DEVICES AND METHODS FOR PARAMETER MEASUREMENT
20190282173 ยท 2019-09-19
Inventors
- Peter Starr (San Antonio, TX, US)
- Steven Bailey (San Antonio, TX, US)
- Mauli Agrawal (San Antonio, TX, US)
Cpc classification
A61B2562/16
HUMAN NECESSITIES
A61B5/686
HUMAN NECESSITIES
A61B2562/028
HUMAN NECESSITIES
A61B5/145
HUMAN NECESSITIES
A61B5/1473
HUMAN NECESSITIES
B29L2031/753
PERFORMING OPERATIONS; TRANSPORTING
A61B2562/12
HUMAN NECESSITIES
A61M60/531
HUMAN NECESSITIES
A61B5/1036
HUMAN NECESSITIES
A61B5/0004
HUMAN NECESSITIES
A61M60/268
HUMAN NECESSITIES
A61B5/0084
HUMAN NECESSITIES
B29C65/48
PERFORMING OPERATIONS; TRANSPORTING
A61B2562/0233
HUMAN NECESSITIES
A61B2562/04
HUMAN NECESSITIES
A61B2562/164
HUMAN NECESSITIES
A61B5/03
HUMAN NECESSITIES
A61M60/438
HUMAN NECESSITIES
A61B7/023
HUMAN NECESSITIES
A61M60/148
HUMAN NECESSITIES
International classification
A61B5/00
HUMAN NECESSITIES
G01L9/00
PHYSICS
A61F2/24
HUMAN NECESSITIES
B29C65/48
PERFORMING OPERATIONS; TRANSPORTING
A61B5/103
HUMAN NECESSITIES
Abstract
A thin-film, diaphragm based device is disclosed which can be used to perform an array of sensing and actuating operations where a very thin profile is desired, such as in millimeter, micrometer, or nanometer tight spaces.
Claims
1. A device comprising: a substrate; a diaphragm coupled to the substrate, wherein the diaphragm is a thin film capacitive transducer between 10 m and 20 m thick; and a chamber structure between the diaphragm and the substrate, wherein: the diaphragm is coupled to the substrate via an adhesive; the chamber structure comprises a bonding pad around the perimeter of the chamber structure; the chamber structure is positioned between the diaphragm and the adhesive; and the substrate is approximately 50 m thick and is electrically conductive.
2.-6. (canceled)
7. The device of claim 1 wherein the substrate and diaphragm are configured as a wireless resonant pressure sensor sized for implantation in a human artery.
8. The device of claim 1 wherein the diaphragm is approximately 15 m thick.
9. (canceled)
10. The device of claim 1 wherein the substrate is configured as an antenna.
11. The device of claim 1 wherein the device is configured to measure pressure with a linear sensitivity of approximately four percent between 0 and 400 mm Hg.
12. The device of claim 1 wherein the substrate and the diaphragm are biocompatible.
13. The device of claim 1 wherein the device is configured as a pressure sensor.
14. The device of claim 1 wherein the device is configured as an audio wave sensor.
15. The device of claim 1 wherein the device is configured as a chemical sensor.
16. The device of claim 1 wherein the device is configured as a biological sensor.
17. The device of claim 1 wherein the device is configured as an optical sensor.
18. The device of claim 1 wherein the device is configured as a pump.
19. The device of claim 1 wherein the device is configured as a valve.
20. The device of claim 1 further comprising a first electrode coupled to the diaphragm and a second electrode coupled to the substrate.
21. A method of fabricating a thin film capacitive transducer, the method comprising; providing a substrate; providing a diaphragm, wherein the diaphragm is between 10 m and 20 m thick; and coupling the diaphragm to the substrate via an adhesive to provide a chamber structure between the diaphragm and the substrate, wherein: the chamber structure comprises a bonding pad around the perimeter of the chamber structure; the chamber structure is positioned between the diaphragm and the adhesive; and the substrate is approximately 50 m thick and is electrically conductive.
22. (canceled)
23. The method of claim 21 further comprising inserting the chamber structure between the diaphragm and the substrate before coupling the diaphragm to the substrate.
24. The method of claim 23 wherein the diaphragm and chamber structure are constructed using photolithography.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0078] The following drawings form part of the present specification and are included to further demonstrate certain aspects of the present disclosure. The invention may be better understood by reference to one of these drawings in combination with the detailed description of specific embodiments presented herein.
