Ultrasound applicators with internal water-cooling for high-powered interstitial thermal therapy

Internal water-cooling of direct-coupled ultrasound (US) applicators for interstitial thermal therapy (hyperthermia and coagulative thermal therapy) was investigated. Implantable applicators were constructed using tubular US sources (360 angular acoustic emittance, approximately 7 MHz) of 10 mm length and 1.5, 1.8, 2.2, and 2.5 mm outer diameter (OD). Directional applicators were also constructed using 2.2 mm OD tubes sectored to provide active acoustic sectors of 90 degrees and 200 degrees. A water-cooling mechanism was integrated within the inner lumen of the applicator to remove heat from the inner transducer surface. High levels of convective heat transfer (2100-3800 W/m2K) were measured for practical water flow rates of 20-80 mL/min. Comparative acoustic measurements demonstrated that internal water-cooling did not significantly degrade the acoustic intensity or beam distribution of the US transducers. Water-cooling allowed substantially higher levels of applied electrical power (> 45 W) than previous designs (with air-cooling or no cooling), without detriment to the applicators. High-temperature heating trials performed with these applicators in vivo (porcine liver and thigh muscle) and in vitro (bovine liver) showed improved thermal penetration and coagulation. Radial depth of coagulation from the applicator surface ranged from 12 to 20 mm for 1-5 min of sonication with 28-W applied power. Higher powers (41 W) demonstrated increased coagulation depths (approximately 9 mm) at shorter times (15 s). Thermal lesion dimensions (angular and axial expanse) produced with directional applicators were controlled and directed, and corresponded to the active zone of the transducer. These characteristic lesion shapes were also generally unchanged with different sonication times and power, and were found to be consistent with previous coagulation studies using air-cooled applicators. The implementation of water-cooling is a significant advance for the application of ultrasound interstitial thermal therapy (USITT), providing greater treatment volumes, shorter treatment times, and the potential for treatment of highly perfused tissue with shaped lesions.