U.S. patent application number 14/134816 was filed with the patent office on 2014-04-17 for method for producing alkali metal niobate particles, and alkali metal niobate particles.
This patent application is currently assigned to Sakai Chemical Industry Co., Ltd.. The applicant listed for this patent is Fuji Ceramics Corporation, Sakai Chemical Industry Co., Ltd., TOHOKU University. Invention is credited to Kiyoshi KANIE, Hideto MIZUTANI, Atsushi MURAMATSU, Yasuhiro OKAMOTO, Satoru SUEDA, Hirofumi TAKAHASHI, Atsuki TERABE.
Application Number | 20140103246 14/134816 |
Document ID | / |
Family ID | 42936258 |
Filed Date | 2014-04-17 |
United States Patent
Application |
20140103246 |
Kind Code |
A1 |
MURAMATSU; Atsushi ; et
al. |
April 17, 2014 |
METHOD FOR PRODUCING ALKALI METAL NIOBATE PARTICLES, AND ALKALI
METAL NIOBATE PARTICLES
Abstract
Disclosed are a method of producing fine particulate alkali
metal niobate in a liquid phase system, wherein the size and shape
of particles of the fine particulate alkali metal niobate can be
controlled; and fine particulate alkali metal niobate having a
controlled shape and size. Specifically disclosed are a method of
producing particulate sodium-potassium niobate represented by the
formula (1): Na.sub.xK.sub.(1-x)NbO.sub.3 (1), the method including
four specific steps, wherein a high-concentration alkaline solution
containing Na.sup.+ ion and K.sup.+ ion is used as an alkaline
solution; and particulate sodium-potassium niobate having a
controlled shape and size.
Inventors: |
MURAMATSU; Atsushi;
(Sendai-shi, JP) ; KANIE; Kiyoshi; (Sendai-shi,
JP) ; TERABE; Atsuki; (Iwaki-shi, JP) ;
OKAMOTO; Yasuhiro; (Iwaki-shi, JP) ; MIZUTANI;
Hideto; (Iwaki-shi, JP) ; SUEDA; Satoru;
(Iwaki-shi, JP) ; TAKAHASHI; Hirofumi; (Fuji-shi,
JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Sakai Chemical Industry Co., Ltd.
Fuji Ceramics Corporation
TOHOKU University |
Osaka
Fujinomiya-shi
Sendai-shi |
|
JP
JP
JP |
|
|
Assignee: |
Sakai Chemical Industry Co.,
Ltd.
Osaka
JP
Fuji Ceramics Corporation
Fujinomiya-shi
JP
TOHOKU University
Sendai-shi
JP
|
Family ID: |
42936258 |
Appl. No.: |
14/134816 |
Filed: |
December 19, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13262788 |
Dec 12, 2011 |
|
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PCT/JP2010/056175 |
Apr 5, 2010 |
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14134816 |
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Current U.S.
Class: |
252/62.9R |
Current CPC
Class: |
C01P 2002/72 20130101;
Y10T 428/2982 20150115; C01D 1/02 20130101; H01L 41/317 20130101;
C01P 2004/62 20130101; C04B 2235/52 20130101; C01P 2002/85
20130101; C01P 2004/54 20130101; C01G 33/006 20130101; C04B 35/495
20130101; H01L 41/1873 20130101; C04B 2235/3201 20130101; C01P
2004/03 20130101; C04B 2235/3255 20130101; C01P 2004/61 20130101;
C01P 2004/41 20130101 |
Class at
Publication: |
252/62.9R |
International
Class: |
H01L 41/187 20060101
H01L041/187 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 9, 2009 |
JP |
2009-095014 |
Claims
1-3. (canceled)
4. A particulate sodium-potassium niobate represented by the
formula (1): Na.sub.xK.sub.(1-x)NbO.sub.3 (1), wherein x is in a
range of 0.05.ltoreq.x.ltoreq.0.8, and wherein particles of the
particulate sodium-potassium niobate have a maximum diameter of
0.05 to 20 .mu.m and an aspect ratio of 1 to 1.5.
5. (canceled)
6. The particulate sodium-potassium niobate according to claim 4,
wherein a cross-sectional plane of the particles of the particulate
sodium-potassium niobate parallel to the longitudinal axis and
including the longitudinal axis has substantial line-symmetry with
respect to the longitudinal axis, wherein in the cross-sectional
plane, a length from the longitudinal axis to an outline of the
particles decreases from an end of the particles on the lateral
axis towards an end of the particles on the longitudinal axis, and
wherein a cross-sectional plane of the particles perpendicular to
the longitudinal axis has a cross shape.
