Ultrasound patch with integrated flexible transducer assembly

An ultrasound patch assembly configured for use on the skin of a patient to detect fluid flow in a vessel in the patient, comprising:

• piezoelectric (piezo) elements configured to transmit ultrasonic energy and detect echo signals, the piezo elements having front and rear surfaces;
• a flex module comprising:
• first and second support portions and a hinged portion coupled to the first and second support portions to allow the first and second support portions to be positioned angularly relative to each other;
• electrodes positioned on the first and second support portions;
• and
• a pair of rigid backing structures each fixedly attached to a respective one of the piezo elements, each rigid backing structure having a blind opening in alignment with a central active area of the respective piezo element, wherein the piezo elements, the flex module, and the rigid backing structures form a transducer assembly;
• pressure contact to electrically interconnect the rear surfaces of associated ones of the piezo elements and the electrodes, wherein a non-conductive epoxy forms a bond between the electrically interconnected piezo elements and the electrodes;
• a transducer frame made of a rigid material and having first and second surfaces and sidewalls that extend outwardly from opposite ends of the first and second surfaces, the sidewalls and first and second surfaces forming a receiving area for the first and second piezo elements, the first and second surfaces receive the first and second support portions of the flex module with the rigid backing structure sandwiched between the respective first and second surfaces and the respective rigid backing structure, the first and second surfaces each having a plurality of deformable protrusions engaging the respective rigid backing structures and positioning the transducer assembly on the transducer frame with the piezo elements in a selected position relative to the first and second surface, the first and second surfaces having an angular arrangement to position the front surfaces of the first and second piezo elements at less than 180 degrees with respect to each other, at least one of the sidewalls including a retention feature protruding from the sidewall into the receiving area proximate the front surface of at least one of the first and second piezo elements;
• and
• a housing comprising:
• a top shell that has a top surface configured to face away from the skin of the patient;
• and
• a base that has a bottom surface opposite the top surface of the top shell, the bottom surface configured to face toward the skin of the patient during use with the patient, the base having a pair of angled support members oriented at angles relative to the bottom surface, the housing having a receiving area that receives and retains the transducer frame with the piezo elements positioned against the pair of angled support members at the angles with the piezo elements and at least a portion of the flex module are sandwiched between the angled support members and the transducer frame at the angles.