CN115069524B - 1-3 Composite piezoelectric material for high-frequency ultrasonic transducer and preparation method thereof - Google Patents
1-3 Composite piezoelectric material for high-frequency ultrasonic transducer and preparation method thereof Download PDFInfo
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Abstract
Description
技术领域Technical Field
本发明涉及一种压电材料,具体涉及一种高频超声换能器用1-3复合压电材料及其制备方法。The invention relates to a piezoelectric material, in particular to a 1-3 composite piezoelectric material for a high-frequency ultrasonic transducer and a preparation method thereof.
背景技术Background technique
高频医用超声成像和工业无损检测能够通过超声换能器对人体组织和重要微型工业零件进行微米级分辨率的微结构超声成像和探测,该技术属于下一代高端医疗和工业装备,是技术研究的重点之一。高频超声换能器的超高空间分辨率要求其具有较高的灵敏度和带宽,但是超声发射和接收的频率越高,决定其机-电转换效率的机电耦合系数越低。因此,需要利用一种在高频超声频段仍具有较高机电耦合系数的压电材料来进行超声成像、探测和识别。High-frequency medical ultrasound imaging and industrial non-destructive testing can use ultrasonic transducers to perform microstructure ultrasound imaging and detection of human tissue and important micro-industrial parts with micron-level resolution. This technology belongs to the next generation of high-end medical and industrial equipment and is one of the key research areas. The ultra-high spatial resolution of high-frequency ultrasonic transducers requires them to have high sensitivity and bandwidth, but the higher the frequency of ultrasonic emission and reception, the lower the electromechanical coupling coefficient that determines its electromechanical conversion efficiency. Therefore, it is necessary to use a piezoelectric material that still has a high electromechanical coupling coefficient in the high-frequency ultrasonic frequency band for ultrasonic imaging, detection and identification.
1-3复合材料相比于传统的单相压电材料(如PZT陶瓷、PMNT单晶等),一方面具有更高的机电耦合系数,可以大幅增加超声换能器回波信号的灵敏度。另一方面,它具有比单相材料更低的声阻抗,易于实现与人体组织和塑料零件的阻抗匹配,能够增加高频超声换能器灵敏度的同时减小换能器制备工艺难度。特别是在30~50MHz的高频超声阶段,1-3复合材料仍具有较高的机电耦合系数,是高性能医用高频超声成像和高频无损检测的必要材料。Compared with traditional single-phase piezoelectric materials (such as PZT ceramics, PMNT single crystals, etc.), 1-3 composite materials have a higher electromechanical coupling coefficient on the one hand, which can greatly increase the sensitivity of the ultrasonic transducer echo signal. On the other hand, it has a lower acoustic impedance than single-phase materials, which makes it easy to achieve impedance matching with human tissue and plastic parts, and can increase the sensitivity of high-frequency ultrasonic transducers while reducing the difficulty of transducer preparation processes. Especially in the high-frequency ultrasonic stage of 30 to 50 MHz, 1-3 composite materials still have a high electromechanical coupling coefficient, and are necessary materials for high-performance medical high-frequency ultrasonic imaging and high-frequency non-destructive testing.
高频超声成像用的1-3复合材料不同于一般中低频使用的压电材料,由于纵向振动模式的需要,要求其压电相微结构在微米尺度上仍具有大的长径比、小的柱间距以及高的压电性能。然而对于高频超声应用的几十微米级压电微结构,机械切割-填充法、等离子体刻蚀法等传统的1-3复合材料制备方法需要大型精密设备、耗时多、压电填充比例小,无法满足高频复合材料的工业化生产。此外,传统硅模板法采用光刻的硅片作为模板,将PZT纳米粉注入微孔并用热等静压烧结制备压电柱阵列,但硅模板的不可压缩性使得陶瓷微柱的烧结致密度低,难以获得较高的压电性能。The 1-3 composite material used for high-frequency ultrasound imaging is different from the piezoelectric materials generally used in medium and low frequencies. Due to the need for longitudinal vibration modes, its piezoelectric phase microstructure is required to still have a large aspect ratio, small column spacing and high piezoelectric performance at the micrometer scale. However, for the tens of micrometer-level piezoelectric microstructures used in high-frequency ultrasound applications, traditional 1-3 composite material preparation methods such as mechanical cutting-filling method and plasma etching method require large precision equipment, are time-consuming, and have a small piezoelectric filling ratio, which cannot meet the industrial production of high-frequency composite materials. In addition, the traditional silicon template method uses a photolithographic silicon wafer as a template, injects PZT nanopowder into micropores, and uses hot isostatic pressing to prepare a piezoelectric column array, but the incompressibility of the silicon template makes the sintering density of the ceramic microcolumns low, making it difficult to obtain high piezoelectric performance.
发明内容Summary of the invention
本发明的目的就是为了解决上述问题至少其一而提供一种高频超声换能器用1-3复合压电材料及其制备方法,实现了制备过程的简化和高效化,同时制备得到的1-3复合压电材料在高频超声范围(30-50MHz)内具有优异的压电性能。The purpose of the present invention is to solve at least one of the above problems and to provide a 1-3 composite piezoelectric material for a high-frequency ultrasonic transducer and a preparation method thereof, thereby simplifying and improving the preparation process. At the same time, the prepared 1-3 composite piezoelectric material has excellent piezoelectric properties within the high-frequency ultrasonic range (30-50MHz).
