NBT based lead-free piezoelectric materials for high power applications

This application claims priority to U.S. provisional patent application 61/194,461 filed Sep. 26, 2008.

The disclosed invention relates to hard lead free piezoelectric materials.

Hard PZT ferroelectric materials such as PZT4 and PZT8 have been the mainstay in last half century for high power applications. However, the lead content in PZT type ceramics is an environmental concern in electronic devices. For example, the European Union is proposing directives on waste from electrical and electronic equipment as well restrictions on hazardous substances and end-of life vehicles. The USA and Japan are expected to issue similar environmental regulations. It therefore is desirable to develop lead-free piezoelectric ceramics to replace lead-based materials.

Lead-free ceramic compounds may be categorized into three primary types, all of which have the ABO 3 perovskite formulation: (1) BaTiO 3 (“BT”), (2) K 0.5 Na 0.5 NbO 3 (“KNN”) and (3) Na 0.5 Bi 0.5 TiO 3 (“NBT”). These compounds, however, either display low T C (≦120° C.), show low piezoelectric activity, multiple polymorphic phase transitions as well as depolarization temperature which limit their utility. Various properties of these compounds are shown in Table I. In Table I, KCN is K 4 CuNb 8 O 23 and MPB is Morphotropic Phase Boundary.

Lead-free ceramic compounds such as solid solutions of NBT with K 0.5 Bi 0.5 TiO 3 (“KBT”), NBT-KBT-BT, NBT-KBT- with Li 0.5 Bi 0.5 TiO 3 (“LBT”) show a morphotropic phase boundary analogous to PZT and relaxor-PT systems. NBT-KBT, NBT-KBT-BT, and NBT-KBT-LBT, however, exhibit a nonpolar antiferroelectric phase transition temperature that occurs below their T C that limits their temperature range of use. Lead-free ceramic compounds such as KNN—LiNbO 3 (“KNN-LN”), KNN—LiTaO 3 (“KNN-LT”), KNN—LiSbO 3 (“KNN-LS”), and KNN—Sr(Ba)TiO 3 have piezoelectric properties comparable to hard PZT ceramic compounds. However, these KNN type lead-free compounds exhibit low mechanical quality factor Q and a shift in the orthorhombic-tetragonal polymorphic phase transition temperature from about 200° C. to about room temperature. This polymorphic phase transition significantly limits their utility due to property variations.

A need therefore exists for high performance lead free piezoelectric ceramic materials that avoid the toxic lead of prior art Pb(Zr x Ti 1-x )O 3 (“PZT”) piezoelectric ceramics and the disadvantages of prior art, lead free piezoelectric ceramics.

FIG. 1 shows a compositional diagram of NBT-based compositions;

FIG. 2 (a) shows piezoelectric coefficient (d 33 ) and mechanical quality factor (Q m ) as a function of Mn level in BNBK 79 piezoelectric compounds;

FIG. 2(b) shows dielectric permittivity (K) and dielectric loss (tan δ) as a function of Mn dopant level in BNBK 79 piezoelectric compounds;

FIG. 2 (c) shows electromechanical coupling factors (k ij ) as a function of Mn dopant level in BNBK79 piezoelectric compounds;

FIG. 3 shows polarization hysteresis for BNBK 79-0.8 wt % MnO 2 piezoelectric compound of example 1G compared to PZT4 and PZT8;

FIG. 4 shows strain hysteresis of lead free BNBK 79 of example 1A and 0.8 wt % MnO 2 doped BNBK 79 of example 1G piezoelectric compounds compared to PZT4 and PZT8;

FIG. 5(a) shows dielectric permittivity and dielectric loss as a function of temperature for undoped BNBK 79 piezoelectric compounds at 1 kHz, 10 kHz and 100 kHz;

FIG. 5(b) shows dielectric permittivity and dielectric loss for 0.5 wt % MnO 2 doped BNBK 79 piezoelectric compounds at 1 kHz, 10 kHz and 100 kHz;

FIG. 5(c) shows dielectric permittivity and dielectric loss for 0.8 wt % MnO 2 doped BNBK 79 piezoelectric compounds at 1 kHz, 10 kHz and 100 kHz;

FIG. 5(d) shows dielectric permittivity and dielectric loss for 1.0 wt % MnO 2 doped BNBK 79 piezoelectric compounds at 1 kHz, 10 kHz and 100 kHz;

FIG. 6 shows electromechanical coupling factors in extensional mode and thickness mode for 0.8 wt % MnO 2 doped BNBK 79 of Example 1G piezoelectric compounds;

FIG. 7 shows variation of planar electromechanical coupling factor as a function of temperature for BNBK 79-0.8 wt % MnO 2 piezoelectric compounds compared to PZT4 and PZT8.

