Encapsulated ultrasound transducer probe assembly

Claim 3

The method of manufacturing as recited in claim 1 wherein positioning of the subassembly includes fitting associated guide pins in the mold to guide holes in the internal structure.

Claim 4

The method of manufacturing as recited in claim 1 wherein the encapsulation is formed by casting.

Claim 5

The method of manufacturing as recited in claim 1 wherein a second encapsulation is performed around the sub-assembly for forming a customized handle which becomes the handle portion.

Claim 6

The method of manufacturing as recited in claim 4 wherein a prefabricated case is further adhered to the handle portion.

Claim 7

The method of manufacturing as recited in claim 1 wherein the method includes the step of dipping.

Claim 8

The method of manufacturing as recited in claim 1 wherein the method includes the step of coating.

Claim 9

The method of manufacturing as recited in claim 1 wherein positioning of the sub-assembly includes fitting associated guide pins in the mold to guide holes of the internal structure.

Claim 10

The method of manufacturing as recited in claim 1 wherein positioning of the subassembly into the mold is performed by a computer automated procedure.

Claim 11

An ultrasound transducer probe having interior transducer probe components, the probe comprising: a substantially continuous one-piece casing for permanently encapsulating the interior transducer probe components, the casing having: a contact portion for use in contacting skin at a target area, the contact portion having a lens; and a handle portion extending from the contact portion, the handle portion being shaped for grasping by the hand of the user; the probe further having a power connection sealed to or integrated with the casing, wherein the contact portion and the handle portion are integrated into the substantially continuous one-piece casing resulting in the casing being sealed and associated with the power connection so as to permit liquid immersion of the casing and the power connection.

Claim 12

An ultrasound transducer probe having interior transducer probe components, the probe comprising: a substantially continuous one-piece casing for permanently encapsulating the interior transducer probe components, the casing having: a contact portion for use in contacting skin at a target area, the contact portion having a lens; and a handle portion extending from the contact portion, the handle portion being shaped for grasping by the hand of the user; the probe further having a power connection sealed to or integrated with the casing, wherein the contact portion and the handle portion are integrated into the substantially continuous one-piece casing resulting in the casing being sealed and associated with the power connection so as to permit liquid immersion of the casing and the power connection.

Claim 13

The ultrasound transducer probe as recited in claim 10 wherein the casing is RTV polymer.

Claim 14

The ultrasound transducer probe according to claim 11 wherein the RTV polymer compound employs a filler for modifying acoustic impedance of the RTV polymer compound.

Claim 15

The ultrasound transducer probe according to claim 12 wherein the filler is silica powder.

Claim 16

The ultrasound transducer probe as recited in claim 10 wherein the casing is a polyurethane.

Claim 17

The ultrasound transducer probe as recited in claim 10 wherein the contact portion comprises as the lens a surface of an acoustic lens from a polyurethane.

Claim 18

The ultrasound transducer probe as recited in claim 10 wherein needle guide locating features protrude through the casing for external attachment of a needle guide.

Claim 19

The ultrasound transducer probe as recited in claim 10 wherein a needle guide is incorporated in the device casing.

Claim 20

The ultrasound transducer probe as recited in claim 10 wherein the handle portion is ergonomically shaped to reduce fatigue for extensive continuous use.

Claim 21

The ultrasound transducer probe as recited in claim 10 wherein the handle portion includes grip enhancing protrusion and indentation patterns.

Claim 22

An ultrasound transducer probe as recited in claim 10 wherein the power connection includes a cable, the handle portion having a bottom, a strain relief being integrated into the bottom and cooperating with the cable for preventing cable degradation.

Claim 23

A method of manufacturing the probe of claim 10 wherein the components include a transducer stack array and the power connections includes a cable assembly, the method comprising attaching the transducer stack array to the cable assembly such that a suitable electrical and mechanical connection is formed, positioning the stack array and attached cable assembly to form the casing therearound, wherein the exterior surface of the casing is impervious to liquid intrusion.

Claim 24

The method of manufacturing as recited in claim 21 wherein the mold is formed by casting a model of a transducer probe.

Claim 25

The method of manufacturing as recited in claim 22 wherein the cast material is one of RTV compound, rubber, plastic, metal.

Claim 26

The method of manufacturing as recited in claim 23 wherein the mold is cured in an oven at about 50 degrees C for approximately 12 hours.

Claim 27

The method of manufacturing as recited in claim 21 wherein the cable assembly is marked for orientation within the mold.

Claim 28

The method of manufacturing as recited in claim 25 wherein the orientation markings are used for positioning in the mold.

Claim 29

The method of manufacturing as recited in claim 26 wherein the mold is cured in an oven at about 50 degrees C for approximately 12 hours thereby forming a usable device.

Claim 30

The method of manufacturing as recited in claim 21 wherein the stack array is prepared by sealing the corners with an epoxy with an adhesion promoter to ensure bonding to the lens material.

Claim 31

An encapsulated ultrasound transducer probe comprising a contact portion, a handle portion, and accessory locating features wherein the encapsulation forms a liquid-proof casing around the probe, and further wherein said locating feature protrude through the casing for attachment of an accessory device.

Claim 32

An encapsulated ultrasound transducer probe comprising a contact portion, a handle portion, and accessory locating features wherein the encapsulation forms a liquid-proof casing around the probe, and further wherein said locating feature protrude through the casing for attachment of an accessory device.

