Sparse 2-D array design for real time rectilinear volumetric imaging

Several sparse 2-D arrays for real time rectilinear volumetric imaging were investigated. All arrays consisted of 128x128=16,384 elements with lambda spacing operating at 5 MHz. Because of system limitations, not all of the elements could be used. From each array, 256 elements were used as transmitters, and 256 elements were used as receivers. These arrays were compared by computer simulation using Field II. For each array, beamplots for the on-axis case and an illustrative off-axis case were obtained. For the off-axis case, the effects of receive mode dynamic focusing were studied to maintain the beam perpendicular to the transducer face. Main lobe widths, side lobe heights, clutter floor levels, and pulse-echo sensitivities were quantified for each array. The sparse arrays, including a vernier periodic array, a random array, and a Mills cross array, were compared with a fully sampled array that served as the "gold standard". The Mills cross design showed the best overall performance under the current system constraints.     

Real-time rectilinear volumetric imaging

Current real-time volumetric scanners use a 2-D array to scan a pyramidal volume consisting of many sector scans stacked in the elevation direction. This scan format is primarily useful for cardiac imaging to avoid interference from the ribs. However, a real-time rectilinear volumetric scan with a wider field of view close to the transducer could prove more useful for abdominal, breast, or vascular imaging. In previous work, computer simulations of very sparse array transducer designs in a rectilinear volumetric scanner demonstrated that a Mills cross array showed the best overall performance given current system constraints. Consequently, a 94×94 Mills cross array including 372 active channels operating at 5 MHz has been developed on a flexible circuit interconnect. In addition, the beam former delay software and scan converter display software of the Duke volumetric scanner were modified to achieve real-time rectilinear volumetric scanning consisting of a 30-mm×8-mm×60-mm scan at a rate of 47 volumes/s. Real-time rectilinear volumetric images were obtained of tissue-mimicking phantoms, showing a spatial resolution of 1 to 2 mm. Images of carotid arteries in normal subjects demonstrated tissue penetration to 6 cm     

Hybrid multi/single layer array transducers for increased signal-to-noise ratio

In medical ultrasound imaging, two-dimensional (2-D) array transducers are necessary to implement dynamic focusing in two dimensions, phase correction in two dimensions and high speed volumetric imaging. However, the small size of a 2-D array element results in a small clamped capacitance and a large electrical impedance, which decreases the transducer signal-to-noise ratio (SNR). We have previously shown that SNR is improved using transducers made from multi-layer PZT, due to their lower electrical impedance. In this work, we hypothesize that SNR is further increased using a hybrid array configuration: in the transmit mode, a 10 Omega electronic transmitter excites a 10 Omega multi-layer array element; in the receive mode, a single layer element drives a high impedance preamplifier located in the transducer handle. The preamplifier drives the coaxial cable connected to the ultrasound scanner. For comparison, the following control configuration was used: in the transmit mode, a 50 Omega source excites a single layer element, and in the receive mode, a single layer element drives a coaxial cable load. For a 5x102 hybrid array operating at 7.5 MHz, maximum transmit output power was obtained with 9 PZT layers according to the KLM transmission line model. In this case, the simulated pulse-echo SNR was improved by 23.7 dB for the hybrid configuration compared to the control. With such dramatic improvement in pulse-echo SNR, low voltage transmitters can be used. These can be fabricated on integrated circuits and incorporated into the transducer handle.     

