Conformally Large-Area Single-Crystal Piezocomposites with High Performance for Acoustic Transducers

Large-area and conformal piezoelectric elements are highly desired for acoustic transducers to possess a large power source level and wide detecting range. To date, single-crystal piezocomposites attract much attention on enhancing the power source level and bandwidth for next-generation acoustic transducers, owing to their higher piezoelectric and electromechanical coupling properties compared to traditional piezocomposites. Unfortunately, it is still challenging to achieve large-area and conformal single-crystal piezocomposites because of the fragile nature, large anisotropy, and the limited grown size of piezoelectric single crystals. Here, we successfully fabricate the conformally large-area single-crystal piezocomposite with an area of 160 × 50 mm² and a bending angle of 162° by a modified 3D-printing-assisted inserting method. The single-crystal piezocomposite exhibits a high thickness electromechanical coupling factor k_t of 85% and a large piezoelectric coefficient d₃₃ of 1150 pC/N, surpassing those of the reported large-area piezocomposites. The influence of the volume fraction and curvature radius of single-crystal PCs and acoustic transducers was investigated. Furthermore, we designed an acoustic transducer based on the conformal single-crystal piezocomposite. Benefiting from the excellent piezoelectric and electromechanical properties of the single-crystal piezocomposite, the transducer indicates a high maximum transmitting voltage response of 171.8 dB. Especially, its bandwidth (-3 dB) achieves 60 kHz with a resonant frequency of 292 kHz, which is about 1.8 times superior to the conformal acoustic transducer based on the ceramic piezocomposite with a similar resonant frequency. This work may benefit the future design and fabrication of high-performance and complex-shape piezoelectric composites as key materials for next-generation transducers.