本发明的目的通过以下技术方案实现:The purpose of the present invention is achieved through the following technical solutions:
本发明第一方面公开了一种高频超声换能器用1-3复合压电材料的制备方法,包括如下步骤:The first aspect of the present invention discloses a method for preparing a 1-3 composite piezoelectric material for a high-frequency ultrasonic transducer, comprising the following steps:
S1:通过刻蚀技术制备含有微孔的软模板;S1: Prepare soft templates containing micropores by etching technology;
S2:利用压电陶瓷粉体填充步骤S1得到的软模板中的微孔;S2: filling the micropores in the soft template obtained in step S1 with piezoelectric ceramic powder;
S3:对步骤S2得到的产物进行高温烧结以除去软模板,得到压电陶瓷柱阵列;S3: sintering the product obtained in step S2 at a high temperature to remove the soft template, thereby obtaining a piezoelectric ceramic column array;
S4:利用高分子聚合物对步骤S3得到的压电陶瓷柱阵列进行填充固化,得到半成品;S4: filling and curing the piezoelectric ceramic column array obtained in step S3 with a high molecular polymer to obtain a semi-finished product;
S5:对步骤S4得到的半成品进行研磨减薄、镀电极并极化,得到所述的1-3复合压电材料。S5: Grind and thin the semi-finished product obtained in step S4, plate electrodes and polarize it to obtain the 1-3 composite piezoelectric material.
优选地,步骤S1中,所述的刻蚀技术为激光刻蚀、等离子体刻蚀和化学腐蚀中的一种;所述的软模板的材料为松香;微孔的直径为25-150μm,长度不超过200μm;微孔在软模板上的密度为400-1000根/mm2。通过模板微孔的设计,可以控制制备完成的产品中压电柱(微柱)的直径、间距及其排列方式,实现微结构调控;并且模板的使用使得该产品能够实现大规模批量化的制备生产。Preferably, in step S1, the etching technology is one of laser etching, plasma etching and chemical etching; the material of the soft template is rosin; the diameter of the micropores is 25-150 μm, and the length does not exceed 200 μm; the density of the micropores on the soft template is 400-1000/ mm2 . Through the design of the template micropores, the diameter, spacing and arrangement of the piezoelectric columns (microcolumns) in the prepared product can be controlled to achieve microstructure regulation; and the use of the template enables the product to be prepared and produced on a large scale.
优选地,步骤S2中,所述的压电陶瓷粉体为钙钛矿结构铁电体粉体。Preferably, in step S2, the piezoelectric ceramic powder is a perovskite structure ferroelectric powder.
优选地,所述的压电陶瓷粉体为锆钛酸铅(PZT)、铌镁钛酸铅(PMN-PT)、铌铟镁钛酸铅(PIN-PMN-PT,即铌铟酸铅-铌镁酸铅-钛酸铅)、铌酸钾钠(KNN)和钛酸铋钠-钛酸钡(NBT-BT)中的一种或多种。Preferably, the piezoelectric ceramic powder is one or more of lead zirconate titanate (PZT), lead magnesium niobate titanate (PMN-PT), lead indium magnesium niobate titanate (PIN-PMN-PT, i.e. lead indium niobate-lead magnesium niobate-lead titanate), sodium potassium niobate (KNN) and sodium bismuth titanate-barium titanate (NBT-BT).
优选地,步骤S2中,所述的填充包括如下步骤:Preferably, in step S2, the filling comprises the following steps:
S21:将压电陶瓷粉体分散于粘合剂中,形成浆料;S21: dispersing piezoelectric ceramic powder in a binder to form a slurry;
S22:将步骤S21得到的浆料真空灌注于步骤S1得到的软模板中的微孔中,随后在常压下干燥,形成密度较大的微柱前驱体;S22: vacuum-infusing the slurry obtained in step S21 into the micropores in the soft template obtained in step S1, and then drying under normal pressure to form a microcolumn precursor with a relatively high density;
S23:向步骤S22得到的微柱前驱体施加垂直于表面的压力。S23: applying pressure perpendicular to the surface to the microcolumn precursor obtained in step S22.
优选地,步骤S21中,所述的粘合剂为丙烯酰胺。Preferably, in step S21, the adhesive is acrylamide.
优选地,步骤S23中,压力大小为6.0MPa,维持时间为30min。Preferably, in step S23, the pressure is 6.0 MPa and the maintenance time is 30 min.
