The requirements of our third generation 3D ultrasound computer tomography system (USCT) led to a transducer array design based on single-fibre piezocomposites. The used piezoelectric ceramic fibres exhibit a thickness to diameter ratio of 4/3. This ratio results in a proximity of the dominant axial and lateral vibration resonances. The standard Krimholtz-Leedom-Matthaei (KLM) model considers only one spatial dimension. This limits the validity of the modelled predictions for our application. By adding a coupled transmission line in series to the axial resonator, the standard model can be extended to take additional spatial dimensions into account. Using model parameters from literature resulted in a low model-to-measurement fit. To enhance the prediction accuracy, a brute-force optimisation over four model parameters was conducted. With the optimal parameter set, a fit of 90.3% could finally be achieved. The necessary model parameter changes were found reasonable for the piezocomposite design. With the presented model enhancement it is now possible to consider both dominant vibration modes of our transducers.

A potential method for future breast cancer screening is 3D ultrasound computed tomography (USCT). The utilized image reconstruction algorithms require transducer characteristics fundamentally different from conventional transducer arrays, leading to the necessity of a custom design. This design has to provide random transducer positioning, isotropic sound emission as well as a large bandwidth and wide opening angle. In this paper, we present a new transducer array design to be utilized in a third generation 3D USCT system. Each system requires 128 cylindrical arrays, mounted into the shell of a hemispherical measurement vessel. Each new array contains a 0.6 mm thick disk with 18 single PZT fibers (0.46 mm diameter) embedded in a polymer matrix. Randomized positioning of the fibers is achieved with an arrange-and-fill process. The single-fiber disks are connected on both ends with a matching and backing disk using simple stacking and adhesives. This enables fast and scalable production. We characterized the acoustic field of 54 transducers with a hydrophone. Measurements in 2D showed isotropic acoustic fields. The mean bandwidth and opening angle are 131% and 42°, respectively (both -10 dB). The large bandwidth arises from two resonances within the utilized frequency range. Parameter studies using different models showed that the realized design is already close to the achievable optimum for the transducer technology used. Two 3D USCT systems were equipped with the new arrays. First images show promising results, with an increase in image contrast and a significant reduction of artifacts.

The objective of this work was to investigate changes in the acoustic characteristics of micromachined transducers caused by acoustic cross-coupling between cells. We used hexagonal, polymer-based capacitive micromachined ultrasonic transducers (polyCMUTs) consisting of 127 cells connected in parallel. The distances between the cells were varied, while the cell dimensions and number of cells remained constant. The resulting changes in characteristics were evaluated in terms of peak frequency f_pk , fractional bandwidth FBW , peak transmit sensitivity S_pk and opening angle Φ _t . The study relies on results from an analytic multicell model (MCM) which considers cross-coupling effects between cells through a mutual acoustic impedance matrix. The results are compared with finite element (FE) analyses and measurements on fabricated prototypes. The manufacturing processes used to produce the polyCMUT prototypes are explained in detail. We found significant changes in all acoustic characteristics: as cell spacing increases, f_pk and Φ _t decrease, while S_pk gradually rises to about twice the initial value. The FBW varies due to the change in f_pk , peaking at small to intermediate cell-to-cell distances. While both modeling approaches cover the general effects, discrepancies in comparison to the measurements were identified. The FE model provided better fits than the analytic MCM, albeit at significantly higher computational costs. The effects on the acoustic characteristics were found strongest at lower frequencies and if many cells are in close proximity to each other. Hence, rotational symmetric or square transducers operating at lower frequencies are affected most. The results demonstrate that design approaches based on modeling single cells may lead to significant deviations from design goals. Both, analytic and FE models are suitable tools to estimate the effects of acoustic interactions and to predict the performance. This aids in meeting design requirements of micromachined ultrasound transducers consisting of multiple radiators.

For breast cancer imaging, ultrasound computer tomography (USCT) is an emerging technology. To improve the image quality of our full 3-D system, a new transducer array system (TAS) design was previously proposed. This work presents a manufacturing approach which realises this new design. To monitor the transducer quality during production, the electro-mechanical impedance (EMI) was measured initially and after each assembly step. To evaluate the measured responses, an extended Krimholtz–Leedom–Matthaei (KLM) transducer model was used. The model aids in interpreting the measured responses and presents a useful tool for evaluating parasitic electric effects and attenuation at resonance. For quality control, the phase angle at thickness resonance ${\phi }_{\mathrm{t}}$ was found to be the most specific EMI property. It can be used to verify the functionality of the piezocomposites and allows reliable detection of faults in the acoustic backing. Evaluating the final response of 68 transducers showed 5% variance of the series resonance frequency. This indicates good consistency of derived ultrasound performance parameters.

A semi-automated packaging process for transducer array manufacturing is presented. As an major innovation, a transducer disc is integrated in a sandwich structure between a printed circuit board (PCB) and an acoustic matching layer. Each of the transducer discs contains 18 lead-zirconium-titanate (PZT) fibres embedded in epoxy. To interconnect the transducer array components, adhesive bonding and automatic pick-and-place processes were used. A pre-series was evaluated by measuring the electro-mechanical impedance (EMI) before and after the assembly. Statistical analysis showed consistent behaviour of the series resonance f s and the electro-mechanical coupling k eff before and after the packaging. This encouraged the manufacturing of 256 arrays. These arrays will now be integrated in an ultrasound computer tomography (USCT) system with 3D scanning aperture for breast cancer imaging. With this system, we intend to bridge the gap towards clinical use of full 3D USCT.