FIGS. 8(a)-8(c) show temperature dependence of dielectric behavior for Co 2 O 3 doped vacancy defect engineered BNKLBT ceramics.

FIG. 9 shows temperature dependence of electromechanical coupling factor, including thickness coupling k t and planar coupling k p , for Co 2 O 3 doped vacancy defect engineered BNKLBT ceramics, exhibiting a very stable temperature behavior till their depolarization temperature T d .

FIG. 10 shows the temperature dependence of mechanical quality factor Q, for Co 2 O 3 doped vacancy defect engineered BNKLBT ceramics, where the Q values are larger than 700 at room temperature, gradually decreased with increasing temperature, keep yet high Q value around 200 when the temperature approaching the depolarization temperature T d .

The NBT-based piezoelectric materials disclosed herein typically possess high internal bias field of more than about 5 kV/cm and high mechanical quality factor of more than about 700, comparable to PZT4 and PZT8. The NBT based materials of the general formula xNa m Bi n TiO 3 -yK m Bi n TiO 3 -zLi m Bi n TiO 3 -pBaTiO 3 where (0<x≦1), preferably (0.3≦x≦0.95), more preferably (0.3≦x≦0.8), (0≦y≦1), preferably (0≦y≦0.7), more preferably (0≦y≦0.2), (0≦z≦1), preferably (0≦z≦0.5), more preferably (0≦z≦0.2); (0.3≦m≦0.7), preferably (0.4≦m≦0.6), more preferably (0.45≦m≦0.55); (0.3≦n≦0.7), preferably (0.4≦n≦0.6), more preferably (0.45≦n≦0.55) such as n=0.495; (0<p<1), preferably (0<p≦0.2), more preferably (0<p≦0.1); (x+y+z+p=1), (0.9≦m+n≦1.1) and (0.9≦m/n≦1.1), may be modified with various acceptor dopants (single dopant, multiple dopant) to have a wide temperature usage range of from about −50° C. to about 200° C. The low densities of NBT-based piezoelectric compounds, on the order of about 5.8 g/cc vs. about 7.6 g/cc for PZT piezoelectric compounds, enable the NBT-based piezoelectric compounds to achieve high acoustic velocities.

The NBT-based piezoelectric compounds possess improved “hardening” effect compared to conventional hard PZT piezoelectric compounds and may be used to replace lead containing piezoelectric materials such as PZT4 and PZT 8.

The NBT-based piezoelectric compounds are environmentally friendly materials that may be used in high power electronic devices such as high power ultrasonic transducers (probes), ultrasonic motors, piezoelectric transformers and high intensity focused ultrasound transducers.

In a first aspect, undoped compounds within the region bounded by y≦50%, z≦20% shown in FIG. 1 may be produced. These compounds are within the general formula (I) xNa m Bi n TiO 3 -yK m Bi n TiO 3 -zLi m Bi n TiO 3 -pBaTiO 3 where (0<x≦1), preferably (0.3≦x≦0.95), more preferably (0.3≦x≦0.8); (0≦y≦1), preferably (0≦y≦0.7), more preferably (0<y≦0.2) and (0≦z≦1), preferably (0≦z≦0.5), more preferably (0<z≦0.2); (0.3≦m≦0.7), preferably (0.4≦m≦0.6), more preferably (0.45≦m≦0.55); (0.3≦n≦0.7), preferably (0.4≦n≦0.6), more preferably (0.45≦n≦0.55); (0<p<1), preferably (0<p≦0.2), more preferably (0<p≦0.1), (x+y+z+p=1) and (0.9≦m/n≦1.1).

