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Medical ultrasound and other devices that require transducer arrays are difficult to manufacture, particularly for high frequency devices (>30 MHz). To enable focusing and beam steering, it is necessary to reduce the center-to-center element spacing to half of the acoustic wavelength. Conventional methodologies prevent co-sintering ceramic–polymer composites due to the low decomposition temperatures of the polymer. Moreover, for ultrasound transducer arrays exceeding 30 MHz, methods such as dice-and-fill cannot provide the dimensional tolerances required. Other techniques in which the ceramic is formed in the green state often fail to retain the required dimensions without distortion on firing the ceramic. This paper explores the use of the cold sintering process to produce dense lead zirconate titanate (PZT) ceramics for application in high frequency transducer arrays. PZT–polymer 2-2 composites were fabricated by cold sintering tape cast PZT with Pb nitrate as a sintering aid and ZnO as the sacrificial layer. PZT beams of 35 μm width with ~5.4 μm kerfs were produced by this technique. The ZnO sacrificial layer was also found to serve as a liquid phase sintering aid that led to grain growth in adjacent PZT. This composite produced resonance frequencies of >17 MHz. 

Polymer nanocomposites exhibit unique effective properties that do not follow conventional effective media approaches. The nanoparticle-polymer interphase has been shown to strongly influence the nanocomposites behavior due o its significant volume when the particles are nano-sized, affording an opportunity to tune the dielectric response of the resulting nanocomposite. In this study, we investigate the effects of TiO2 nanoparticles on the electrical properties and the charges distribution and transport in polydimethylsiloxane (PDMS) nanocomposites. Impedance spectroscopy shows suppression of interfacial Maxwell-Wagner-Sillars (MWS) polarization accompanied by a reduction in the low frequency dielectric permittivity and loss at high temperatures in the presence of the TiO2 nanoparticles. Thermally stimulated discharge current measurements confirm that the suppression of the interfacial polarization relaxations happens by redistributing or depleting the charges through the composite and hindering their mobility, potentially resulting in lower electrical conduction and higher breakdown strength. Although the model materials investigated here are TiO2 nanoparticles and Sylgard 184 PDMS, our findings can be extended to other nanoparticulate-filled elastomer composites to design lightweight dielectrics, actuators and sensors with improved capabilities.