WO1995003632A1 - Procede de fabrication de materiau piezocomposite - Google Patents

Procede de fabrication de materiau piezocomposite Download PDF

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Publication number
WO1995003632A1
WO1995003632A1 PCT/US1994/006515 US9406515W WO9503632A1 WO 1995003632 A1 WO1995003632 A1 WO 1995003632A1 US 9406515 W US9406515 W US 9406515W WO 9503632 A1 WO9503632 A1 WO 9503632A1
Authority
WO
WIPO (PCT)
Prior art keywords
rods
jigs
holes
set forth
mold
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US1994/006515
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English (en)
Inventor
Howard Dean Batha
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Fiber Materials Inc
Original Assignee
Fiber Materials Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Fiber Materials Inc filed Critical Fiber Materials Inc
Publication of WO1995003632A1 publication Critical patent/WO1995003632A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C31/00—Handling, e.g. feeding of the material to be shaped, storage of plastics material before moulding; Automation, i.e. automated handling lines in plastics processing plants, e.g. using manipulators or robots
    • B29C31/008—Handling preformed parts, e.g. inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/12—Moulds or cores; Details thereof or accessories therefor with incorporated means for positioning inserts, e.g. labels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
    • B29C39/02—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C39/10—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. casting around inserts or for coating articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/72—Encapsulating inserts having non-encapsulated projections, e.g. extremities or terminal portions of electrical components
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10N—ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10N30/00—Piezoelectric or electrostrictive devices
    • H10N30/01—Manufacture or treatment
    • H10N30/09—Forming piezoelectric or electrostrictive materials
    • H10N30/092—Forming composite materials
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10N—ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10N30/00—Piezoelectric or electrostrictive devices
    • H10N30/80—Constructional details
    • H10N30/85—Piezoelectric or electrostrictive active materials
    • H10N30/852—Composite materials, e.g. having 1-3 or 2-2 type connectivity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/44—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles
    • B29C33/448—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles destructible
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3055—Cars
    • B29L2031/3061—Number plates
    • H—ELECTRICITY
    • H04—ELECTRIC COMMUNICATION TECHNIQUE
    • H04R—LOUDSPEAKERS, MICROPHONES, GRAMOPHONE PICK-UPS OR LIKE ACOUSTIC ELECTROMECHANICAL TRANSDUCERS; ELECTRIC HEARING AIDS; PUBLIC ADDRESS SYSTEMS
    • H04R17/00—Piezoelectric transducers; Electrostrictive transducers