2-D array for 3-D ultrasound imaging using synthetic aperture techniques

A two-dimensional (2-D) array of 256 X 256 = 65,536 elements, with total area 4 X 4 = 16 cm2, serves as a flexible platform for developing acquisition schemes for 3-D rectilinear ultrasound imaging at 10 MHz using synthetic aperture techniques. This innovative system combines a simplified interconnect scheme and synthetic aperture techniques with a 2-D array for 3-D imaging. A row-column addressing scheme is used to access different elements for different transmit events. This addressing scheme is achieved through a simple interconnect, consisting of one top, one bottom single-layer, flex circuits that, compared to multilayer flex circuits, are simpler to design, cheaper to manufacture, and thinner so their effect on the acoustic response is minimized. We present three designs that prioritize different design objectives: volume acquisiton time, resolution, and sensitivity, while maintaining acceptable figures for the other design objectives. For example, one design overlooks time-acquisition requirements, assumes good noise conditions, and optimizes for resolution, achieving -6 dB and -20 dB beamwidths of less than 0.2 and 0.5 mm, respectively, for an F/2 aperture. Another design can acquire an entire volume in 256 transmit events, with -6 dB and -20 dB beamwidths in the order of 0.4 and 0.8 mm, respectively.     

A 256 x 256 2-D array transducer with row-column addressing for 3-D rectilinear imaging

We present simulation and experimental results from a 5-MHz, 256times256 2-D (65536 elements, 38.4times38.4 mm) 2-D array transducer with row-column addressing. The main benefits of this design are a reduced number of interconnects, a modified transmit/receive switching scheme with a simple diode circuit, and an ability to perform volumetric imaging of targets near the transducer with transmit beamforming in azimuth and receive beamforming in elevation. The final dimensions of the transducer were 38.4 mm times 38.4 mm times 300 mum. After a row-column transducer was prototyped, the series resonance impedance was 104 Omega at 5.4 MHz. The measured -6 dB fractional bandwidth was 53% with a center frequency of 5.3 MHz. The SNR at the transmit focus was measured to be 30 dB. At 5 MHz, the average nearest neighbor crosstalk was -25 dB. In this paper, we present 3-D images of both 5 pairs of nylon wires embedded in a clear gelatin phantom and an 8 mm diameter cylindrical anechoic cyst phantom acquired from a 256 times 256 2-D array transducer made from a 1-3 composite. We display the azimuth and elevation B-scans as well as the C-scan for each image. The cross-section of the wires is visible in the azimuth B-scan, and the long axes can be seen in the elevation B-scan and C-scans. The pair of wires with 1-mm axial separation is discernible in the elevational B-scan. When a single wire from the wire target phantom was used, the measured lateral beamwidth was 0.68 mm and 0.70 mm at 30 mm depth in transmit beamforming and receive beamforming, respectively, compared with the simulated beamwidth of 0.55 mm. The cross-section of the cyst is visible in the azimuth B-scan whereas the long axes can be seen as a rectangle in the elevation B-scan and C-scans.     

A 32 x 32 capacitive micromachined ultrasonic transducer array manufactured in standard CMOS

As ultrasound imagers become increasingly portable and lower cost, breakthroughs in transducer technology will be needed to provide high-resolution, real-time 3-D imaging while maintaining the affordability needed for portable systems. This paper presents a 32 x 32 ultrasound array prototype, manufactured using a CMUT-in-CMOS approach whereby ultrasonic transducer elements and readout circuits are integrated on a single chip using a standard integrated circuit manufacturing process in a commercial CMOS foundry. Only blanket wet-etch and sealing steps are added to complete the MEMS devices after the CMOS process. This process typically yields better than 99% working elements per array, with less than ±1.5 dB variation in receive sensitivity among the 1024 individually addressable elements. The CMUT pulseecho frequency response is typically centered at 2.1 MHz with a -6 dB fractional bandwidth of 60%, and elements are arranged on a 250 μm hexagonal grid (less than half-wavelength pitch). Multiplexers and CMOS buffers within the array are used to make on-chip routing manageable, reduce the number of physical output leads, and drive the transducer cable. The array has been interfaced to a commercial imager as well as a set of custom transmit and receive electronics, and volumetric images of nylon fishing line targets have been produced.     