Starting materials which may be used include but are not limited to K 2 CO 3 (99.9% pure from Alfa Aesar), Na 2 CO 3 (99.9% pure from Alfa Aesar), Li 2 CO 3 (99.9% pure from Alfa Aesar), BaCO 3 (99.9% pure from Alfa Aesar), Bi 2 O 3 (99.99% pure from MCP) and TiO 2 (99.99% pure from Ishihara). Dopant sources which may be employed include but are not limited to Al 2 O 3 , CoO, Co 2 O 3 , Re 2 O 3 (where Re is rare earth element), NiCO 3 , MnO 2 , MnCO 3 , Fe 2 O 3 , and mixtures thereof. The dopants have a purity of 99.99% or more and are commercially available from sources such as Alfa Aesar.

Manufacture of piezoelectric compounds within general formula (I) entails use of starting materials such as those above that are dried at about 120° C. in air for about 10 hrs to about 20 hrs to remove moisture.

The dried starting materials are blended into a mixture for use in manufacture of undoped BNBK type compound such as xNa 0.5 Bi 0.5 TiO 3 -yK 0.5 Bi 0.5 TiO 3 -zBaTiO 3 . The mixture then is calcined in an oxidizing atmosphere such as air at about 700° C. to about 950° C., preferably about 800° C. to about 900° C., more preferably about 850° C. to about 880° C. for about 0.5 hr to about 5 hrs, preferably about 1 hr to about 3 hrs, more preferably about 2 hrs to yield a calcined mixture. The calcined mixture then is vibration milled in a lower alkanol such as anhydrous ethanol to produce a milled material that has a particle size of about 0.5 micron to about 3 microns preferably about 1 micron to about 2 microns, more preferably about 1 micron.

The milled material is optionally mixed with up to about 2 wt. % of an optional organic binder based on the weight of milled material to produce a milled material composition. Useful binders include but are not limited to polyvinyl alcohol, polyvinyl butyral, and aqueous acrylic polymer emulsions such as Rhoplex from Rohm & Haas, polyethyleneimine and mixtures thereof. The milled material, optionally with binder composition is compressed at about 3000 PSI to about 10000 PSI, preferably about 5000 PSI to about 8000 PSI, more preferably about 5000 PSI to about 6000 PSI to yield a preform.

The preform is heated to about 500° C. to about 600° C., preferably about 350° C. to about 550° C., more preferably about 500° C. to about 550° C. to remove binder that may be present and to yield a green preform. The green preform then is sintered at about 1000° C. to about 1250° C., such as about 1060° C. to about 1220° C. preferably about 1050° C. to about 1150° C., more preferably about 1100° C. for about 0.5 hr to about 5 hrs, preferably about 1 hr to about 2 hrs, more preferably about 2 hrs to yield a sintered product.

The density of the sintered product typically is about 5.0 g/cm 3 to about 5.7 g/cm 3 , preferably about 5.7 g/cm 3 which represents ≧95% of the theoretical density. The sintered products typically have a perovskite type crystal structure.

The sintered products are polished to a thickness of about 0.5 mm. The resulting polished products are electroded with fire-on-silver paste such a DuPont 6160 to produce an electroded sample. The electroded samples are poled at about 20° C. to about 120° C., preferably about 20° C. to about 50° C., more preferably about 25° C. (room temperature) with an electric field of about 30 kV/cm to about 60 kV/cm, preferably about 40 kV/cm to about 50 kV/cm, more preferably about 40 kV/cm for about 3 min to about 30 min, preferably about 5 min to about 10 min, more preferably about 10 min.