7. The particulate sodium-potassium niobate according to claim 4,
wherein a cross-sectional plane of the particles of the particulate
sodium-potassium niobate parallel to the longitudinal axis and
including the longitudinal axis has substantial line-symmetry with
respect to the longitudinal axis, wherein in the cross-sectional
plane, a length from the longitudinal axis to an outline of the
particles decreases from an end of the particles on the lateral
axis towards an end of the particles on the longitudinal axis, and
wherein a cross-sectional plane of the particles perpendicular to
the longitudinal axis has a substantially circular shape.
8. (canceled)
9. A piezoelectric ceramic material comprising the particulate
sodium-potassium niobate according to claim 4.
Description
TECHNICAL FIELD
[0001] The present invention relates to a method of producing
particulate alkali metal niobate, and particulate alkali metal
niobate.
BACKGROUND OF THE INVENTION
[0002] Piezoelectric ceramics have significantly contributed to
downsizing and sophistication of electronic devices. In addition to
applications to conventional devices such as sensors or ultrasonic
transducers, piezoelectric ceramics are recently used, for example,
as a raw material of transformers for LCD backlights of personal
computers or a raw material of head parts of ink jet printers.
[0003] Lead-based materials such as PZT-based materials prevail
nowadays as such piezoelectric ceramic devices. However, lead-based
materials contain large amounts of harmful lead oxide, and thus,
for example, environmental pollution by spilled lead oxide on
disposal has been a matter of concern. Therefore, development has
been strongly demanded for lead-free piezoelectric ceramic
materials which can be used for alternatives to conventional lead
based materials.
[0004] Recently, alkali niobate piezoelectric ceramics draw
attention as lead-free ceramic materials, which exhibit relatively
high piezoelectricity. Patent Document 1, for example, proposes a
piezoelectric ceramic including a solid solution mainly composed of
lithium sodium niobate, together with minor components as aluminum
oxide and iron oxide. Patent Document 2 proposes an improved
composition for a piezoelectric ceramic, which includes potassium
niobate and sodium niobate, as main components, and copper,
lithium, and tantalum, as additional components.
[0005] As a method of producing such piezoelectric ceramics, a
method called a solid phase method has been widely known. The solid
phase method typically includes mechanically mixing or kneading
plural kinds of particulate materials as raw materials, then
pelletizing, and calcining the obtained pellets.
[0006] In recent years, liquid phase methods of synthesizing
NaNbO.sub.3 particles have also been studied. For example,
Non-Patent Document 1 reports a method of synthesizing NaNbO.sub.5
particles by reacting NaOH or KOH solution with Nb.sub.2O.sub.5
particles.
[0007] Another technique has been recently reported on a method for
producing particulate KNbO.sub.3 by once synthesizing layered
K.sub.4Nb.sub.6O.sub.17 particles, and then heating the particles
at a high temperature in a molten salt (Non-Patent Document 2).
PRIOR ART DOCUMENTS
Patent Documents
[0008] [Patent Document 1] JP 60-52098 B [0009] [Patent Document 2]
JP 2000-313664 A
Non-Patent Document
[0009] [0010] [Non-Patent Document 1] C. Sun et al., European
Journal of Inorganic Chemistry, 2007, 1884 [0011] [Non-Patent
Document 2] Y. Saito et al., Journal of the European Ceramic
Society, 27 (2007) 4085
SUMMARY OF THE INVENTION
Problem to be Solved by the Invention
[0012] However, solid phase methods are disadvantageous in that
nanoscale uniform mixing of raw material particles is generally
difficult because commonly available raw material particles often
have a larger size, like about several millimeters to several
micrometers. When raw material particles are calcined at a high
temperature, the original crystal structure of the raw material
changes into perovskite crystal structure. Thus, it is difficult to
precisely control crystallite size and grain boundaries in a solid
phase method. Control of grain boundaries is especially
indispensable for enhancing properties of piezoelectric ceramics
because grain boundaries significantly affect some properties such
as piezoelectric properties or strength. Therefore, use of a
material in which control of grain boundaries are insufficient may
lead to problems such as defects of products and deterioration of
properties.
[0013] Conventional liquid phase methods may cause particle
agglomeration. Also, it is generally difficult to control the size
and shape of particles in a uniform state by a conventional liquid
phase method. For example, particles produced by the method
described in Patent Document 1 are given as aggregates, and are not
suitable as a material to form piezoelectric devices, for which
downsizing has been recently demanded.
