Processing of 1-3 Piezoelectric Ceramic/Polymer Composites

Several methods of forming fine-scale 1–3 piezoelectric ceramic/polymer composites for possible transducer applications were demonstrated. These methods include tape casting, honeycomb dicing, and ceramic fiber weaving. In the tape casting technique, laminated structures were formed using thin PZT tapes. The tapes were stacked, with spacers separating the layers, and the stack embedded in polymer. Dicing the stack resulted in a composite with 1–3 connectivity. The thin tape technique can be used to develop composites with ceramic or polymer volume fraction gradients and multifunctional ceramics. Dicing of PZT honeycombs yields 1–3 composites with uniquely shaped rods. Shapes included +, T, and L. In the ceramic fiber weaving technique, green PZT fibers were woven through a PZT honeycomb support structure. The structure was fired to sinter the PZT fibers, and embedded with polymer to yield 1–3 composites. All 1–3 composites showed high and uniform piezoelectric coefficients across the electroded area.