in underwater acoustics. The generated harmonic pressure fields caused by nonlinear wave propagation were modeled with the iterative nonlinear contrast source (INCS) method, the KZK, or the Burger's equation. The optimal topology for superharmonic imaging was an interleaved design with 1 transmit element per 6 receive elements. It improves the SNR by ~5 dB compared with the interleaved (1/2) design reported in literature. The optimal transmit frequency for superharmonic echocardiography was found to be 1.0 to 1.2 MHz. For superharmonic abdominal imaging this frequency was found to be 1.7 to 1.9 MHz. For 2nd-harmonic echocardiography, the optimal transmit frequency of 1.8 MHz reported in the literature was corroborated with our simulation results.

Reflector-based phase calibration of ultrasound transducers.

Recently, the measurement of phase transfer functions (PTFs) of piezoelectric transducers has received more attention. These PTFs are useful for e.g. coding and interference based imaging methods, and ultrasound contrast microbubble research. Several optical and acoustic methods to measure a transducer's PTF have been reported in literature. The optical methods require a setup to which not all ultrasound laboratories have access to. The acoustic methods require accurate distance and acoustic wave speed measurements. A small error in these leads to a large error in phase, e.g. an accuracy of 0.1% on an axial distance of 10cm leads to an uncertainty in the PTF measurement of ±97° at 4MHz. In this paper we present an acoustic pulse-echo method to measure the PTF of a transducer, which is based on linear wave propagation and only requires an estimate of the wave travel distance and the acoustic wave speed. In our method the transducer is excited by a monofrequency sine burst with a rectangular envelope. The transducer initially vibrates at resonance (transient regime) prior to the forcing frequency response (steady state regime). The PTF value of the system is the difference between the phases deduced from the transient and the steady state regimes. Good agreement, to within 7°, was obtained between KLM simulations and measurements on two transducers in a 1-8MHz frequency range. The reproducibility of the method was ±10°, with a systematic error of 2° at 1MHz increasing to 16° at 8MHz. This work demonstrates that the PTF of a transducer can be measured in a simple laboratory setting.

Acoustic sizing of an ultrasound contrast agent.

Because the properties of ultrasound contrast agent populations after administration to patients are largely unknown, methods able to study them noninvasively are required. In this study, we acoustically performed a size distribution measurement of the ultrasound contrast agent Definity(®). Single lipid-shelled microbubbles were insonified at 25 MHz, which is considerably higher than their resonance frequency, so that their acoustic responses depended on their geometrical cross sections only. We calculated the size of each microbubble from their measured backscattered pressures. The acoustic size measurements were compared with optical reference size measurements to test their accuracy. Our acoustic sizing method was applied to 88 individual Definity(®) bubbles to derive a size distribution of this agent. The size distribution obtained acoustically showed a mean diameter (2.5 µm) and a standard deviation (0.9 µm) in agreement within 8% with the optical reference measurement. At 25 MHz, this method can be applied to bubble sizes larger than 1.2 µm in diameter. It was observed that similar sized bubbles can give different responses (up to a factor 1.5), probably because of shell differences. These limitations should be taken into account when implementing the method in vivo. This acoustic sizing method has potential for estimating the size distribution of an ultrasound contrast agent noninvasively.

Super-harmonic imaging: development of an interleaved phased-array transducer.

For several years, the standard in ultrasound imaging has been second-harmonic imaging. A new imaging technique dubbed "super-harmonic imaging" (SHI) was recently proposed. It takes advantage of the higher - third to fifth - harmonics arising from nonlinear propagation or ultrasound-contrast-agent (UCA) response. Next to its better suppression of near-field artifacts, tissue SHI is expected to improve axial and lateral resolutions resulting in clearer images than second-harmonic imaging. When SHI is used in combination with UCAs, a better contrast-to-tissue ratio can be obtained. The use of SHI implies a large dynamic range and requires a sufficiently sensitive array over a frequency range from the transmission frequency up to its fifth harmonic (bandwidth > 130%). In this paper, we present the characteristics and performance of a new interleaved dual frequency array built chiefly for SHI. We report the rationale behind the design choice, frequencies, aperture, and piezomaterials used. The array is efficient both in transmission and reception with well-behaved transfer functions and a combined -6-dB bandwidth of 144%. In addition, there is virtually no contamination of the harmonic components by spurious transducer transmission, due to low element-to-element crosstalk (< 30 dB) and a low transmission efficiency of the odd harmonics (< 46 dB). The interleaved array presented in this article possesses ideal characteristics for SHI and is suitable for other methods like second-harmonic, subharmonic, and second-order ultrasound field (SURF) imaging.

A new transesophageal probe for newborns.

Current transesophageal probes are designed for adults and are used both in the operating theatre for monitoring as well as in the outpatient clinic for patients with specific indications, like obesity, artificial valves, etc. For newborns (<5 kg), transesophageal echocardiography (TEE) is not possible because the current probes are too big for introducing them into the esophagus. There is a clear need for a small probe in newborns that are scheduled for complicated cardiac surgery and catheterization. We present the design and realization of a small TEE phased array probe with a tube diameter of 5.2mm and head size of only 8.2-7 mm. The number of elements is 48 and the center frequency of the probe is 7.5 MHz. A separate clinical evaluation study was carried out in 42 patients (Scohy et al. 2007).