优选地,步骤S3中,所述的高温烧结为单向热压烧结,包括如下步骤:将软模板以50℃/h的升温速率升至500-530℃并保温2-3h,随后以相同升温速率升至1150-1200℃并保温1.5-2h。本发明中选用单向热压烧结主要的优势是,首先,设备要求没等静压热压烧结(另一种热压烧结的方式)那么高,工艺过程简单,成本低,同时还能达到烧结致密化的效果。另外,因为是对软模板加压,单向热压烧结可使样品烧出保持平整,而等静压会把模板压成不规则形状,无法使用。Preferably, in step S3, the high temperature sintering is unidirectional hot pressing sintering, comprising the following steps: heating the soft template to 500-530°C at a heating rate of 50°C/h and keeping it warm for 2-3h, then heating it to 1150-1200°C at the same heating rate and keeping it warm for 1.5-2h. The main advantage of using unidirectional hot pressing sintering in the present invention is that, first of all, the equipment requirements are not as high as isostatic hot pressing sintering (another hot pressing sintering method), the process is simple, the cost is low, and the effect of sintering densification can be achieved. In addition, because the soft template is pressurized, unidirectional hot pressing sintering can keep the sample flat after burning, while isostatic pressing will press the template into an irregular shape and cannot be used.
步骤S3中的高温烧结具有三个作用:一是去除软模板;二是使烧结后的压电微柱竖立在基板上,形成压电陶瓷微柱阵列;三是烧结过程中基板会发生收缩,用于缩小压电微柱之间的间距,使排列更加紧密,增加压电相的填充比例。The high-temperature sintering in step S3 has three functions: first, to remove the soft template; second, to make the sintered piezoelectric microcolumns stand upright on the substrate to form a piezoelectric ceramic microcolumn array; third, the substrate will shrink during the sintering process, which is used to reduce the spacing between the piezoelectric microcolumns, make the arrangement more compact, and increase the filling ratio of the piezoelectric phase.
优选地,步骤S4中,所述的高分子聚合物为环氧树脂;所述的填充固化在真空条件下进行。在抽真空条件下进行环氧固化,可以排除陶瓷微柱间隙中的气泡。Preferably, in step S4, the high molecular polymer is epoxy resin, and the filling and curing is performed under vacuum conditions. Epoxy curing under vacuum conditions can eliminate bubbles in the gaps between ceramic micro-pillars.
优选地,步骤S5中,固化后的复合材料上下表面通过研磨减薄以保持平行,并且基板同样需要通过研磨减薄去除;根据换能器频率的需要,将复合材料研磨减薄到所需要的厚度,并利用磁控溅射在上下表面镀电极;对样品进行极化,极化在硅油和室温条件下进行,施加电场为3kV/mm,极化时间为30分钟。Preferably, in step S5, the upper and lower surfaces of the cured composite material are thinned by grinding to keep them parallel, and the substrate also needs to be removed by grinding and thinning; according to the requirements of the transducer frequency, the composite material is ground and thinned to the required thickness, and electrodes are plated on the upper and lower surfaces by magnetron sputtering; the sample is polarized, and the polarization is carried out under silicone oil and room temperature conditions, the applied electric field is 3 kV/mm, and the polarization time is 30 minutes.
本发明第二方面公开了一种高频超声换能器用1-3复合压电材料,由如上任一所述的高频超声换能器用1-3复合压电材料的制备方法制备得到。The second aspect of the present invention discloses a 1-3 composite piezoelectric material for a high-frequency ultrasonic transducer, which is prepared by any of the above methods for preparing a 1-3 composite piezoelectric material for a high-frequency ultrasonic transducer.
与现有技术相比,本发明具有以下有益效果:Compared with the prior art, the present invention has the following beneficial effects:
1、在制备方面,本方法是一种有效的制备高频1-3复合压电材料的新方法,其制备效率高,成本低,有利于1-3复合压电材料在高频超声技术领域的工业化制备和应用。1. In terms of preparation, this method is a new and effective method for preparing high-frequency 1-3 composite piezoelectric materials. It has high preparation efficiency and low cost, and is conducive to the industrial preparation and application of 1-3 composite piezoelectric materials in the field of high-frequency ultrasonic technology.
2、本发明所制备的压电陶瓷微柱中元素含量径向分布均匀,相结构单纯且晶格较完整。经综合性能测试表明,本发明所制备的高频1-3复合压电材料在高频超声范围内(30~50MHz)具有优异的压电性能,特别是机电耦合系数可以达到61.5%以上,向比同组分单相PZT陶瓷大幅提高。2. The piezoelectric ceramic microcolumns prepared by the present invention have uniform radial distribution of element content, simple phase structure and relatively complete lattice. Comprehensive performance tests show that the high-frequency 1-3 composite piezoelectric material prepared by the present invention has excellent piezoelectric properties in the high-frequency ultrasonic range (30-50MHz), especially the electromechanical coupling coefficient can reach more than 61.5%, which is greatly improved compared with the single-phase PZT ceramics with the same components.