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DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0103] Referring initially to
[0104] In the illustrated embodiment, chamber structure 120 comprises a bonding pad 125 around its perimeter and chamber structure 120 is positioned between diaphragm 110 and substrate 140. In exemplary embodiments of device 100, substrate 140 can be electrically conductive, and in certain embodiments can be configured as an antenna.
[0105] Exemplary embodiments of device 100 may be fabricated by constructing a thin sensing film, which comprises of an array of diaphragms 110 enclosed by bonding pads 125. In certain embodiments, to construct the sensing film, multiple layers of photolithography with various polyimides can be performed on a carrier substrate. The diaphragm can be defined in one step, the chamber walls can be defined in a second step, and a thin adhesive film applied in a third step. The sensing film can then be released from the carrier.
[0106] In exemplary fabrication techniques, the sensing film can then be bonded to the substrate of choice. In certain embodiments, the thin adhesive can be deposited onto a conductive substrate. If the substrate is not inherently conductive, a thin conductive film may be deposited to provide a bottom electrode of the diaphragm sensor. The sensing film can then be bonded to the substrate under pressure and temperature.
[0107] In certain embodiments, the final fabrication step is to sputter an electrode and bond lead wires. For example, a thin conductive film can be deposited on top of the sensing film to define the top electrode of the diaphragm sensor. Lead wires can then be bonded onto the top and bottom electrodes.
[0108] In certain embodiments of the sensor, the sensing film (e.g. diaphragm 110) is 10-15 m thick and substrate 140 is 50 m thick stainless steel. In certain embodiments, diaphragms 110 form a sensing film that is 3 mm10 mm, but it can be of arbitrary size to suit the application.
[0109] In certain embodiments, substrate 140 may be formed by polymers processing techniques. Other microfabrication techniques could produce a similarly-structured device composed of other materials, including traditional microfabrication ceramics such as silicon, silica, quartz, silicon nitrides, other nitrides, other oxides, and other insulating or semiconducting materials.
[0110] During operation of device 100, deflection of diaphragm 110 toward and away from substrate 140 can be measured by changes in electrical properties and correlated to environmental conditions or parameters affecting device 100. For example, in certain embodiments, the capacitance of device 100 (measured between diaphragm 110 and substrate 140) can be correlated to pressure. Referring now to
[0111] Referring now to
[0112] In the graph shown in
[0113] Device 100 can be used in many different applications. For example, device 100 can be configured for use as a sensor, including a pressure, acoustic, force or flow sensor. Device 100 may also be configured as a mechanical actuating device, including for example an electrostatically (or pneumatically)-driven membrane that can be used as a pump or valve in microfluidics applications. For example, in a valve configuration, diaphragm 110 can be deflected outward (e.g. away from substrate 140) to occlude flow and toward substrate 140 to allow flow to pass over diaphragm 110.
[0114] In still other embodiments, device 100 can be configured a capacitive microphone, including for example configuration a hearing aid.
[0115] In certain embodiments, device 100 can be configured as a chemical or biological sensor. For example, chamber structure 120 can be configured as a polymer or hydrogel with selective absorption that can swell and deflect diaphragm 110 in the presence of certain analytes.
[0116] In particular embodiments, device 100 may also be used for detecting chemical or biological analytes by mass loading of the sensing diaphragm, which changes its resonance frequency. The sensing diaphragm can have analyte receptors bound to its surface and the resonance frequency of the sensing diaphragm can be monitored by actuating device 100 electrostatically or thermally. Detection of the analyte occurs by recording the shift in resonant frequency of the diaphragm.
[0117] In specific embodiments, device 100 may be configured for indirect sensing by principles similar to those used in a Golay cell. For example, chamber structure 120 may be filled with a gas that expands with increased temperature and causes deflection of diaphragm 110. In particular embodiments, diaphragm 110 may be coated with a bandpass filter to provide for specific detection of light wavelengths or color. Such configurations could be used in imaging or retinal implant applications.