High-speed ultrasound volumetric imaging system. I. Transducer design and beam steering

Transducer design and phased array beam steering are developed for a volumetric ultrasound scanner that enables the 3-D visualization of dynamic structures in real time. The authors describe the design considerations and preliminary evaluation of a high-speed, online volumetric ultrasound imaging system that uses the principles of pulse-echo, phased array scanning with a 2-D array transducer. Several 2-D array designs are analyzed for resolution and main lobe-side lobe ratio by simulation using 2-D fast Fourier transform methods. Fabrication techniques are described for 2-D array transducer. Experimental measurements of pulse-echo point spread responses for 2-D arrays agree with the simulations. Measurements of pulse-echo sensitivity, bandwidth, and crosstalk are included     

Ultrasonic imaging using a 5-MHz multilayer/single-layer hybrid array for increased signal-to-noise ratio

Conventional diagnostic ultrasound scanners are bulky and require significant amounts of electrical power during operation. Reducing the size, weight, and consumption of electrical power is made easier through the use of highly integrated compact transmit and receive electronics that may be incorporated in the transducer handle. This necessitates the use of low voltage transmitters and low power receive preamplifiers. Conventional scanners typically use approximately 100-V pulses during transmit; therefore, decreasing the transmit voltage to 15 V decreases the transmit sensitivity. Conventional receive electronics that are located at the scanner degrade the received signal-to-noise ratio (SNR) because the array element cannot efficiently drive the coaxial cable. Transmit sensitivity and received SNR can be radically improved using a multilayer/single-layer hybrid array making integration of electronics into the transducer handle more feasible. In this paper, we discuss the design, fabrication, and testing of a 5-MHz hybrid linear array. The hybrid array included 16 multilayer transmit elements (10 Omega impedance) and 24 single-layer receive elements at a half wavelength element pitch. Low voltage transmitters with an output resistance of 7 Omega and high impedance JFET preamplifiers using 15 V for biasing were located adjacent to the hybrid array in the transducer handle. The transmit sensitivity and received SNR of the hybrid array were compared with a conventional array using 50-Omega transmitters and receive preamplifiers at the scanner. The transmit sensitivity improved by 12.8 dB, and the received SNR improved by 7.8 dB, yielding an overall improvement of 20.6 dB, which compared well with predictions from the KLM model. Images of phantoms and in vivo images of the kidney obtained with the Siemens Model 1200 phased array system showed the increased SNR using the hybrid array. Estimates of penetration in tissue mimicking phantoms (alpha=0.5 dB/(cm MHz)) improved by 7 cm compared with the control.     

Multilayer piezoelectric ceramics for two-dimensional array transducers

In medical ultrasound imaging, 2-D array transducers have become essential to implement dynamic focusing and phase-correction in the elevation dimension as well as real-time volumetric scanning. Unfortunately, the small size of a 2-D array element results in a small clamped capacitance and a large electrical impedance near resonance. These elements have poor sensitivity because their impedance is much higher than the electrical impedance of the transmit and receive circuitry. Sensitivity can be improved by using an N layer structure of PZT ceramic with the layers connected acoustically in series and electrically in parallel. For the multilayer ceramic (MLC), the damped capacitance is multiplied by a factor of N(2) and the electrical impedance by 1/N(2) compared to a single layer element of the same dimensions. A 3x43 phased-array transducer has been fabricated using 3 layer PZT-5H material. Each element had a thickness of 0.66 mm and an area of 0.37x3.5 mm. The MLC was manufactured using thick film technology with plated-through vias to electrically interconnect the electrode layers. The completed transducer was compared to a single layer control array of similar dimensions. With a light epoxy backing and a lambda/4 matching layer, the MLC array elements had an impedance of 100 Omega at series resonance of 2.25 MHz, compared to 800 Omega for the control elements. The lower impedance of the MLC elements resulted in a minimum round-trip insertion loss of 24.0 dB, compared to an 34.1 dB for the control array elements. These results were consistent with KLM modeling. B-scan images were made of cysts in a tissue-mimicking phantom and of the left kidney in vivo. The images clearly showed a higher signal-to-noise ratio for the MLC array compared to the control. As a result, 2-D arrays made of multilayer ceramics can be used to form images at a higher frequency and greater range than single layer arrays.     