In a second aspect, doped piezoelectric compounds of the general formula (IA),

((xNa m Bi n TiO 3 -yK m Bi n TiO 3 -zLi m Bi n TiO 3 -pBaTiO 3 )rM)   (IA),

where (0<x≦1), preferably (0.3≦x≦0.95), more preferably (0.3≦x≦0.8); (0≦y≦1), preferably (0≦y≦0.7), more preferably (0≦y≦0.2), (0≦z≦1), preferably (0≦z≦0.5), more preferably (0≦z≦0.2); (0<p<1), preferably (0<p≦0.2), more preferably (0<p≦0.1); (x+y+z+p=1); 0.3≦m≦0.7, preferably 0.4≦m≦0.6, more preferably 0.45≦m≦0.55; 0.3≦n≦0.7, preferably 0.4≦n≦0.6, more preferably 0.45≦n≦0.55; and 0.9≦m/n≦1.1, preferably 0.95≦m/n≦1.05, more preferably 0.98≦m/n≦1.02 and (0 wt %<r≦5 wt %), preferably 0.2 wt %≦r≦2 wt %, more preferably 0.5 wt %≦r≦1 wt %, where r is based on the weight of a compound within the scope of xNa m Bi n TiO 3 -yK m Bi n TiO 3 -zLi m Bi n TiO 3 -pBaTiO 3 where x, y, z, m, n and p are defined as above, and M is a dopant such as Al 2 O 3 , CoO, Re 2 O 3 where Re is a rare earth element, NiO, MnO 2 , Fe 2 O 3 , and mixtures thereof may be produced.

In this second aspect, the starting materials are dried and then blended into a mixture for use in manufacture of undoped compound within the scope of general formula (I). The mixture then is calcined in an oxidizing atmosphere such as air at about 700° C. to about 950° C., preferably about 800° C. to about 900° C., more preferably about 850° C. to about 880° C. for about 0.5 hr to about 5 hrs, preferably about 1 hr to about 3 hrs, more preferably about 2 hrs to yield a calcined mixture. The calcined mixture then is blended with a dopant to provide a doped mixture suitable for manufacture of a compound with the general formula (IIA) that is vibration milled in a lower alkanol such as anhydrous ethanol to produce a milled material that has a particle size of about 0.5 micron to about 3 microns, preferably about 1 micron to about 2 microns, more preferably about 1 micron.

The milled material optionally may be mixed with an optional organic binder in an amount of up to about 2 wt. %, based on the weight of milled material to produce a milled material composition. Useful binders include but are not limited to polyvinyl alcohol, polyvinyl butyral, aqueous acrylic polymer emulsions such as Rhoplex from Rohm 86 Haas, polyethyleneimine and mixtures thereof.

The milled material composition is compressed at about 3000 PSI to about 10000 PSI, preferably about 5000 PSI to about 8000 PSI, more preferably about 5000 PSI to about 6000 PSI to yield a preform. The preform then is heated to about 500° C. to about 600° C., preferably about 350° C. to about 550° C., more preferably about 550° C. to remove binder that may be present and to yield a green preform. The green preform is sintered at about 1000° C. to about 1250° C., preferably about 1050° C. to about 1150° C., more preferably about 1100° C. for about 0.5 hr to about 5 hrs, preferably about 1 hr to about 2 hrs, more preferably about 2 hrs to yield a sintered product.

The sintered products are polished and electroded with fire-on-silver paste such as DuPont 6160 to produce electroded samples. The electroded samples are poled at about 20° C. to about 120° C., preferably about 20° C. to about 50° C., more preferably about 25° C. (room temperature) with an electric field of about 30 kV/cm to about 60 kV/cm, preferably about 40 kV/cm to about 50 kV/cm, more preferably about 40 kV/cm for about 3 min to about 30 min, preferably about 5 min to about 10 min, more preferably 10 min.

In a third aspect, compounds of the general formula (II)

xNa m Bi n TiO 3 -yK m Bi n TiO 3 -zLi m Ba n TiO 3   (II)

such as xNa 0.5 Bi 0.5 TiO 3 -yK 0.5 Bi 0.5 TiO 3 -zLi 0.5 Ba 0.5 TiO 3 where (0<x≦1), preferably (0.3≦x≦0.95), more preferably (0.30≦x≦0.8); (0<y≦1), preferably (0<y≦0.7), more preferably (0<y≦0.5), (0<z≦1), preferably (0<z≦0.5), more preferably (0<z≦0.2) (x+y+z=1); 0.3≦m≦0.7, preferably 0.4≦m≦0.6, more preferably 0.45≦m≦0.55; 0.3≦n≦0.7, preferably 0.4≦n≦0.6, more preferably 0.45≦n≦0.55; 0.9<m+n<1.1 and 0.9≦m/n≦1.1, preferably 0.95≦m/n≦1.05, more preferably 0.98≦m/n≦1.02 may be produced.

