Smart Material is manufacturing 1-3 composites using piezo ceramic fibers as active rods.
1-3 fiber piezo composites are prepared by epoxy infiltration of fiber bundles and dicing of the cube-shaped blocks perpendicular to the direction of the fibers. This patented method is also called Arrange & Fill as outlined in the schematic below.

 

Regular pixel distribution is achieved by arranging ceramic fibers with 800µm diameter with a constant pitch. This yields fill factors of approx. 25% to a maximum of 48%.

 

1-3 Regular Fiber Composite specifications:

Resonance Frequencies	40kHz up to 1MHz
Available Fill Factors, approx.	25% up to 48%
Acoustic Impedance	~ 9 to 16 MRayl
Typical coupling coefficient kt	~0.65
PZT materials	Navy type II and VI, SP505 and SP53
Maximum Dimensions	60mm by 60mm (2.36" by 2.36"), typical sizes 50mm by 50mm and 30mm by 30mm
Operational Temp.	typical 100°C, maximum available 130°C
Interstitial Material	various Epoxy and Polyurethane systems
Available Electrodes	CuSn (Std.), AgAu 2.5µm up to 6µm

 

The regular 1-3 fiber regular composite material was especially designed for SONAR applications. The electrode material was designed for long life time and durability. A modified vacuum deposition methods allows for a low impedance copper-flash tin layer with a typical thickness of 2.5µm for high durability and improved solderability.

 

 

Due to the Arrange&Fill production method the raw 1-3 fiber composite material are typical blocks of up to 10cm length and the lateral dimensions of the targeted element. It also allows to machine 1-3 composites into various shapes and forms, in addition to slicing elements with the desired resonance frequency of the raw fiber block

This includes precise concave or convex contours for superior broadband ultrasound receiver applications.

 

 

 

 

The Arrange&Fill production method is easily scaleable for volume quantities which also allows for short lead time, a major advantage over the commonly used Dice&Fill methods.

 

 

1-3 Regular Fiber Composite typical applications:

• SONAR, array transducer
• SONAR, single element
• Air ultrasound transducer