3、本发明所提供的复合压电材料由两部分组成,起主要作用的是压电相(压电柱),所以,1)压电柱材料本身的压电性能越高,复合材料的压电响应就越大。常用压电材料的压电常数d33在600~1300pC/N之间。2)长径比(圆柱形),也就是通常的“宽高比”(长条形),本发明介于1.2~5之间,属于纵向振动模式,具有较高的机电耦合系数(>60%),而非复合材料长径比~0.1,如单片PZT陶瓷,机电耦合系数仅50%。3)又如切割填充法制备的复合材料柱间距一般>12μm,本发明的制备方法可以做到>3μm,柱间距更小,两者比较,可使复合材料压电常数提升30%。3. The composite piezoelectric material provided by the present invention is composed of two parts, and the main function is the piezoelectric phase (piezoelectric column), so 1) the higher the piezoelectric performance of the piezoelectric column material itself, the greater the piezoelectric response of the composite material. The piezoelectric constant d33 of commonly used piezoelectric materials is between 600 and 1300pC/N. 2) The aspect ratio (cylindrical), that is, the usual "width-to-height ratio" (long strip), is between 1.2 and 5 in the present invention, belonging to the longitudinal vibration mode, and has a higher electromechanical coupling coefficient (>60%), while the aspect ratio of non-composite materials is ~0.1, such as a single piece of PZT ceramic, and the electromechanical coupling coefficient is only 50%. 3) For example, the spacing between the columns of the composite material prepared by the cutting and filling method is generally >12μm, and the preparation method of the present invention can achieve >3μm, and the column spacing is smaller. Compared with the two, the piezoelectric constant of the composite material can be increased by 30%.
4、本发明通过利用软模板进行制备,使得制得的复合压电材料具有如下优势:4. The present invention uses a soft template for preparation, so that the prepared composite piezoelectric material has the following advantages:
1)直径:直径可以做的很小,最小25微米。在维持长径比较大(1.2~5)的情况下,直径越小,柱长度(复合材料厚度)也可以越小,厚度小,频率高,那么复合材料谐振频率也越高,即能提高材料和超声换能器频率,达到高频(30~50MHz)。只有当直径足够小时,才能做到高频,例如采用传统切割填充法时,柱子太细就会倒,最多只能做到10MHz,无法满足高频需求。1) Diameter: The diameter can be made very small, with a minimum of 25 microns. While maintaining a large aspect ratio (1.2-5), the smaller the diameter, the smaller the column length (composite material thickness) can be. The smaller the thickness and the higher the frequency, the higher the resonant frequency of the composite material, which can increase the material and ultrasonic transducer frequency to a high frequency (30-50MHz). High frequency can only be achieved when the diameter is small enough. For example, when using the traditional cutting and filling method, the column will fall if it is too thin, and the maximum can only reach 10MHz, which cannot meet the high frequency requirements.
2)间距:间距小时,压电相的比例就可以做的高,复合材料整体的压电响应就大,或者说压电性能就好,压电系数就大。传统方法可以得到的间距最小12微米,而本方法最小达3微米,使得复合材料压电常数相比于传统方法可提升30%~40%。2) Spacing: When the spacing is small, the proportion of the piezoelectric phase can be high, and the overall piezoelectric response of the composite material is large, or the piezoelectric performance is good, and the piezoelectric coefficient is large. The minimum spacing that can be obtained by the traditional method is 12 microns, while the minimum spacing of this method is 3 microns, which can increase the piezoelectric constant of the composite material by 30% to 40% compared with the traditional method.
3)排列方式:均匀无规排列,可以抑制柱子之间的振动模式,使整体复合材料振动模式较纯,压电响应的信号也更纯。3) Arrangement: Uniform and random arrangement can suppress the vibration mode between the pillars, making the vibration mode of the overall composite material purer and the piezoelectric response signal purer.
附图说明BRIEF DESCRIPTION OF THE DRAWINGS
图1为本发明的制备方法的流程示意图;FIG1 is a schematic flow diagram of the preparation method of the present invention;
图2为实施例1制得的1-3复合压电材料的显微结构图;FIG2 is a microstructure diagram of the 1-3 composite piezoelectric material prepared in Example 1;
图3为实施例1制得的1-3复合压电材料的阻抗性能与谐振/反谐振频率图。FIG. 3 is a graph showing the impedance performance and resonance/anti-resonance frequency of the 1-3 composite piezoelectric material prepared in Example 1.
具体实施方式Detailed ways
下面结合附图和具体实施例对本发明进行详细说明。The present invention is described in detail below with reference to the accompanying drawings and specific embodiments.
以下实施例中,若所用试剂未作特别说明,则可采用本领域技术人员能够常规获得的市售产品。以下实施例中,若所用方法未作特别说明,则可采用本领域技术人员能够常规了解和使用的方法。In the following examples, if the reagents used are not specifically described, commercial products that can be routinely obtained by those skilled in the art can be used. In the following examples, if the methods used are not specifically described, methods that can be routinely understood and used by those skilled in the art can be used.
