Method and Apparatus for Shaping Transducer Membranes

A system for fabricating an ultrasound transducer, the system comprising:

• a control panel that includes a plurality of control mechanisms configured to set a plurality of fabrication process parameters, the fabrication process parameters being selected from the group consisting of:
• process pressure, process time, process duration, and process voltage;
• and
• a transducer shaping chamber communicatively coupled to the control panel and configured to implement the fabrication process parameters therein in response to instructions from the control panel, the transducer shaping chamber including:
• a removable part carrier configured to load a transducer coupon having a plurality of transducers formed thereon, the transducers each having a transducer membrane disposed over a well partially filled with an epoxy;
• a first plate configured to support and seal against the part carrier from a first side, the first plate facing the transducer well;
• and
• a second plate configured to support and seal against the part carrier from a second side opposite the first side, the second plate facing toward the transducer membrane;
• wherein:
• the first and second plates are configured to be moved toward each other until the part carrier is sealed between the first plate and the second plate;
• and
• the transducer shaping chamber is configured to deflect the transducer membrane into an arcuate shape through application of pressurized air.

A method of operating a transducer shaping apparatus for shaping a plurality of ultrasound transducers collectively, comprising:

• providing a bottom plate having an air hole that allows a pressurized air to be delivered into the transducer shaping apparatus;
• providing a removable transducer coupon carrier disposed over the bottom plate, the transducer coupon carrier including a slot that is geometrically configured to hold and support a transducer coupon, wherein the slot includes an air inlet coupled to the air hole of the bottom plate;
• placing a transducer coupon in the slot, the transducer coupon having a plurality of ultrasonic transducers formed thereon;
• applying the pressurized air to the plurality of transducers collectively from the air inlet;
• placing a top plate over the transducer coupon carrier;
• heating the top plate;
• and
• moving the top plate and the bottom plate toward each other so as to seal against the transducer coupon carrier from opposites sides and sealing the transducer coupon carrier therebetween while the pressurized air is applied to the plurality of transducers.