[0118] In certain embodiments, device 100 can be configured as a thin-film pressure sensor in an inductor-capacitor (LC) resonator for a wireless implantable blood pressure sensor. In particular embodiments, device 100 can operate by capacitive, resistive, and resonant mechanisms. In exemplary embodiments, device 100 can sense a broad range of factors, individually and multiple simultaneously. Device 100 can be configured as an electrical inductor-capacitor (LC) resonator that measures pressure by a thin film capacitive transducer that resonates with a stent-like antenna.
[0119] In exemplary embodiments, the thin active region of the sensor is decoupled from a thick inactive substrate. Certain embodiments can incorporate the use of a shape-memory NiTi as an antenna for percutaneous catheter delivery of the device. In certain embodiments, movements in local pressure change the transducer capacitance and thus shift the resonance frequency. In particular embodiments, the resonance frequency can be monitored externally by magnetic coupling to determine intravascular pressure.
[0120] In specific embodiments, the sensor can be bonded to a thin metallic substrate and coupled to a flexible NiTi stent-antenna (inductor), and the diaphragm sensor and inductive antenna form an electrical inductor-capacitor (LC) resonator.
[0121] In certain exemplary embodiments, device 100 has a thin profile, is wireless, biocompatible, implantable, and allows for intravascular implantation for blood pressure sensing. In particular embodiments, device 100 can be fabricated with biocompatible materials, is flexible and due to thin profile allows for 3-D conformations of sensor in vivo, allows for implementation in medium to small arteries, including the peripheral arteries.
[0122] In particular embodiments, device 100 can be bonded to virtually any substrate, and be integrated or embedded into various devices. The thin and flexible profile of device 100 is suitable for implantation into constrained spaces which were previously inaccessible for sensors.
[0123] The replacement of a thick silicon wafer onto which most pressure sensors are built with a very thin substrate (or the surface of an existing device or implant, including e.g. a stent) can save hundreds of micrometers of thickness which can be critical in particular applications. For example, one embodiment enables the development of a wireless resonant pressure sensor which is suitable for implantation in a large, medium, or small sized artery. As described in the literature reviews on endovascular blood pressure sensing devices and on pressure transducers, transducer size has been a limiting factor in the development of small implantable devices.
[0124] As described previously, exemplary embodiments of the present disclosure substitute the platform for the sensing diaphragm to reduce sensor thickness. Commercially available pressure sensors use silicon wafer as substrates with a thickness of about 500 m, most of which can be eliminated by integrating the sensing element onto a robust surface of the device.
Test Data
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[0128] Design and fabrication of exemplary embodiments requires detailed knowledge and synthesis of multiple fields including microelectronics, microfabrication, cardiovascular medicine, and biomaterials. Additionally, silicon wafers are the epicenter of the microelectronics and microfabrication fields; departing from this fabrication orthodoxy is difficult.
[0129] Embodiments of the current invention include a class of resonant sensors which can be used in a shoe insole for monitoring foot pressures. The general sensor is a resistor-inductor-capacitor (RLC) resonant circuit, which allows for either capacitive sensing or resistive sensing.
[0130] In the capacitive design, a planar conductive coil is electrically connected to a capacitive pressure transducer to form an RLC tank, which is then embedded into an insole. The resonance frequency of the tank depends on the applied pressure. The sensor can be interrogated by an external coil which sweeps across a specified frequency range to monitor shifts in the resonance frequency.
[0131] In the resistive design, a planar conductive coil is electrically connected to a capacitor and a resistive transducer to form an RLC tank, which is then embedded into an insole. In this case, the resonance frequency of the tank is fixed, but the quality of resonance (quality factor Q) depends on the applied pressure. The sensor can be interrogated by an external coil at a fixed frequency by monitoring the strength of the magnetically coupled signal.
[0132] The capacitive design of an RLC sensor has been enabled. Referring back now to
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[0135] It is understood that the above-described devices and methods are merely non-limiting examples of embodiments of the devices and methods disclosed herein.
[0136] Exemplary embodiments of the present disclosure include resonators that operate in the audible acoustic range. Existing systems typically stipulate stimulation in the ultrasound range.
[0137] Bandwidth of the acoustic transmitter and/or receiver in exemplary embodiments of the present disclosure is much lower than standard ultrasound crystals. In certain embodiments, a unique probe may be developed for this application in the 1-20 kHz range.