High-speed ultrasound volumetric imaging system. II. Parallel processing and image display

For pt.I see ibid., vol.38, no.2, p.100-8 (1991). The authors describe the design, application, and evaluation of parallel processing to the high-speed volumetric ultrasound imaging system. The scanner produces images analogous to an optical camera or the human eye and supplies more information than conventional sonograms. Potential medical applications include improved anatomic visualization, tumor localization, and better assessment of cardiac function. The system uses pulse-echo phased array principles to steer a 2-D array transducer of 289 elements in a pyramidal scan format. Parallel processing in the receive mode produces 4992 scan lines at a rate of approximately 8 frames/s. Echo data for the scanned volume is presented online as projection images with depth perspective, stereoscopic pairs, or multiple tomographic images. The authors also describe the techniques developed for the online display of volumetric images on a conventional CRT oscilloscope and show preliminary volumetric images for each display mode.     

Multi-layered PZT/polymer composites to increase signal-to-noise ratio and resolution for medical ultrasound transducers part II: thick film technology

For pt.I, see ibid., vol.46, no.4, p.961-71 (1999). Increasing transducer bandwidth and signal-to-noise ratio (SNR) is fundamental to improving the quality of medical ultrasound images. In previous work, we have proposed the use of multi-layer 1-3 PZT/polymer composites to increase both, but have encountered significant fabrication challenges. Thus, we have developed a multi-layer composite hybrid array that will not require post alignment. Starting from a 2-MHz, three-layer PZT-5H, thick film transducer designed for 1.5-D arrays, cuts are made only through the top layer and back-filled with epoxy, forming a composite layer on top of two ceramic layers. Finite element (PZFlex) simulations show that for a 2-MHz phased-array element with a single matching layer, the three-layer hybrid structure increases the pulse echo SNR by 11 dB versus a single layer PZT element and improves -6 dB pulse echo fractional bandwidth by a factor of 1.4. Composite hybrid arrays fabricated in our laboratory showed an improvement in SNR of 6 to 11 dB over a PZT control and an increase in -6 dB bandwidth by a factor of 1.1. Images from a phased-array scanner confirmed these improvements     

Ultrasparse, ultrawideband arrays

This paper investigates the properties of highly thinned ultrawideband (UWB) arrays. The design aim is high resolution and very low side radiation levels (SL). One- and two-dimensional ultrasparse UWB arrays can be designed to achieve both. The minimum available pulse-echo SL is shown to approach N(-4) where N is the number of elements in the transmit and receive arrays. Periodic thinning is shown to be superior to random thinning, and amplitude taper is shown to raise the SL. Two-dimensional curvilinear deployment of elements are shown to outperform rectilinear designs, and different transmit and receive arrays in pulse-echo systems are shown to outperform systems that use the same array for transmit and receive. Very low SL is achievable in an ultrasparse UWB system with so few elements that echo signal-to-noise ratio (SNR) rather than SL becomes the constraint on the minimum number of elements required by the system for the array to be useful for imaging. For example, in ultrasonic pulse-echo breast imaging, SL approximately -70 dB is desired to distinguish small cysts from tumors. A 2-D randomly thinned array requires about 10,000 elements. A 2-D ultrasparse UWB periodic array requires less than 100 to satisfy SL, a reduction of 100:1, but provides insufficient SNR. A 500-element, 7.5 MHz array operating with 4 cm penetration depth satisfies both. Experimental results demonstrate the theory.     

An integrated circuit with transmit beamforming flip-chip bonded to a 2-D CMUT array for 3-D ultrasound imaging