Claim 33

The encapsulated ultrasound transducer probe as recited in claim 29 wherein the attached accessory device is a needle guide.

Claim 34

The encapsulated ultrasound transducer probe as recited in claim 29 wherein the probe further includes a plastic casing adhered to the handle portion.

Claim 35

The encapsulated ultrasound transducer probe as recited in claim 29 wherein the encapsulation is RTV.

Claim 36

The encapsulated ultrasound transducer probe as recited in claim 29 wherein the encapsulation is a polyurethane.

Claim 37

A probe having interior components electrically connected to a cable, the probe comprising: a substantially continuous liquid-impermeable encapsulate comprised of a solid piece of material permanently and sealingly surrounding the components such that upon immersion of the encapsulate in liquid the components remain dry, the encapsulate defining a first end; a second end opposite the first end; and a handle portion extending between the first end and the second end, the first end, second end and handle portion being integrally formed, the first end being a lens carrying end and having a width and a length, the width varying along the length such that the width of the first end increases toward the handle portion; the handle portion being elongate and shaped for gripping by the human hand, the handle portion having a handle width near the first end and a handle width near the second end, the handle width near the first end being less than the handle width near the second end and less than the width of the first end near the handle portion; the second end surrounding and being permanently bonded in a liquid tight fashion to the cable; the second end having a length and a width, the width varying along the length of the second end, the width of the second end being greatest near the handle portion, the probe being an ultrasound transducer probe for direct gripping and control by the hand of the user on the skin, the shape of the handle portion being ergonomically fashioned to reduce fatigue by the user, the probe being immersible in liquid for the cleansing of the encapsulant.

Claim 38

A probe having interior components electrically connected to a cable, the probe comprising: a substantially continuous liquid-impermeable encapsulate comprised of a solid piece of material permanently and sealingly surrounding the components such that upon immersion of the encapsulate in liquid the components remain dry, the encapsulate defining a first end; a second end opposite the first end; and a handle portion extending between the first end and the second end, the first end, second end and handle portion being integrally formed, the first end being a lens carrying end and having a width and a length, the width varying along the length such that the width of the first end increases toward the handle portion; the handle portion being elongate and shaped for gripping by the human hand, the handle portion having a handle width near the first end and a handle width near the second end, the handle width near the first end being less than the handle width near the second end and less than the width of the first end near the handle portion; the second end surrounding and being permanently bonded in a liquid tight fashion to the cable; the second end having a length and a width, the width varying along the length of the second end, the width of the second end being greatest near the handle portion, the probe being an ultrasound transducer probe for direct gripping and control by the hand of the user on the skin, the shape of the handle portion being ergonomically fashioned to reduce fatigue by the user, the probe being immersible in liquid for the cleansing of the encapsulant.

Claim 39

An ultrasound assembly comprising: a liquid-impermeable, substantially continous outer casing, the casing being permanently connected around and housing in a liquid impermeable fashion interior components, the casing defining: a contact portion; and a handle portion extending from the contact portion and integrally connected thereto, the handle portion being shaped to be grasped by the hand of the user for movement and placement of the contact portion for contacting skin at a target area, wherein the casing with the components held therein is immersible in liquid without the liquid contacting the components.

Claim 40

An ultrasound assembly comprising: a liquid-impermeable, substantially continous outer casing, the casing being permanently connected around and housing in a liquid impermeable fashion interior components, the casing defining: a contact portion; and a handle portion extending from the contact portion and integrally connected thereto, the handle portion being shaped to be grasped by the hand of the user for movement and placement of the contact portion for contacting skin at a target area, wherein the casing with the components held therein is immersible in liquid without the liquid contacting the components.

Claim 41

An ultrasound transducer probe having interior components comprising: a rubber-like, liquid impermeable casing permanently and sealingly surrounding the interior components of the ultrasound transducer probe to act as a bar between the components and liquids, the casing being comprised of: a contact portion for use in contacting the skin at a target area, the contact portion having a lens therein with a thickness of between about 22 and about 80 mils; a handle portion for grasping by the hand of the user, the handle portion having a diameter of between about one to about two inches and being shaped to ergonomically reduce fatigue by the user during use of the probe; and a cable extending from the handle portion, wherein the contact portion and the handle portion are integrated into a substantially continuous one-piece unit resulting in the casing encapsulating the interior components and being sealed to or integrated with the cable to permit liquid immersion of the contact and handle portion and the cable without damage thereto by the liquid.

Claim 42

An ultrasound transducer probe having interior components comprising: a rubber-like, liquid impermeable casing permanently and sealingly surrounding the interior components of the ultrasound transducer probe to act as a bar between the components and liquids, the casing being comprised of: a contact portion for use in contacting the skin at a target area, the contact portion having a lens therein with a thickness of between about 22 and about 80 mils; a handle portion for grasping by the hand of the user, the handle portion having a diameter of between about one to about two inches and being shaped to ergonomically reduce fatigue by the user during use of the probe; and a cable extending from the handle portion, wherein the contact portion and the handle portion are integrated into a substantially continuous one-piece unit resulting in the casing encapsulating the interior components and being sealed to or integrated with the cable to permit liquid immersion of the contact and handle portion and the cable without damage thereto by the liquid.