Ultrasonic transducer using aerogel as filler material

A method of manufacturing an ultrasonic transducer comprising the steps of:

• providing a layer of ultrasonic composite having an emitting face and a non-emitting face, which further comprises the steps of,
• forming an upper block section of a piezoelectric ceramic block to form an array of posts, leaving an unworked lower block section, wherein neighboring posts are separated by kerf spaces, the posts having top post surfaces and lower connections to the lower block section;
• filling the kerf spaces with a filler material comprising an aerogel precursor material, the filler material having a top filler surface after the filling;
• drying the filler material to form an aerogel filler material;
• removing the lower block section, thereby exposing bottom post surfaces and a bottom filler surface;
• providing a layer of connection circuit having a first face with an array of conductive contacts, each conductive contact making electrical contact with a corresponding post connection surface;
• and,
• providing a backing layer attached to a second face of the layer of connection circuit, the backing layer substantially preventing acoustic emission from the non-emitting face.