State-of-the-art 3-D medical ultrasound imaging requires transmitting and receiving ultrasound using a 2-D array of ultrasound transducers with hundreds or thousands of elements. A tight combination of the transducer array with integrated circuitry eliminates bulky cables connecting the elements of the transducer array to a separate system of electronics. Furthermore, preamplifiers located close to the array can lead to improved receive sensitivity. A combined IC and transducer array can lead to a portable, high-performance, and inexpensive 3-D ultrasound imaging system. This paper presents an IC flip-chip bonded to a 16 x 16-element capacitive micromachined ultrasonic transducer (CMUT) array for 3-D ultrasound imaging. The IC includes a transmit beamformer that generates 25-V unipolar pulses with programmable focusing delays to 224 of the 256 transducer elements. One-shot circuits allow adjustment of the pulse widths for different ultrasound transducer center frequencies. For receiving reflected ultrasound signals, the IC uses the 32-elements along the array diagonals. The IC provides each receiving element with a low-noise 25-MHz-bandwidth transimpedance amplifier. Using a field-programmable gate array (FPGA) clocked at 100 MHz to operate the IC, the IC generated properly timed transmit pulses with 5-ns accuracy. With the IC flip-chip bonded to a CMUT array, we show that the IC can produce steered and focused ultrasound beams. We present 2-D and 3-D images of a wire phantom and 2-D orthogonal cross-sectional images (Bscans) of a latex heart phantom.     

3-D ultrasound imaging using a forward-looking CMUT ring array for intravascular/intracardiac applications

Forward-viewing ring arrays can enable new applications in intravascular and intracardiac ultrasound. This work presents compelling, full-synthetic, phased-array volumetric images from a forward-viewing capacitive micromachined ultrasonic transducer (CMUT) ring array wire bonded to a custom integrated circuit front end. The CMUT ring array has a diameter of 2 mm and 64 elements each 100 microm x 100 microm in size. In conventional mode, echo signals received from a plane reflector at 5 mm had 70% fractional bandwidth around a center frequency of 8.3 MHz. In collapse mode, 69% fractional bandwidth is measured around 19 MHz. Measured signal-to-noise ratio (SNR) of the echo averaged 16 times was 29 dB for conventional operation and 35 dB for collapse mode. B-scans were generated of a target consisting of steel wires 0.3 mm in diameter to determine resolution performance. The 6 dB axial and lateral resolutions for the B-scan of the wire target are 189 microm and 0.112 radians for 8 MHz, and 78 microm and 0.051 radians for 19 MHz. A reduced firing set suitable for real-time, intravascular applications was generated and shown to produce acceptable images. Rendered three-dimensional (3-D) images of a Palmaz-Schatz stent also are shown, demonstrating that the imaging quality is sufficient for practical applications.     

Real-time 3-D ultrasound guidance of interventional devices

We have previously developed 2-D array transducers for many real-time volumetric imaging applications. These applications include transducers operating up to 7 MHz for transthoracic imaging, up to 15 MHz for intracardiac echocardiography (ICE), 5 MHz for transesophageal echocardiography (TEE) and intracranial imaging, and 7 MHz for laparoscopic ultrasound imaging (LUS). Now we have developed a new generation of miniature ring-array transducers integrated into the catheter deployment kits of interventional devices to enable real-time 3-D ultrasound scanning for improved guidance of minimally invasive procedures. We have constructed 3 new ring transducers. The first consists of 54 elements operating at 5 MHz. Typical measured transducer element bandwidth was 25%, and the 50 Ohm round trip insertion loss was -65 dB. Average nearest neighbor cross talk was -23.8 dB. The second is a prototype 108-element transducer operating at 5 MHz. The third is a prototype 108-element ring array with a transducer center frequency of 8.9 MHz and a -6 dB bandwidth of 25%. All transducers were integrated with an 8.5 French catheter sheath of a Cook Medical, Inc. vena cava filter deployment device.     