一种高频超声换能器用1-3复合压电材料的制备方法,如图1所示,包括如下步骤:A method for preparing a 1-3 composite piezoelectric material for a high-frequency ultrasonic transducer, as shown in FIG1 , comprises the following steps:
S1:通过激光刻蚀制备含有微孔的软模板;S1: Preparation of soft templates containing micropores by laser etching;
S2:利用压电陶瓷粉体填充步骤S1得到的软模板中的微孔;S2: filling the micropores in the soft template obtained in step S1 with piezoelectric ceramic powder;
S3:对步骤S2得到的产物进行高温烧结以除去软模板,得到压电陶瓷柱阵列;S3: sintering the product obtained in step S2 at a high temperature to remove the soft template, thereby obtaining a piezoelectric ceramic column array;
S4:利用高分子聚合物对步骤S3得到的压电陶瓷柱阵列进行填充固化,得到半成品;S4: filling and curing the piezoelectric ceramic column array obtained in step S3 with a high molecular polymer to obtain a semi-finished product;
S5:对步骤S4得到的半成品进行研磨减薄、镀电极并极化,得到1-3复合压电材料。S5: Grind and thin the semi-finished product obtained in step S4, plate electrodes and polarize it to obtain 1-3 composite piezoelectric material.
其中,步骤S1中,软模板的材料为松香,厚度为0.5±0.2mm;微孔的直径为25-70μm,长度不超过200μm;微孔在软模板上的密度为400-1000根/mm2。Wherein, in step S1, the material of the soft template is rosin with a thickness of 0.5±0.2 mm; the diameter of the micropores is 25-70 μm and the length is not more than 200 μm; the density of the micropores on the soft template is 400-1000 micropores/mm 2 .
其中,步骤S2中,压电陶瓷粉体为钙钛矿结构铁电体粉体,具体可以是锆钛酸铅(PZT)、铌镁钛酸铅(PMN-PT)、铌铟镁钛酸铅(PIN-PMN-PT)、铌酸钾钠(KNN)和钛酸铋钠-钛酸钡(NBBT)中的一种或多种。Among them, in step S2, the piezoelectric ceramic powder is a perovskite structure ferroelectric powder, which can specifically be one or more of lead zirconate titanate (PZT), lead magnesium niobate titanate (PMN-PT), lead indium magnesium niobate titanate (PIN-PMN-PT), sodium potassium niobate (KNN) and sodium bismuth titanate-barium titanate (NBBT).
其中,步骤S2中的填充包括如下子步骤:The filling in step S2 includes the following sub-steps:
S21:将颗粒度为1-3μm压电陶瓷粉体分散于粘合剂中,形成浆料;S21: dispersing piezoelectric ceramic powder with a particle size of 1-3 μm in a binder to form a slurry;
S22:将步骤S21得到的浆料真空灌注于步骤S1得到的软模板中的微孔中,随后在常压下干燥,形成密度较大的微柱前驱体;S22: vacuum-infusing the slurry obtained in step S21 into the micropores in the soft template obtained in step S1, and then drying under normal pressure to form a microcolumn precursor with a relatively high density;
S23:向步骤S22得到的微柱前驱体施加6.0MPa垂直于表面的压力,并维持30分钟。S23: Apply a pressure of 6.0 MPa perpendicular to the surface to the microcolumn precursor obtained in step S22 and maintain it for 30 minutes.
其中,步骤S3中,高温烧结为单向热压烧结,包括如下步骤:将软模板以50℃/h的升温速率升至500-530℃并保温2-3h,随后以相同升温速率升至1150-1200℃并保温1.5-2h。Among them, in step S3, the high temperature sintering is unidirectional hot pressing sintering, including the following steps: heating the soft template to 500-530°C at a heating rate of 50°C/h and keeping it warm for 2-3h, and then heating it to 1150-1200°C at the same heating rate and keeping it warm for 1.5-2h.
其中,步骤S4中,高分子聚合物为环氧树脂;填充固化在真空条件下进行。Wherein, in step S4, the high molecular polymer is epoxy resin; and the filling and curing are performed under vacuum conditions.
其中,步骤S5中,固化后的复合材料上下表面通过研磨减薄以保持平行,并且基板同样需要通过研磨减薄去除;根据换能器频率的需要,将复合材料研磨减薄到所需要的厚度,并利用磁控溅射在上下表面镀电极;对样品进行极化,极化在硅油和室温条件下进行,施加电场为3kV/mm,极化时间为30分钟。Among them, in step S5, the upper and lower surfaces of the cured composite material are thinned by grinding to keep them parallel, and the substrate also needs to be removed by grinding and thinning; according to the requirements of the transducer frequency, the composite material is ground and thinned to the required thickness, and electrodes are plated on the upper and lower surfaces by magnetron sputtering; the sample is polarized, and the polarization is carried out under silicone oil and room temperature conditions, the applied electric field is 3kV/mm, and the polarization time is 30 minutes.
实施例1Example 1
制备微柱直径为25μm的高均匀度1-3复合压电材料:Preparation of high uniformity 1-3 composite piezoelectric material with micro-pillar diameter of 25 μm:
本实施例中选用具有准同型相界组分的锆钛酸铅(PZT)纳米粉体作为压电相,PZT平均粒径为500nm;并选择了环氧树脂(Epo-Tek 301-2)作为聚合物基体。In this embodiment, lead zirconate titanate (PZT) nanopowder with a morphotropic phase boundary component is selected as the piezoelectric phase, and the average particle size of PZT is 500 nm; and epoxy resin (Epo-Tek 301-2) is selected as the polymer matrix.