[0138] Mechanical resonators are most sensitive to gauge pressure, and only to the first several hundred mmHg, after which sensitivity drops considerably. Therefore, it is not possible simply to use or test any commercially available pressure sensor with a micromachined diaphragm, which have chambers underneath which are frequently hermetically sealed under vacuum. In the case of vacuum sealed, commercially available pressure sensors, the gauge pressure across the diaphragm at the physiological range is >800 mmHg, which offers negligible pressure sensitivity if used as a mechanical resonator.
[0139] An exemplary embodiment of a prototype resonator is square polyimide diaphragm (500 um long, 5 um thick) over a closed air chamber, as shown in
[0140] Modification of the standard equation for determining the resonance frequency of such a diaphragm (Roark) yields the following expression for resonance frequency with a strong pressure dependence
where
is the flexural rigidity of the diaphragm, v is the poisson ratio of the diaphragm material, E is the elastic modulus of the diaphragm material, t is the diaphragm thickness, a is the square diaphragm length, g is the gravitational constant, w is the weight of the diaphragm per unit area, and p is externally applied pressure (gauge pressure across the diaphragm).
[0141] Experimental testing shows good agreement with the theory. An impulse test was applied to the prototype diaphragms at various pressures to induce resonance.
[0142] Further theoretical analysis shows that ceramic resonators should given even better pressure responses, due to their rigidity. Additionally, the outstanding mechanical stability of ceramics, particularly monocrystalline ceramics of silicon and SiO.sub.2 (quartz), should lend excellent robustness and long term sensing stability.
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[0144] Once percutaneously implanted, the resonator can be interrogated wirelessly by an acoustic impulse test.
[0145] If the resonance frequency of the resonator is sufficiently high (>1 kHz), >>100 samples of blood pressure samples can be taken during the pressure wave cycle. This should allow for a dense recreation of the blood pressure waveform.
[0146] In the past several decades, many wireless sensing platforms have been developed which utilize a radio link to transmit the sensed data. Currently, with small Bluetooth-like radio links and smart devices, these platforms are still in full force. There is a miniaturization limit, however, due the numerous components such as power sources, circuitry, and antennas. Resonance based systems offer an alternative for wireless sensing, because resonators are typically very simple structures, can be made small, and efficiently receive and transmit energy within a certain frequency range.
[0147] While well known in the physics, mechanics, and electrical literatures for over a century, resonance based sensing systems have become more intensively investigated since the 1990s, with a particular focus on electrical resonators. These electrical resonators require only a capacitive sensor and a coil to operate, and can be interrogated magnetically. Mechanical resonators, however, have not been intensively investigated for stand-alone sensing purposes.
[0148] The scientific literature is full of discussion of electrical and mechanical resonance and resonators. The engineering literature has several well recognized instances, the most prominent one being the class of resonant pressure sensors in silicon microsensors. Incidentally, these resonant pressure sensors are known to have sensitivity and stability at least an order of magnitude great than piezoresistive and capacitive sensors. In this class, a micro-beam lies on a deflecting diaphragm and is induced into resonance. Pressure deflects the diaphragm and changes the strain on the beam, whose resonance frequency then shifts. This shift is monitored by piezoresistors on the beam, which are then processed by circuitry on or near the transducer chip. An important aspect is that most declared resonant sensors operate similarly to this class of sensors and are not stand-alone, passive resonant sensors which can be wirelessly interrogated.
[0149] Significant intellectual property exists on the class of stand-alone, passive mechanical resonators. Included is an appendix table with examples of differences between the disclosed invention and the relevant patents. The significant point is that the inventions are largely undeveloped and, without a known exception, utilize a very different acoustic frequency range. The work in patents is done predominantly in the medical ultrasound range (MHz), whereas the disclosed invention here operates in the audible range (<20 kHz). Additionally, and related to this distinction, the method of interrogation of the patented inventions is frequently different from that of this disclosed invention.
[0150] Exemplary embodiments of the present disclosure provide numerous non-obvious advantages over existing systems. For example, the analytic solutions for resonance frequency of diaphragms and beams do not contain explicit pressure terms, and thus the pressure dependence is not obvious. Minor modifications of the formulas readily yield pressure dependence, but the insight to make them must first be had. In addition, the mechanism of sensing is fundamentally different from that of most silicon-based resonant pressure sensors. Most silicon-based resonant pressure sensors focus on inducing a pressure dependent strain on a resonating beam. This is typically done by deflecting the mechanical base on which the beam lies, or by deflecting another mechanical member onto the beam. IE, the resonance frequency of the sensing element is not directly shifted by local pressure. In our case, resonance frequency of our disclosed invention is directly shifted by local pressure.