Element shape design of 2-D CMUT arrays for reducing grating lobes

Fully populated two-dimensional (2-D) arrays are needed to produce high quality ultrasonic volumetric images for real-time applications, but they present many challenges for their physical realization because of the large number of elements. In fact, lambda/2 and lambda minimum spacing between elements is required, respectively, for pyramidal and rectilinear scanning in order to avoid unwanted grating lobes (GLs). However, in past years, capacitive micromachined ultrasonic transducer (CMUT) technology has made possible the production of arrays with large flexibility in element shape and size. In this paper, this property is analyzed, and a new element shape, based on the concept of spatial interpenetration of adjacent elements, is proposed in order to design fully populated 2-D CMUT arrays with a low number of elements, whose beam characteristics are valid for volumetric imaging. Through the use of simulations, it is demonstrated that arrays with pitch larger than lambda (up to 3lambda) used for rectilinear scanning, have notably lower GLs than the equivalent standard arrays designed according to the classical squared element shape. As consequence, the proposed geometry has the advantage of reducing the number of elements (up to a factor of 9) and of enlarging the element size, implying an increase of the SNR relative to the single element. When beam steering is required, arrays can be designed with pitch equal to lambda, reducing the number of elements by a factor of 4 if the maximum steering angle is limited to +/-15 degrees .     

Intracardiac catheter 2-D arrays on a silicon substrate

The design, fabrication, and characterization of a 7 MHz, two-dimensional (2-D) array transducer built on a silicon substrate is described. The array fits inside a 9-French (2.9 mm O.D.) catheter for use in real-time intracardiac volumetric imaging. The -6 dB fractional bandwidth of the transducer is 30%, the 50 /spl Omega/ pitch-catch insertion loss is 78 dB, and the interelement crosstalk is -25 dB. Realtime volumetric images in phantoms and in-vitro images of a sheep heart have been acquired yielding measured spatial resolution of 2 mm at a depth of 1 cm. The cardiac structures imaged include ventricular chambers, interventricular septum, mitral and tricuspid valves and real-time 3-D rendered volumes of the tricuspid valve in the open and closed position.     

One-dimensional to two-dimensional channel formatting with micro-optics for wavelength division multiplexing networks

We present a method of interfacing a conventional wavelength multiplexing and demultiplexing device with a two-dimensional (2-D) array of surface-active elements, such as micro-electromechanical system devices or photodetectors. We use diffractive optical elements to transform wavelength division multiplexed signals spread along a line into a 2-D array. We applied this technique to build a device that is compatible with an arrayed-waveguide grating. The theoretical insertion loss predicted by combining beam propagation and rigorous coupled-wave analysis is 2.75 dB. However, the experimental loss is 10 dB. The difference is due to the poor quality of the diffraction gratings. Nevertheless, the formatting operation was performed successfully.     

Real-time 3-D ultrasound imaging using sparse synthetic aperture beamforming

A method for real-time three-dimensional (3-D) ultrasound imaging using a mechanically scanned linear phased array is proposed. The high frame rate necessary for real-time volumetric imaging is achieved using a sparse synthetic aperture beamforming technique utilizing only a few transmit pulses for each image. Grating lobes in the two-way radiation pattern are avoided by adjusting the transmit element spacing and the receive aperture functions to account for the missing transmit elements. The signal loss associated with fewer transmit pulses is minimized by increasing the power delivered to each transmit element and by using multiple transmit elements for each transmit pulse. By mechanically rocking the array, in a way similar to what is done with an annular array, a 3-D set of images can be collected in the time normally required for a single image.     

Novel transmit protection scheme for ultrasound systems

The problem of protecting or isolating extremely sensitive receive circuitry from high-voltage transmit circuitry is commonly addressed through the use of diode bridges, transformers, or high-voltage switches, which prove to be prohibitively expensive, bulky, and power consuming for use in portable, low-cost, battery-powered systems. These approaches also compound the interconnect difficulties associated with two-dimensional (2-D) transducer arrays. In this paper we present a novel transmit protection scheme that allows compact MOSFET shunting devices to be brought on-chip within each receive channel implemented in a standard CMOS integrated circuit process. During transmit, the high voltage transmit pulse is driven onto the common connection of the transducer array and the on-chip MOSFET devices shunt the current to ground. During receive, these devices are turned off, the common connection of the transducer array is shunted to ground, and the received echo can be detected as usual. The transmit protection scheme was experimentally shown to shunt a 16 mA peak current resulting from the equivalent of a 100-V, 25-ns-risetime transmit pulse through a 4 pF transducer element. The scheme was also incorporated into a prototype 1024-channel, low-cost, ultrasound system successfully used to form pulse echo images.