S1:采用激光刻蚀塑料薄板制备软模板,如图1所示。软模板的厚度为0.5±0.2mm,微孔的直径为25μm。S1: A soft template is prepared by laser etching a plastic sheet, as shown in Figure 1. The thickness of the soft template is 0.5±0.2 mm, and the diameter of the micropore is 25 μm.
S2,采用PZT-5H组分的粉料进行模板微孔的填充。S2, using PZT-5H component powder to fill the template micropores.
1)将颗粒度为1~3μm范围内的PZT粉体分散到粘合剂溶液中,形成PZT浆料。1) PZT powder with a particle size of 1 to 3 μm is dispersed in a binder solution to form a PZT slurry.
2)在真空环境下将浆料灌注进塑料薄板微孔中,并在常压下干燥,使熔剂挥发,从而形成密度较大的微柱前驱体。2) The slurry is poured into the micropores of the plastic sheet under a vacuum environment and dried under normal pressure to volatilize the flux, thereby forming a microcolumn precursor with a higher density.
3)将填充过PZT粉料的模板施加垂直于表面的6.0MPa的压力下维持30分钟。3) The template filled with PZT powder is subjected to a pressure of 6.0 MPa perpendicular to the surface and maintained for 30 minutes.
S3:将软模板以50℃/h的升温速度升温至500℃,保温3h,并继续以同样的升温速率升温至1200℃,保温2h,进行PZT陶瓷微柱的烧结。S3: The soft template is heated to 500°C at a heating rate of 50°C/h, kept at this temperature for 3 hours, and then continued to be heated to 1200°C at the same heating rate, kept at this temperature for 2 hours, to sinter the PZT ceramic microcolumns.
S4:采用环氧树脂聚合物(Epo-Tek 301-2)进行填充、固化得到1-3型压电复合材料,如图1。选择PZT粉体压片作为微柱阵列基底,压片的密度为3.52g/cm3,压片的直径为10mm,厚度为1mm。烧结过程中压片产生收缩,能够显著缩小其上PZT压电微柱之间的间距,使其排列更加紧密。如图2所示。S4: Epoxy resin polymer (Epo-Tek 301-2) is used for filling and curing to obtain a 1-3 type piezoelectric composite material, as shown in Figure 1. PZT powder pressed tablets are selected as the micro-pillar array substrate, the density of the pressed tablets is 3.52g/ cm3 , the diameter of the pressed tablets is 10mm, and the thickness is 1mm. The pressed tablets shrink during the sintering process, which can significantly reduce the spacing between the PZT piezoelectric micro-pillars on them, making them more closely arranged. As shown in Figure 2.
S5:通过切割机将样品进行研磨减薄,具体是采用机械研磨机对固化得到的1-3复合压电材料进行减薄,研磨采用1000目金刚石磨盘进行粗磨,然后采用氧化铝模板进行细磨,最终获得厚度为50μm的1-3复合压电材料薄片。随后利用磁控溅射在样品上下表面镀金电极,如图1。具体操作如下:利用超声清洗机对晶片分别在酒精、丙酮、去离子水中进行超声清洗个15分钟,然后50℃烘干。然后利用磁控溅射对样品上下表面进行多层复合电极被覆。在此示例中,先溅射镍电极,再溅射一层铬电极,作为过渡电极,其厚度控制在900-1500nm之间均可,之后溅射一层金电极,其厚度控制在1-2μm之间均可。每层电极溅射时间为10分钟,样品表面温度保持在80℃以下。S5: The sample is ground and thinned by a cutting machine. Specifically, a mechanical grinder is used to thin the solidified 1-3 composite piezoelectric material. A 1000 mesh diamond grinding disc is used for rough grinding, and then an alumina template is used for fine grinding. Finally, a 1-3 composite piezoelectric material sheet with a thickness of 50 μm is obtained. Then, gold electrodes are plated on the upper and lower surfaces of the sample by magnetron sputtering, as shown in Figure 1. The specific operation is as follows: The wafer is ultrasonically cleaned in alcohol, acetone, and deionized water for 15 minutes using an ultrasonic cleaning machine, and then dried at 50°C. Then, magnetron sputtering is used to coat the upper and lower surfaces of the sample with multiple layers of composite electrodes. In this example, a nickel electrode is sputtered first, and then a layer of chromium electrode is sputtered as a transition electrode, and its thickness can be controlled between 900-1500nm. Then a layer of gold electrode is sputtered, and its thickness can be controlled between 1-2μm. The sputtering time for each layer of electrode is 10 minutes, and the surface temperature of the sample is kept below 80°C.
S6:对样品进行极化,极化在硅油和室温条件下进行,施加电场为3kV/mm,极化时间为30分钟。S6: The sample is polarized in silicone oil at room temperature with an applied electric field of 3 kV/mm for 30 minutes.
使用光学显微镜对制备的1-3复合材料进行微结构观察,放大倍数为1000倍,如图2所示。压电柱排列较为整齐、分布均匀,且单个压电柱的直径较小,达到25μm。陶瓷微柱之间的平均间距较小,达到3μm。The microstructure of the prepared 1-3 composite material was observed using an optical microscope at a magnification of 1000 times, as shown in Figure 2. The piezoelectric columns are arranged neatly and evenly, and the diameter of a single piezoelectric column is small, reaching 25μm. The average spacing between ceramic microcolumns is small, reaching 3μm.
