Prototyping of piezoceramic-polymer composites using Solution Casting method for use in acoustic Transducers

Since piezocomposites with 0-3 connectivity are flexible and commonly used in acoustic transducers, we review some of their fabrication methods, which are mainly under the development stage, and evaluate cons and pros of each method. We then suggest a budget type solution casting method to prototype 0-3 piezocomposites which can be used with a wide range of polymeric materials. Using this method, we fabricate PZT/EP and PZT/EP+TPU piezocomposites with PZT weight fractions from 30 to 70 percent. First, PZT powder was mixed with the epoxy resin, and a magnetic stirrer was used to achieve a uniform dispersion of PZT particles in the polymer. After adding the hardener to the solution, a sonicator were used to avoid agglomeration of PZT particles and prepare a uniform solution. The solution was then poured it into a mold and placed in a desiccator container, connected to a vacuum pump, to perform the degassing process. After the polymerization process was completed, samples were dried to complete the curing process. After polishing, the copper electrode plates were placed on both sides of the piezocomposite elements. Finally, the polarization process was performed using the corona discharge method. The results of XRD, FT-IR and SEM analysis depict the uniform dispersion of the PZT particles within the polymer. The prototyped specimens generate electric charge, measured by an oscilloscope, under a dynamic loading.