[0014] The method described in Patent Document 2 also requires some
improvement in that control of the particle size is actually
impossible or that multi-step synthesis is required.
[0015] In view of the current state, there has been a demand for
developing a method of producing particulate alkali metal niobate,
which is suitable for mass production, can prevent agglomeration of
particles, and can control the grain boundaries and particle size.
Further, there has been a demand for fine particulate alkali metal
niobate having a highly uniform particle size.
Means for Solving the Problem
[0016] The present invention has an object to provide a liquid
phase method of producing fine particulate alkali metal niobate
which can control the size and shape of the fine particulate alkali
metal niobate.
[0017] The inventors of the present invention have found that
combination of sodium and potassium, among alkaline metals, at a
specific ratio enables production of particulate sodium-potassium
niobate consisting of secondary particles having a uniform size and
a unique shape in a well reproducible manner. Thereby, the present
inventors have completed the present invention.
[0018] Namely, a first aspect of the present invention relates to a
method of producing particulate sodium-potassium niobate
represented by the formula (1):
Na.sub.xK.sub.(1-x)NbO.sub.3 (1),
[0019] including the steps of:
[0020] (a) mixing a niobium-containing solution with an alkaline
solution having a concentration of 0.1 to 30 mol/L, to prepare a
suspension;
[0021] (b) still standing the suspension at between 80.degree. C.
and 150.degree. C. for 12 to 48 hours;
[0022] (c) performing solvothermal reaction of the suspension at
between 150.degree. C. and 300.degree. C. for 1 to 12 hours;
and
[0023] (d) separating the particulate sodium-potassium niobate from
a reaction mixture
[0024] wherein the alkaline solution contains Na.sup.+ ion and
K.sup.+ ion.
[0025] In a preferred embodiment, a molar ratio between the
Na.sup.+ ion and the K.sup.+ ion, Na:K, is from 1:17 to 17:1.
[0026] In another preferred embodiment, the niobium-containing
solution includes: [0027] niobium oxide and/or niobium halide;
[0028] a solvent selected from the group consisting of water,
ethylene glycol, and polyethylene glycol; and [0029] an acid.
[0030] A second aspect of the present invention relates to
particulate sodium-potassium niobate represented by the formula
(1):
Na.sub.xK.sub.(1-x)NbO.sub.3 (1)
wherein each particle of the particulate sodium-potassium niobate
has a maximum diameter of 0.05 to 20 .mu.m and an aspect ratio of 1
to 5.
[0031] In a preferred embodiment, the x is in the range of
0.05.ltoreq.x.ltoreq.0.8.
[0032] In another preferred embodiment, a cross-sectional plane of
each particle of the particulate sodium-potassium niobate parallel
to the longitudinal axis, the plane including the longitudinal
axis, is substantially line-symmetrical with respect to the
longitudinal axis, the length from the longitudinal axis to the
outline of the particle decreasing towards the end of the particle
along the longitudinal axis, and
[0033] a cross-sectional plane of the particle perpendicular to the
longitudinal axis is in a cross shape.
[0034] In yet another preferred embodiment, a cross-sectional plane
of each particle of the particulate sodium-potassium niobate
parallel to the longitudinal axis, the plane including the
longitudinal axis, is substantially line-symmetrical with respect
to the longitudinal axis, the length from the longitudinal axis to
the outline of the particle decreasing towards the end of the
particle along the longitudinal axis, and
[0035] a cross-sectional plane of the particle perpendicular to the
longitudinal axis is in a substantially circle shape.
[0036] In yet another preferred embodiment, the particulate
sodium-potassium niobate is produced by the aforementioned
method.
[0037] A third aspect of the present invention relates to a
piezoelectric ceramic material that comprises the particulate
sodium-potassium niobate.
Effect of the Invention
[0038] According to the production method of the present invention,
secondary particles of particulate sodium-potassium niobate can be
synthesized in a large scale while controlling the size and shape.
Moreover, the shape and size of the particles can be freely
controlled by adjusting the ratio of the sodium and potassium. The
method of the present invention is advantageous because the method
gives submicron to several micrometer particles, which are
practically favorable as piezoelectric elements, in a manner
suitable for mass production.
[0039] In addition, ceramic materials obtained by pelletizing the
niobate particles and calcining the resultant pellet are
advantageous than niobium-based piezoelectric ceramic materials
obtained by conventional solid phase methods, in the following
points:
[0040] 1. Low-temperature calcination is practicable;
[0041] 2. Excellent piezoelectric properties will be exhibited;
[0042] 3. Densification of ceramic materials are easily achievable;
and
[0043] 4. Slurry preparation prior to production of layered
articles is easy.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] FIG. 1 illustrates a schematic diagram of a cross-section
(cross-section in the xy-plane) parallel to the longitudinal axis
of particulate sodium-potassium niobate which is a first aspect of
the present invention.