压电柱的形状尺寸,一是直接决定着材料的压电常数,二是决定着材料的振动模式,而振动模式决定着机电耦合性能。因此,压电柱的整齐、均匀,可以一致柱子之间的振动模式干扰,使振动模式较纯,增强其产生和接收压电信号的纯度。此外,柱子直径较小,可以在维持一定长径比(决定机电耦合性能大小)的情况下,样品可以做的更薄,进而频率做的更高,实现高频。平均间距较小,可以提升压电相的比例,获得更大的压电常数,也就是更高的压电响应。The shape and size of the piezoelectric column directly determine the piezoelectric constant of the material and the vibration mode of the material, while the vibration mode determines the electromechanical coupling performance. Therefore, the neatness and uniformity of the piezoelectric column can prevent the interference of the vibration modes between the columns, making the vibration mode purer and enhancing the purity of the piezoelectric signal generated and received. In addition, the column has a small diameter, so the sample can be made thinner while maintaining a certain aspect ratio (which determines the size of the electromechanical coupling performance), and the frequency can be made higher to achieve high frequency. The smaller average spacing can increase the proportion of the piezoelectric phase and obtain a larger piezoelectric constant, that is, a higher piezoelectric response.
阻抗谱测试,根据《压电陶瓷材料性能测试方法——性能参数的测定》(GB/T3389-2008),采用精密LCR分析仪HP4284A测量产品的阻抗-频率谱和损耗-频率谱。测量温度为室温,测试频率范围为20-60MHz,如图3所示。Impedance spectrum test, according to "Piezoelectric ceramic material performance test method - Determination of performance parameters" (GB/T3389-2008), the product's impedance-frequency spectrum and loss-frequency spectrum are measured using a precision LCR analyzer HP4284A. The measurement temperature is room temperature and the test frequency range is 20-60MHz, as shown in Figure 3.
由图3可见,本实施例的高频1-3复合压电材料的谐振频率为37.4MHz,反谐振频率为46.1MHz,根据《压电陶瓷材料性能测试方法——性能参数的测定》(GB/T 3389-2008)计算其机电耦合系数达到62.4%,显著高于PZT单相陶瓷片(kt~50%)。As can be seen from FIG3 , the resonant frequency of the high-frequency 1-3 composite piezoelectric material of this embodiment is 37.4 MHz, and the anti-resonant frequency is 46.1 MHz. According to the "Test Methods for Performance of Piezoelectric Ceramic Materials - Determination of Performance Parameters" (GB/T 3389-2008), its electromechanical coupling coefficient is calculated to be 62.4%, which is significantly higher than that of the PZT single-phase ceramic sheet (k t ~50%).
实施例2-5Embodiment 2-5
制备过程与实施例1基本相同,区别在于步骤S1中微孔的设计尺寸,具体数据见表1。The preparation process is basically the same as that of Example 1, except for the design size of the micropores in step S1. The specific data are shown in Table 1.
性能测试方法与实施例1相同。The performance testing method is the same as that in Example 1.
实施例6Example 6
S1,采用激光刻蚀不同厚度塑料薄板的方法制备不同厚度和不同微孔直径的软模板,如图1所示。软模板的厚度为0.5±0.2mm,微孔的直径为120μm。S1, soft templates with different thicknesses and different micropore diameters were prepared by laser etching plastic sheets of different thicknesses, as shown in Figure 1. The thickness of the soft template was 0.5±0.2 mm, and the diameter of the micropore was 120 μm.
S2,采用PZT-5H组分的粉料进行模板微孔的填充。S2, using PZT-5H component powder to fill the template micropores.
1)将颗粒度为1~3μm的PZT粉体分散到粘合剂溶液中,形成PZT浆料。1) PZT powder with a particle size of 1 to 3 μm is dispersed in a binder solution to form a PZT slurry.
2)在真空环境下将浆料灌注进塑料薄板微孔中,并在常压下干燥,使熔剂挥发,从而形成密度较大的微柱前驱体。2) The slurry is poured into the micropores of the plastic sheet under a vacuum environment and dried under normal pressure to volatilize the flux, thereby forming a microcolumn precursor with a higher density.
3)将填充过PZT粉料的模板施加垂直于表面的6MPa的压力下维持30分钟。3) The template filled with PZT powder is subjected to a pressure of 6 MPa perpendicular to the surface and maintained for 30 minutes.
S3,将软模板以50℃/h的升温速度升温至530℃,保温2h,并继续以同样的升温速率升温至1200℃,保温2h,进行PZT陶瓷微柱的烧结。S3, heating the soft template to 530°C at a heating rate of 50°C/h, keeping the temperature for 2h, and then continuing to heat to 1200°C at the same heating rate, keeping the temperature for 2h, to sinter the PZT ceramic microcolumns.