In this third aspect, dried starting materials such as K 2 CO 3 , Na 2 CO 3 , TiO 2 , Bi 2 O 3 , BaCO 3 and Li 2 CO 3 are blended into a mixture for use in manufacture of undoped piezoelectric compound within general formula (II). The mixture then is calcined in air at about 700° C. to about 950° C., preferably about 800° C. to about 900° C., more preferably about 850° C. to about 880° C. for about 0.5 hr to about 5 hrs, preferably about 1 hr to about 3 hrs, more preferably about 2 hrs to yield a calcined mixture.

The calcined mixture then is vibration milled in a lower alcohol such as anhydrous ethanol to produce a milled material that has a particle size of about 0.5 micron to about 3 microns, preferably about 1 micron to about 2 microns, more preferably about 1 micron. The milled material then is optionally mixed with up to about 2 wt. % of an organic binder based on the weight of milled material to produce a milled material composition. Useful binders include but are not limited to polyvinyl alcohol, polyvinyl butyral, aqueous acrylic polymer emulsions such as Rhoplex from Rohm & Haas, polyethyleneimine and mixtures thereof.

The milled material composition, optionally with binder, is compressed at about 3000 PSI to about 8000 PSI preferably about 5000 PSI to about 8000 PSI, more preferably about 5000 PSI to about 6000 PSI to yield a preform. The preform then is heated to about 500° C. to about 550° C., preferably about 550° C. to remove binder that may be present and to yield a green preform. The green preform then is sintered at about 1000° C. to about 1250° C., preferably about 1050° C. to about 1150° C., more preferably about 1100° C. for about 0.5 hrs to about 5 hrs, preferably about 1 hrs to about 2 hrs, more preferably about 2 hrs to yield a sintered product.

The sintered products are polished and electroded with fire-on-silver paste such a DuPont 6160 to produce electroded samples. The electroded samples are poled at about 20° C. to about 120° C., preferably about 20° C. to about 50° C., more preferably about 25° C. with an electric field of about 20 kV/cm to about 60 kV/cm, preferably about 40 kV/cm to about 50 kV/cm, more preferably about 40 kV/cm for about 3 min to about 30 minutes, preferably about 5 min to about 10 min, more preferably about 10 min.

In a fourth aspect, doped compounds within the general formula (IIA)

((xNa m Bi n TiO 3 -yK m Bi n TiO 3 -zLi m Ba n TiO 3 )-vN)   (IIA)

where (0<x≦1), preferably (0.3≦x≦0.9), more preferably (0.30≦x≦0.8); (0<y≦1), preferably (0<y≦0.7), more preferably (0<y≦0.2), (0<z≦1), preferably (0<z≦0.5), more preferably (0<z≦0.2); (x+y+z=1), 0.3≦m≦0.7, preferably 0.4≦m≦0.6, more preferably 0.45≦m≦0.55, 0.3≦n≦0.7, preferably 0.4≦n≦0.6, more preferably 0.45≦n≦0.55; 0.9≦m/n≦1.1, preferably 0.95≦m/n≦1.05, more preferably 0.98≦m/n≦1.02; 0.9<m+n<1.1 and N is a dopant such as Al 2 O 3 , CoO, Re 2 O 3 where Re is a rare earth element, NiO, MnO 2 , Fe 2 O 3 , and mixtures thereof may be produced and (0<v≦5 wt %) preferably 0.2 wt %≦v≦2 wt %, more preferably 0.5 wt %≦v≦1 wt %, where v is based on the weight of a compound within the scope of the formula xNa m Bi n TiO 3 -yK m Bi n TiO 3 -zLi m Ba n TiO 3 where x, y, z, m and n are defined as above.

In this fourth aspect, starting materials are dried and then blended into a mixture for use in manufacture of undoped compounds within the scope of general formula (II). The mixture then is calcined in air at about 700° C. to about 950° C., preferably about 800° C. to about 900° C., more preferably about 850° C. to about 880° C. for about 0.5 hrs to about 3 hrs, preferably about 1 hr to about 2 hrs, more preferably about 2 hrs to yield a calcined mixture. The calcined mixture then is blended with a dopant to provide a doped mixture that is vibration milled in a lower alkanol such as anhydrous ethanol to produce a milled material that has a particle size of about 0.5 micron to about 3 microns, preferably about 1 micron to about 2 microns, more preferably about 1 micron.