Definitions

  • the . present invention relates to piezoelectric composites, and more particularly to a novel method of manufacturing composite material formed of piezoelectric rods embedded in a polymcic matrix.
  • Composite piezoelectric materials have been conventionally employed widely for the generation and detection of sound waves.
  • One class of these materials known generally as 1-3 piezocomposites, is formed of a.plurality of parallel, long, thin rods of electrically active ceramic disposed in a continuous passive matrix that completely surrounds the rods, the rods being normal to a substantially plane surface of the composite.
  • Such materials can operate as true composite materials, where the acoustic wavelengths involved are so much longer than the detailed structure of the piezocomposite mat the material can be considered homogeneous.
  • piezocomposites The more important mechanical properties of piezocomposites are the effectiveness of electromechanical conversion, and the acoustic and electrical impedances. These properties are generally improved in 1-3 composites as has been described in a number of papers published in the late 1970's and early 1980's. Such composites have found extensive use in medical transducers where the rods are spaced very closely together and the resin matrix is a high modulus material that responds substantially in phase with the rods.
  • P pieocomposites of this type are exemplified by the PZT/polymer material described in U.S. Patent No. 4,613,784 issued to M. K - et al.
  • Assembling such piezocomposites involves arranging the rods in a uniform array, with or without lateral reinforcements, the rods being precisely located in a relatively expensive holding alignment rack or tooling.
  • the matrix material typically a resin, is introduced into the interspaces between the aligned ceramic rods, as by injection or transfer molding.
  • the composite is then machined to final dimensions, removing excess resin and creating a composite in which all of the rods are of the same length, the composite having parallel, smooth end faces.
  • a principal object of the present invention is to provide a method of manufacturing a piezocomposite, which method overcomes the problems noted above hitherto experienced in manufacturing such piezocomposites; and specifically to provide such a method which permits one to utilize the entire length of the expensive rod and eliminates or substantially reduces machining operations.
  • the present invention provides active composites in which the placement of the ends of the piezoelectric rods is precisely controlled to be at or just above the surface of the resin matrix, thereby solving the machining problem that has hitherto plagued the manufacture of piezoelectric composites.
  • the invention accordingly comprises the processes and the several steps and relation of one or more of such steps with respect to each of the others as are exemplified in the following detailed disclosure, the apparatus possessing the construction, combination of elements and arrangement of parts, and the product possessing the features and the relation of components, all of which are exemplified in the following detailed disclosure and the scope of the application of which will be indicated in the claims.
  • the present invention provides a method of fabricating novel piezocomposites, such as a 1-3 material, in which the ends of the ceramic piezoelectric rods extend beyond the resin matrix by a uniform precise amount.
  • the method of the present invention comprises the steps of forming a flat, preferably metallic, bottom jig of predetermined thickness and having a specific pattern of a plurality of spaced-apart, elongated parallel holes of substantially the same diameter as the rods. Respective first ends of a plurality of piezoelectric rods of equal or nearly equal length are inserted within those holes through the thickness of the bottom, and those ends are then positioned adjacent a base plate of a mold.
  • the other ends of the rods are inserted in corresponding holes in a similar top jig which is then adhered to a top plate of the mold.
  • the mold is closed and resin is infiltrated into the mold in the interspaces between the rods bounded by the jigs.
  • the resin is then cured and the mold removed.
  • the resulting article composite now comprises a plurality of rods captured in a matrix with jigs covering the ends of the matrix.
  • the rod ends may be machined, if necessary, to assure uniform lengths.
  • the jigs are removed mechanically if reasonably possible, or etched away with an appropriate etchant. It will be seen that the length of the rods then extending beyond the resin surfaces is controlled by the thickness of the jigs-
  • Fig. 1 is a flow chart showing a typical process for forming a piezocomposite in accordance with the present invention.
  • Fig. 2 is an exploded isometric schematic of apparatus comprising a mold and jig embodying principles of the present invention
  • Fig. 3 is an enlarged cross-section of a piezocomposite made in accordance the present invention with the jigs still in place;
  • Fig. 4 is an illustration of the piezocomposite of Fig. 3 with the jigs removed.
  • the present invention involves a series of steps shown generally in Fig. 1 wherein step 20 of preparation of tooling.
  • Such tooling shown in Fig. 2, includes mold 22 shown schematically as comprising first end plate 24 and second end plate 26.
  • Both end plates 24 and 26 are preferably made of metal or other heat-resistant, strong, rigid material, have substantially flat surfaces facing one another in parallel and preferably have identical cross-sectional configurations, e.g square, rectangular, circular and the like.
  • the sides of the mold are shown formed as a single unit in the form of metal frame 28, the cross-sectional configuration of which is congruent with or matched to the cross-sectional configuration of end plates 24 and 26, but frame 28 can be assembled of several parts or sections if desired.
  • Frame 28 has a depth or thickness typically of about 5.9 mm.
  • mold 22 can be any of a large number of prior art molds.
  • first jig 34 and second jig 36 each in the form of a relatively rigid, strong, flat plate, typically made of metal.
  • these jigs are removed from the final product, and where the removal is to be effected by etching, it is preferred that the jigs be made of a readily etchable metal such as copper, aluminum and the like.
  • Each of jigs 34 and 36 exhibit a cross-sectional configuration of lesser dimensions than the cross-sectional configuration of the interior of frame 28, and a thickness selected according to the desired extent to which the ends of piezoelectric rods will extend beyond the surface of the piezocomposite to be formed, e.g. 0.2mm.
  • Each of jigs 34 and 36 are provided with a plurality of apertures or holes 38 through at least one of the flat surfaces thereof and disposed in identical specific patterns, as by drilling or punching.
