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1. WO2010080615 - ROTATIONAL INTRAVASCULAR ULTRASOUND PROBE AND METHOD OF MANUFACTURING THE SAME

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What is claimed is:

1. A method of manufacturing a rotational intravascular ultrasound probe for insertion into a vasculature, the method comprising:

providing an injection mold having a recess;

providing an ultrasonic transducer for obtaining a circumferential image through rotation, the transducer being coupled to a wire;

disposing the transducer within the recess;

placing a drive cable over the wire; and

injecting a material into the injection mold to form a transducer housing attached to the transducer and the drive cable.

2. The method of claim 1 wherein the transducer has a front surface and a sacrificial layer disposed over the front surface, and further comprising removing the sacrificial layer after the transducer housing is formed.

3. The method of claim 1 wherein the transducer is oversized when disposed within the recess, and further comprising reducing the size of the transducer after the transducer housing is formed.

4. The method of claim 1 wherein the transducer is the only transducer molded to the transducer housing.

5. The method of claim 1 wherein the mold has a channel, and further comprising placing the drive cable and the wire within the channel.

6. The method of claim 1 wherein the transducer includes a plurality of layers.

7. The method of claim 1 wherein the transducer housing is rigid.

8. The method of claim 1 wherein the material is an epoxy.

9. The method of claim 1 wherein the transducer includes a piezoelectric material.

10. The method of claim 1 wherein the transducer, the transducer housing, and the drive cable form a transducer shaft, and further comprising inserting the transducer shaft into a catheter.

11. The method of claim 1 wherein the transducer housing is generally cylindrical.

12. The method of claim 1 wherein the transducer housing has a domed end.

13. The method of claim 1 wherein the transducer housing has a linear shape.

14. A rotational intravascular ultrasound probe for insertion into a vasculature, the probe comprising:

an elongate catheter having a flexible body;

an elongate transducer shaft disposed within the flexible body, the transducer shaft having:

a proximal end portion and a distal end portion;

a drive shaft extending from the proximal end portion to the distal end portion;

an ultrasonic transducer for obtaining a circumferential image through rotation, the transducer disposed near the distal end portion; and

a transducer housing molded to the drive shaft and the ultrasonic transducer.

15. The rotational intravascular ultrasound probe of claim 14 wherein the transducer is the only transducer molded to the transducer housing.

16. The rotational intravascular ultrasound probe of claim 14 wherein the transducer housing is rigid.

17. The rotational intravascular ultrasound probe of claim 14 wherein the transducer housing is molded with an epoxy.

18. The rotational intravascular ultrasound probe of claim 14 wherein the transducer includes a piezoelectric material.

19. The rotational intravascular ultrasound probe of claim 14 wherein the transducer housing is generally cylindrical.

20. The rotational intravascular ultrasound probe of claim 14 wherein the transducer housing has a linear shape.