The milled material optionally may be mixed with up to about 2 wt. % of an organic binder, based on the weight of milled material to produce a milled material composition. Useful binders include but are not limited to polyvinyl alcohol, polyvinyl butyral, aqueous acrylic polymer emulsions such as Rhoplex from Rohm 85 Haas, polyethyleneimine and mixtures thereof.

The milled material composition is compressed at about 3000 PSI to about 10000 PSI, preferably about 5000 PSI to about 8000 PSI, more preferably about 5000 PSI to about 6000 PSI to yield a preform. The preform then is heated to about 500° C. to about 700° C., preferably about 550° C. to remove any binder present to yield a green preform. The green preform then is sintered at about 1000° C. to about 1250° C., preferably about 1050° C. to about 1150° C., more preferably about 1100° C. for about 0.5 hr to about 5 hrs, preferably about 1 hr to about 2 hrs, more preferably about 2 hrs to yield a sintered product.

The sintered products are polished and electroded with fire-on-silver paste such a DuPont 6160 to produce an electroded sample. The electroded samples are poled at about 20° C. to about 120° C., preferably 20° C. to about 50° C., more preferably about 25° C. with an electric field of about 30 kV/cm to about 60 kV/cm, preferably about 40 kV/cm to about 50 kV/cm, more preferably about 40 kV/cm for about 3 min to about 30 min, preferably about 5 min to about 10 min, more preferably 10 min.

In a fifth aspect, compounds of the general formula (III)

(xNa m Bi n TiO 3 -yLi m Bi n TiO 3 -zBaTiO 3 )   (III)

where (0<x≦1), preferably (0.3≦x≦0.95), more preferably (0.3≦x≦0.8); (0<y≦1), preferably (0<y≦0.7), more preferably (0<y≦0.2) and (0<z≦1), preferably (0<z≦0.5), more preferably (0<z≦0.2); (x+y+z=1) 0.3≦m≦0.7, preferably 0.4≦m≦0.6, more preferably 0.45≦m≦0.55; 0.3≦n≦0.7, preferably 0.4≦n≦0.6, more preferably 0.45≦n≦0.55; 0.9<m+n<1.1, and 0.9≦m/n≦1.1, preferably 0.95≦m/n≦1.05, more preferably 0.98≦m/n≦1.02 may be produced.

Dried starting materials such as Na 2 CO 3 , TiO 2 , Bi 2 O 3 , BaCO 3 and Li 2 CO 3 are blended into a mixture for use in manufacture of undoped piezoelectric compounds within general formula (III) such as xNa 0.5 Bi 0.5 TiO 3 -yLi 0.5 Bi 0.5 TiO 3 -zBaTiO 3 . The mixture then is calcined in air at about 700° C. to about 950° C., preferably about 800° C. to about 900° C., more preferably about 850° C. to about 880° C. for about 0.5 hr to about 2 hrs, preferably about 2 hrs yield a calcined mixture. The calcined mixture then is vibration milled in a lower alkanol such as anhydrous ethanol to produce a milled material that has a particle size of about 0.5 micron to about 3 microns, preferably about 1 micron to about 2 microns, more preferably about 2 microns. The milled material then is optionally mixed with up to about 2 wt. % of an organic binder based on the weight of milled material to produce a milled material composition. Useful binders include but are not limited to polyvinyl alcohol, polyvinyl butyral, aqueous acrylic polymer emulsions such as Rhoplex from Rohm & Haas, polyethyleneimine and mixtures thereof.

The milled material, optionally with binder, is compressed at about 3000 PSI to about 10000 PSI, preferably about 5000 PSI to about 8000 PSI, more preferably about 5000 PSI to about 6000 PSI to yield a preform. The preform then is heated to about 500° C. to about 650° C., preferably about 550° C. to remove binder that may be present and to yield a green preform. The green preform then is sintered at about 1000° C. to about 1250° C., preferably about 1050° C. to about 1150° C., more preferably about 1100° C. for about 0.5 hr to about 5 hrs, preferably about 1 hr to about 2 hrs, more preferably about 2 hrs to yield a sintered product.