  • Holes 38 are shaped and dimensioned in cross-section to provide a tight sliding fit for piezoelectric rods to be inserted therein.
  • holes 38 are drilled in a hexagonal array perpendicular to the plane of the jig, each hole having a diameter of 0.15 cm, the center-to-center spacing being 0.24 cm, with all of the axes of elongation of the holes being substantially parallel to one another.
  • holes 38 can extend completely through the jig.
  • one surface of the jig is covered or capped with a very thin (e.g. 0.1 mm) metal sheet or foil so that holes 38 are blind, or holes 38 are blind because they simply are not drilled all the way through the jig.
  • Piezoceramic rods 40 typically barium titanate, lead zirconate titanate (PZT), or the like, of diameter substantially the same as that of holes 38 and a length (e.g. 6.3 mm) preferably slightly greater than the desired thickness of the final composite, are provided. It will be appreciated that substantially any piezoceramic material in rolled form may be used to form such rods.
  • the process of the present invention includes step 41 of precleaning the rods, coating the ends thereof with a coupling agent or adhesive.
  • step 42 the ends of the precleaned, coated rods are fitted snugly within holes 38 in jig 34. Only a few rods 40 are shown emplaced in Fig. 2.
  • Jig 34 either before or after an assembly of rods 40 is made therein, is placed in contact with plate 26 which is intended, for example, to serve as the bottom of the mold, the rods being so pressed into holes 38 as to insure that ends of each of the rods are closely adjacent or butt against plate 26. It will be z predated that the coupling agent applied to the rods serves to retain the latter witnin the holes in the jig.
  • Jig 36 is then placed over the other ends of rods 40 to provide the desired array of spaced-apart, parallel piezoceramic elements.
  • Jig 36 is brought into facing contact with a surface of end plate 24, again with those ends of rods 40 extended into holes 38 in jig 36 so as to be adjacent or butt against the plate depending on whether the holes are blind or not.
  • Jig 36 is then temporarily bonded or adhered to plate 24, as with any suitable coupling agent or adhesive.
  • Step 43 of Fig. 1 indicates that either prior to or after completing the assembly of the tooling comprising the end plates, rods and jigs, reinforcing fibers may be emplaced in the interspaces between the rods in the assembly, if desired.
  • the reinforcing fibers preferably continuous, may be any of a large number of materials such as carbon fiber, glass, alumina, polyester, rayon and alumina-boria- silica and the like, distributed substantially randomly or with any desired orientation to provide between about 5 and 20 volume percent of the volume of the interspaces.
  • Mold 22 is then finally assembled by emplacing frame 28 about end plates 24 and 26 to completely enclose the assembly of rods 40 and jigs 34 and 36, the assembled mold being so designed as to effectively seal the interior thereof except for the inlet aperture 30 and vents 31.
  • the interspaces among the array of rods in the interior of the latter is impregnated, shown as step 44 of Fig. 1, for example, with an epoxy, or with any of a variety of other resins, monomers or polymers, in liquid form or as finely comminuted particles suspended in an appropriate vehicle.
  • the impregnant is introduced by pumping the latter from a supply source or reservoir (not shown) through inlet aperture 30 and drawing a vacuum on vents 31 with pump 33 until the impregnant is thoroughly distributed throughout the interstices of the rod array.
  • the impregnant liquid is introduced -into mold 22 through inlet aperture 30 under high pressure e.g. of 500 psi or above.
  • the impregnant is cured or solidified in step 45, typically by initiating polymerization by irradiation, chemically or by heating to achieve polymerization or drive off a binder vehicle or the like.
  • the solidified assembly is allowed to cure, and in step 46, the mold is disassembled, care being taken to remove both end plates from the resulting composite as shown in Fig. 3.
  • the coupling agent used to adhere the rods ends to the jigs is temperature degradable, it will be understood that the heat of the polymerization or curing processes can provide the energy necessary to degrade the bond sufficiently to permit easy removal of the jigs.
  • the resulting composite now comprises an array of rods 40 captured within a solid matrix of solidified resin with or without reinforcing fibers embedded therein as desired, but with both jigs capping the ends of the composite.
  • the jigs and captured rod ends may be machined in step 47 as by milling to insure the desired coplanarity of the rod ends.
  • the jigs are thereafter removed mechanically or by etching away the metal with an appropriate known etchant, thereby to form a composite formed, as shown in Fig. 4, of solidified resin 50 having embedded therein rods 40, the ends of the latter extending from opposite surfaces of resin 50.
  • electrodes 52 are applied to the opposite surfaces of the composite from which the rod ends extend.
  • Such application can be achieved by any of several known techniques, e.g. by applying an epoxy loaded with a conductive metal such as copper or silver.
  • the transducers thus formed are poled by, for example, attaching the transducer to a high voltage source with one electrode at the top and in contact with all rods and the substrate.
  • the other electrode is bonded to the bottom conductive electrode.
  • the composite is immersed in an oil bath and heated to between 75°C and 160°C. A voltage of about 20,000 volts is applied for several minutes and then slowly reduced while the transducer is still immersed in the constant temperature bath.
  • An alternative and preferred method of poling the composite is to expose the ⁇ ⁇ T to a corona discharge field.
  • the specimen is electroded on one side and placed, electrode side down, on a conductive ground plate.
  • the plate is placed on a heat source capable of being heated to 150°C and capable of being cooled rapidly as by passing water through holes provided in the heat source.
  • An upper electrode is provided consisting of one or more needles suspended above and aimed at the center of the composite.
  • the entire system is placed within a grounded conductive screen cage and a potential of 20,000 volts per centimeter is applied for about 10 minutes to the heated composite. That temperature is maintained until the composite cools to about 35°C.
  • the effectiveness of the poling is confirmed by measuring the d 33 piezoelectric coefficient.
  • the coupling coefficient is determined in accordance with the impedance level measured as a function of frequency.
  • a special cell is used to determine the impedance curves from liquid nitrogen temperatures, at about -50°C, the impedance analyzer being used with that cold cell. The measurements are made in air.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Robotics (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

