Advanced electrical array interconnections for ultrasound probes integrated in surgical needles

Real-time ultrasound guidance during neurosurgery is a novel and sought-after technique that enables imaging data to be acquired with improved precision during surgical intervention. Surgical needles that are inserted in the tissue of interest can be guided using the real-time graphical information collected by an embedded ultrasound transducer. The miniaturisation capabilities of modern manufacturing technologies allow the fabrication of ultrasound probes that are small enough to be fitted in needles conventionally used in surgical practices (down to ~2 mm inner diameter). High lateral resolution may in fact be achieved by producing miniaturised ultrasound transducer arrays with a series of emitting/receiving elements, each electrically isolated from the others. To guarantee the functionality of such devices, a series of independent electrical interconnections must be implemented that enables the external driving electronics of the imaging system to be connected to the miniaturised ultrasound probe array. This paper presents a novel interconnection scheme designed to interface ultrasound probes integrated in surgical needles with the driving electronics. The presented solution utilises a flexible printed circuit board carrying the electrical tracks and a bonding technique with an anisotropic conductive paste.