S4,采用环氧树脂聚合物(Epo-Tek 301-2)进行填充、固化得到1-3型压电复合材料,如图1。选择PZT粉体压片作为微柱阵列基底,压片的密度为3.52g/cm3,压片的直径为10mm,厚度为1mm。S4, epoxy resin polymer (Epo-Tek 301-2) is used for filling and curing to obtain a 1-3 type piezoelectric composite material, as shown in Figure 1. PZT powder pressed tablets are selected as micropillar array substrates, the density of the pressed tablets is 3.52g/ cm3 , the diameter of the pressed tablets is 10mm, and the thickness is 1mm.
S5,通过切割机将样品切成不同的厚度,利用磁控溅射在样品上下表面镀金电极,如图1。该过程与实施例1中的步骤S5相一致。S5, cutting the sample into different thicknesses by a cutting machine, and plating gold electrodes on the upper and lower surfaces of the sample by magnetron sputtering, as shown in FIG1. This process is consistent with step S5 in Example 1.
S6,对样品进行极化,极化在硅油和室温条件下进行,施加电场为3kV/mm,极化时间为30分钟。S6, polarizing the sample. The polarization is carried out in silicone oil at room temperature. The applied electric field is 3 kV/mm and the polarization time is 30 minutes.
性能测试方法与实施例1相同,结果见表1。The performance test method is the same as that in Example 1, and the results are shown in Table 1.
表1实施例1-6数据汇总表Table 1 Data summary of Examples 1-6
表1中,样品编号1#即对应于实施例1制得的样品,样品编号2#即对应于实施例2制得的样品,以此类推。In Table 1, sample number 1# corresponds to the sample prepared in Example 1, sample number 2# corresponds to the sample prepared in Example 2, and so on.
进一步利用扫描电镜SEM对所制备的6个1-3复合压电材料样品的微结构进行观察。例如,获得微柱直径d、微柱间距s、微柱长度h等微结构信息,如表1所示。可见,本制备方法可以制备获得PZT陶瓷微柱直径从25μm到120μm之间的任何微柱直径的样品;可获得的陶瓷微柱间距范围为3~10μm;可获得PZT陶瓷微柱长度范围为40~100μm;可获得的1-3复合压电材料陶瓷相的比例范围为43~55%;能够实现的谐振频率可高于35MHz,样品中最大的反谐振频率达到了46.1MHz。复合材料在用于制作超声换能器后,换能器的一个重要参数是中心频率,其是由复合材料的谐振频率和反谐振频率共同决定的。材料的谐振、反谐振频率越高,换能器的中心频率就越高。结合表1中检测数据可见,通过本发明提供的方法制得的材料在进一步制成超声换能器后,其中心频率可达高频。The microstructures of the six 1-3 composite piezoelectric material samples prepared were further observed using a scanning electron microscope (SEM). For example, microstructure information such as microcolumn diameter d, microcolumn spacing s, and microcolumn length h were obtained, as shown in Table 1. It can be seen that this preparation method can prepare samples with any microcolumn diameter between 25μm and 120μm for PZT ceramic microcolumns; the available ceramic microcolumn spacing range is 3 to 10μm; the available PZT ceramic microcolumn length range is 40 to 100μm; the available 1-3 composite piezoelectric material ceramic phase ratio range is 43 to 55%; the achievable resonant frequency can be higher than 35MHz, and the maximum anti-resonance frequency in the sample reaches 46.1MHz. After the composite material is used to make an ultrasonic transducer, an important parameter of the transducer is the center frequency, which is jointly determined by the resonant frequency and anti-resonance frequency of the composite material. The higher the resonance and anti-resonance frequencies of the material, the higher the center frequency of the transducer. Combined with the test data in Table 1, it can be seen that the center frequency of the material prepared by the method provided by the present invention can reach high frequency after being further made into an ultrasonic transducer.
此外,由表1还可知机电耦合系数在高频时(~40MHz)分布在61~71%之间,远高于PZT陶瓷单片的50~55%,表现出了较大的机电耦合性能优势,有利于提升高频超声换能器性能。In addition, it can be seen from Table 1 that the electromechanical coupling coefficient is distributed between 61% and 71% at high frequency (~40MHz), which is much higher than the 50% to 55% of the PZT ceramic monolith, showing a large electromechanical coupling performance advantage, which is beneficial to improving the performance of high-frequency ultrasonic transducers.
上述的对实施例的描述是为便于该技术领域的普通技术人员能理解和使用发明。熟悉本领域技术的人员显然可以容易地对这些实施例做出各种修改,并把在此说明的一般原理应用到其他实施例中而不必经过创造性的劳动。因此,本发明不限于上述实施例,本领域技术人员根据本发明的揭示,不脱离本发明范畴所做出的改进和修改都应该在本发明的保护范围之内。The above description of the embodiments is to facilitate the understanding and use of the invention by those skilled in the art. It is obvious that those skilled in the art can easily make various modifications to these embodiments and apply the general principles described herein to other embodiments without creative work. Therefore, the present invention is not limited to the above embodiments, and improvements and modifications made by those skilled in the art based on the disclosure of the present invention without departing from the scope of the present invention should be within the scope of protection of the present invention.
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