The sintered products are polished and electroded with fire-on-silver paste such a DuPont 6160 to produce an electroded sample. The electroded samples are poled at about 20° C. to about 120° C., preferably about 20° C. to about 50° C., more preferably about 25° C. with an electric field of about 30 kV/cm to about 60 kV/cm, preferably about 40 kV/cm to about 50 kV/cm, more preferably about 40 kV/cm for about 3 min to about 30 min, preferably about 5 min to about 10 min, more preferably about 10 min.

In a sixth aspect, doped compounds of the general formula IIIA

((xNa m Bi n TiO 3 -yLi m Bi n TiO 3 -zBaTiO 3 )-wN)   (IIIA)

where (0<x≦1), preferably (0.3≦x≦0.95), more preferably (0.3≦x≦0.8); (0<y≦1), preferably (0<y≦0.7), more preferably (0<y≦0.2) and (0<z≦1), preferably (0<z≦0.5), more preferably (0<z≦0.2), (x+y+z=1); 0.3≦m≦0.7, preferably 0.4≦m≦0.6, more preferably 0.45≦m≦0.55; 0.3≦n≦0.7, preferably 0.4≦n≦0.6, more preferably 0.45≦n≦0.55; 0.9<m+n<1.1, and 0.9≦m/n≦1.1, preferably 0.95≦m/n≦1.05, more preferably 0.98≦m/n≦1.02 (0<w≦5 wt %) preferably 0.2 wt %≦w≦2 wt %, more preferably 0.5 wt %≦w≦1 wt %, where w is based on the weight of a compound within the scope of the formula xNa m Bi n TiO 3 -yLi m Bi n TiO 3 -zBaTiO 3 where x, y, z, m and n are defined as above and where N is a dopant such as Al 2 O 3 , CoO, Re 2 O 3 where Re is a rare earth element, NiO, MnO 2 , Fe 2 O 3 , and mixtures thereof.

In this sixth aspect, starting materials are dried and then blended into a mixture for use in manufacture of undoped piezoelectric compounds within general formula (III). The mixture then is calcined in air at about 700° C. to about 950° C., preferably about 800° C. to about 900° C., more preferably about 850° C. to about 880° C. for about 0.5 hr to about 5 hrs, preferably about 1 hr to about 3 hrs, more preferably about 2 hrs to yield a calcined mixture.

The calcined mixture then is blended with a dopant to provide a doped mixture that is vibration milled in a lower alkanol such as anhydrous ethanol to produce a milled material that has a particle size of about 0.5 micron to about 3 microns, preferably about 1 micron to about 2 microns, more preferably about 2 microns.

The milled material optionally may be mixed with an organic binder in an amount of up to about 2 wt. %, based on the weight of milled material to produce a milled material composition. Useful binders include but are not limited to polyvinyl alcohol, polyvinyl butyral, aqueous acrylic polymer emulsions such as Rhoplex from Rohm & Haas, polyethyleneimine and mixtures thereof. The milled material composition is compressed at about 3000 PSI to about 10000 PSI, preferably about 5000 PSI to about 8000 PSI, more preferably about 5000 PSI to about 6000 PSI to yield a preform.

The preform is heated to about 500° C. to about 650° C., preferably about 550° C. to remove binder that may be present to yield a green preform. The green preform then is sintered at about 1000° C. to about 1250° C., preferably about 1050° C. to about 1150° C., more preferably about 1100° C. about 0.5 hr to about 5 hrs, preferably about 1 hr to about 2 hrs, more preferably about 2 hrs to yield a sintered product.

The sintered products are polished and electroded with fire-on-silver paste such a DuPont 6160 to produce an electroded sample. The electroded samples are poled at room temperature with an electric field of about 30 kV/cm to about 60 kV/cm, preferably about 40 kV/cm to about 50 kV/cm, more preferably about 40 kV/cm for about 3 min to about 30 min, preferably about 5 min to about 10 min, more preferably about 10 min.

The invention is further described below by reference to the following, non-limiting examples.