[0151] Furthermore, the acoustic frequency range of the disclosed invention is fully audible (<20 kHz) rather than very high ultrasound (MHz). The largely undeveloped inventions covered in the scientific and patent literature typically operate in the medical ultrasound frequency range, which is 2 to 4 orders of magnitude higher than that of the disclosed invention here. The interrogation systems for this prior art are typically standard medical ultrasound probes, which limits the frequency range of the implantable sensors. Additionally, embodiments of the disclosed invention are only sensitive to low levels (several 100 mmHg) of gauge pressure across the diaphragm. That is, silicon transducers with diaphragms over vacuum sealed chambers (most of them) will not exhibit significant pressure dependence of their resonance frequency; at sensing levels, gauge pressure across the diaphragm is >800 mmHg. For example, the theory of the disclosed invention must be understood, and additionally, an off the shelf transducer cannot be used to empirically validate that theory.
[0152] To date, numerous systems exist for attempting to measure intravascular blood pressure, but all have significant limitations. For implantable devices, miniaturization and powering are the key limitations. For noninvasive devices (optical, tonometry), blood pressure waveforms can easily be generated, but scaling them with accurate systolic and diastolic values has been a persistent challenge.
[0153] Embodiments of the disclosed invention offer a solution, by providing simple passive sensor which can be anchored onto stent-like structure and be acoustically interrogated. The sensor can be made extremely small (low micron), and can be made of extremely stable ceramics (SiO2) to confer long term sensing stability. Additionally, the device has strong pressure sensitivity, enabling tenths of mmHg to be accurately measured
[0154] In one example, a mechanical resonator can be configured as an implantable blood pressure sensor capable of measuring varying low, medium, and high pressure ranges and operating in one of the wireless modalities shown in
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Analytic Expression for Resonance Frequency
[0156] In an air environment, the analytical solution for the natural resonance frequency of a square plate with clamped edges
where
is the flexural rigidity of the diaphragm, a is the square diaphragm length and q is the load on the diaphragm including its weight per unit area and applied pressure. Here, the spring constant of the diaphragm is
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[0161] As demonstrated herein, resonators used as implantable sensors provide numerous advantages, including no on-site power source or circuitry requirements, very small, and a robust design. Mechanical resonators provide numerous advantages (e.g. over electrical resonators), including the fact that non-electrical, extremely small mechanical resonator sensors can be implanted. In addition, mechanical resonators provide incredible sensitivity, given how sensitive mechanical resonance is to external pressure, and can be tailored to specific pressure ranges. Mechanical resonators theoretically excellent readout range given how well acoustic signals travel through the body. In addition, mechanical resonators have much more sensing stability over time, again because electronics are not necessary, and an elastic ceramic (quartz, glass, silicon, whatever) will not plastically deform over time. Furthermore, mechanical resonators provide for pulsewave recreation because the resonance frequency is high enough to permit dozens of samples per second in an unoptimized sensor, and possibly hundreds per second in an optimized sensor.
[0162] In addition, mechanical resonators provide audible acoustic (<10 kHz) interrogation rather than ultrasound and inexpensive piezoelectrics can be used instead of expensive ultrasound crystals and devices. Mechanical resonators provide much simpler readout electronics with inexpensive piezoelctrics and without frequency sweeps utilizing a simple, one-time acoustic pulse and then listen for the resonance echo. Furthermore, mechanical resonators can be configured with a very small size (m range in any dimension). In certain embodiments, mechanical resonators can be sized small enough to be coupled to a stent and/or for percutaneous delivery to implantation size.
[0163] All of the apparatus, devices, systems and/or methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the devices, systems and methods of this invention have been described in terms of particular embodiments, it will be apparent to those of skill in the art that variations may be applied to the devices, systems and/or methods in the steps or in the sequence of steps of the method described herein without departing from the concept, spirit and scope of the invention. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope and concept of the invention as defined by the appended claims.
REFERENCES
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