Novel method for producing high frequency 2-2 composites from PZT ceramic

The fabrication of 2-2 PZT/epoxy composites by laminating ceramic tape printed with carbon black was investigated as a way to make very high frequency ultrasound transducers. When the laminates were fired, the tape layers densified to form the PZT beams and the carbon volatilized leaving behind kerf space. The kerf was then filled with epoxy, and resulting composites had properties equivalent to those routinely made by conventional dice and fill technology. Since tape casting and screen printing methods can provide feature sizes less than 5 μm, the techniques investigated in this work could potentially be used to fabricate linear and perhaps even phased arrays in the 30 to >50 MHz range