Hybrid Packaging and Integration Methods for Miniature Ultrasound Imaging Array

The feasibility of building small ultrasound imaging arrays with integrated electronics is explored. These arrays will ultimately be used to build laparoscopic, ultrasound imaging probes which can be used at forward military surgical locations or in emergency rooms and surgical suites. The methods for building miniature laparoscopic probes are described and arguments presented which indicated the need for small (5 mm or less) articulation mechanisms. To achieve this goal, the critical item required is a multilayer interconnect means which provides for mounting of the active multiplexer electronics, connection to 128 individual array elements, and connection to the imaging system console via a reduced number of signal channels. Methods for making the required interconnect structure will be evaluated and the most promising design will be fabricated and demonstrated. The outcome of this research benefits the military by making it possible to build light-weight, articulated intraoperative and emergency surgery probes to be used in forward surgical facilities or in field hospitals. Ultrasound imaging in these locations will guide emergency care by identification of bleeding and internal damage while simultaneously reducing surgical exploration. Ultimately, this type of care for wounded soldiers will increase survival rate and decrease recovery time. Anticipated Military Benefits/Potential Commercial Applications of the Research or Development: The military gains a new tool which can be used at forward surgery locations or field hospitals to perform quick exploration of wound sites and internal bleeding. Private sector surgeons will gain a small, flexible means to guide minimally invasive surgery and therapy.