Method of Forming a Sound Lens

Abstract

A method of forming a sound lens having a coating of a first metal, that utilizes a lens-shaped piece of heat resistant material, having a convex major surface, and having a sonic impedance similar to that of human tissue, taken from a group consisting essentially of high temperature plastics and silicone. In the method, the convex major surface is sputter coated with a layer of the first metal, less than 10 microns thick.

1 . A method of forming a sound lens having a coating of a first metal, comprising:
 (a) providing a lens-shaped piece of heat resistant material, having a convex major surface, and having a sonic impedance similar to that of human tissue, taken from a group consisting essentially of high temperature plastics and silicone;   (b) sputter coating said convex major surface with a layer of said first metal, less than 10 microns thick.   
     
     
         2 . The method of  claim 1 , wherein said first metal is titanium. 
     
     
         3 . The method of  claim 1 , wherein said first metal is an alloy of titanium. 
     
     
         4 . The method of  claim 1 , wherein said layer of said first metal is less than 6 microns thick. 
     
     
         5 . The method of  claim 1 , wherein said layer of said first metal is less than 2 microns thick. 
     
     
         6 . A method of forming a sound lens having a surface of a target convex shape, and having a coating of a first metal, comprising:
 (a) providing a foil of said first metal, thinner than 10 microns thick;   (b) pressing said foil into a mold, having a concave shape, reverse to said target convex shape;   (c) pouring a material in a melt state taken from a group consisting essentially of a high temperature polymer and a high temperature castable silicone elastomer, into said foil and permitting said molten material to cure;   (d) removing said molten material and foil from said mold.   
     
     
         7 . The method of  claim 6 , wherein said first metal is titanium. 
     
     
         8 . The method of  claim 6 , wherein said first metal is an alloy of titanium. 
     
     
         9 . The method of  claim 6 , wherein said layer of said first metal is less than 6 microns thick. 
     
     
         10 . The method of  claim 6 , wherein said layer of said first metal is less than 2 microns thick.