On fabrique un matériau composite piezoélectrique en formant une paire de gabarits (20) présentant chacun des motifs de perforations spécifiques de mêmes diamètres que les diamètres cylindriques de tiges. Les extrémités opposées respectives des tiges sont ensuite placées dans les orifices des gabarits de manière à former un assemblage de gabarits et de tiges parallèles (42). On place ledit assemblage dans un moule, les extrémités des tiges étant adjacentes aux surfaces internes opposées et parallèles du moule. On remplit ledit moule de résine ou d'un autre matériau qui peut être traité pour former une matrice solide (44), et on laisse sécher (45) la résine. On ouvre le moule, on enlève (48) les gabarits, ce qui permet de produire un composite solidifié de tiges et un matériau matriciel, les surfaces d'extrémité opposées des tiges saillant de la matrice en rangées pratiquement coplanaires.
PCT/US1994/006515 1993-07-19 1994-06-10 Procede de fabrication de materiau piezocomposite Ceased WO1995003632A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US9393793A 1993-07-19 1993-07-19
US08/093,937 1993-07-19

Publications (1)

Publication Number Publication Date
WO1995003632A1 true WO1995003632A1 (fr) 1995-02-02

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE19743859A1 (de) * 1997-10-04 1999-04-15 Stn Atlas Elektronik Gmbh Verfahren zur Herstellung eines Verbund-Ultraschallwandlers
US6574842B2 (en) 2000-10-24 2003-06-10 Stn Atlas Elecktronic Gmbh Method for producing an ultrasonic transducer
WO2005120792A1 (fr) * 2004-06-09 2005-12-22 Atraverda Limited Procede de fabrication
WO2011038703A1 (fr) 2009-09-29 2011-04-07 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Module fonctionnel piézo-électrique et procédé de production

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3218497A (en) * 1962-10-10 1965-11-16 James F Motson Miniaturized electroluminescent lamp
US3516753A (en) * 1968-04-12 1970-06-23 Berol Corp Writing instrument and process of making the same
US3517093A (en) * 1967-06-28 1970-06-23 Us Navy Method for producing lead zirconate-titanate transducer materials by slip casting
US3772774A (en) * 1967-04-26 1973-11-20 Philips Corp Method of manufacturing multiple conductive lead-in members
US4422003A (en) * 1982-08-16 1983-12-20 The United States Of America As Represented By The Secretary Of The Navy Perforated PZT polymer composites
US4613784A (en) * 1984-12-21 1986-09-23 The United States Of America As Represented By The Secretary Of The Navy Transversely reinforced piezoelectric composites
US4732717A (en) * 1985-10-11 1988-03-22 Sumitomo Bakelite Company Limited Process for producing piezo-electric or pyro-electric composite sheet

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3218497A (en) * 1962-10-10 1965-11-16 James F Motson Miniaturized electroluminescent lamp
US3772774A (en) * 1967-04-26 1973-11-20 Philips Corp Method of manufacturing multiple conductive lead-in members
US3517093A (en) * 1967-06-28 1970-06-23 Us Navy Method for producing lead zirconate-titanate transducer materials by slip casting
US3516753A (en) * 1968-04-12 1970-06-23 Berol Corp Writing instrument and process of making the same
US4422003A (en) * 1982-08-16 1983-12-20 The United States Of America As Represented By The Secretary Of The Navy Perforated PZT polymer composites
US4613784A (en) * 1984-12-21 1986-09-23 The United States Of America As Represented By The Secretary Of The Navy Transversely reinforced piezoelectric composites
US4732717A (en) * 1985-10-11 1988-03-22 Sumitomo Bakelite Company Limited Process for producing piezo-electric or pyro-electric composite sheet

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE19743859A1 (de) * 1997-10-04 1999-04-15 Stn Atlas Elektronik Gmbh Verfahren zur Herstellung eines Verbund-Ultraschallwandlers
DE19743859C2 (de) * 1997-10-04 2000-11-16 Stn Atlas Elektronik Gmbh Verfahren zur Herstellung eines Verbund-Ultraschallwandlers
US6301761B1 (en) 1997-10-04 2001-10-16 Stn Atlas Elektronik Gmbh Method for producing a composite ultrasonic transducer
US6574842B2 (en) 2000-10-24 2003-06-10 Stn Atlas Elecktronic Gmbh Method for producing an ultrasonic transducer
WO2005120792A1 (fr) * 2004-06-09 2005-12-22 Atraverda Limited Procede de fabrication
US8038739B2 (en) 2004-06-09 2011-10-18 Atraverda Limited Manufacturing method
WO2011038703A1 (fr) 2009-09-29 2011-04-07 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Module fonctionnel piézo-électrique et procédé de production

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