[0045] FIG. 2 illustrates a schematic diagram of a cross-section
(cross-section in the xz-plane) cut perpendicular to the
longitudinal axis of the particulate sodium-potassium niobate which
is the first aspect of the present invention.
[0046] FIG. 3 illustrates a schematic diagram of a cross-section
(cross-section in the xy-plane) parallel to the longitudinal axis
of particulate sodium-potassium niobate which is a second aspect of
the present invention.
[0047] FIG. 4 illustrates a schematic diagram of a cross-section
(cross-section in the xz-plane) cut perpendicular to the
longitudinal axis of the particulate sodium-potassium niobate which
is the second aspect of the present invention.
[0048] FIG. 5 shows a SEM image of particulate sodium-potassium
niobate obtained when the ratio of Na:K was 6:12.
[0049] FIG. 6 shows a SEM image of particulate sodium-potassium
niobate obtained when the ratio of Na:K was 5:13.
[0050] FIG. 7 shows a SEM image of Na.sub.xK.sub.(1-x)NbO.sub.3
particles having an octahedral structure synthesized in Example
4.
[0051] FIG. 8 is an enlarged view of FIG. 7.
[0052] FIG. 9 shows an XRD pattern of Na.sub.xK.sub.(1-x)NbO.sub.3
particles synthesized in Example 4.
[0053] FIG. 10 shows a SEM image of a cross section of
Na.sub.xK.sub.(1-x)NbO.sub.3 particles synthesized in Example
4.
[0054] FIG. 11 shows a SEM image of a cross section of
Na.sub.xK.sub.(1-x)NbO.sub.3 particles synthesized in Example
4.
[0055] FIG. 12 shows results of EDS analysis on a cross section of
Na.sub.xK.sub.(1-x)NbO.sub.3 particles synthesized in Example
4.
[0056] FIG. 13 shows a SEM image of particulate sodium-potassium
niobate obtained when the ratio of Na:K was 4:14.
[0057] FIG. 14 shows a SEM image of particulate sodium-potassium
niobate obtained when the ratio of Na:K was 3:15.
[0058] FIG. 15 shows a SEM image of particulate sodium-potassium
niobate obtained when the ratio of Na:K was 2:16.
[0059] FIG. 16 shows a SEM image of particulate sodium-potassium
niobate obtained when the ratio of Na:K was 1:17.
[0060] FIG. 17 shows a SEM image of particulate sodium niobate
obtained when NaOH was used as an alkaline solution.
[0061] FIG. 18 shows a SEM image of particulate potassium niobate
obtained when KOH is used as an alkaline solution.
[0062] FIG. 19 shows a SEM image of a ceramic prepared from
Na.sub.xK.sub.(1-x)NbO.sub.3 particles having an octahedral
structure synthesized in Example 9.
[0063] FIG. 20 is an enlarged view of FIG. 19.
MODE FOR CARRYING OUT THE INVENTION
[0064] The present invention will be explained in detail below.
<Method of Producing Particulate Sodium-Potassium
Niobate>
[0065] As mentioned above, a first aspect of the present invention
relates to a method of producing particulate sodium-potassium
niobate represented by the formula (1):
Na.sub.xK.sub.(1-x)NbO.sub.3 (1)
[0066] including the steps of:
[0067] (a) mixing a niobium-containing solution with an alkaline
solution having a concentration of 0.1 to 30 mol/L, to prepare a
suspension;
[0068] (b) still standing the suspension at 80.degree. C. to
150.degree. C. for 12 to 48 hours;
[0069] (c) performing solvothermal reaction of the suspension at
between 150.degree. C. and 300.degree. C. for 1 to 12 hours;
and
[0070] (d) separating particulate sodium-potassium niobate from a
reaction mixture,
[0071] wherein the alkaline solution contains Na.sup.+ ion and
K.sup.+ ion.
[0072] In the following, each step is described.
[0073] The step (a) is for preparing a suspension by mixing a
niobium-containing solution as a niobium source with a
high-concentration alkaline solution.
[0074] The method to prepare a niobium-containing solution is not
particularly limited. For example, such a solution can be prepared
by dissolving a niobium compound in an acidic liquid solvent.
Preferably, such a niobium compound may be, but not limited to, at
least one selected from niobium oxide and niobium halides. Niobium
oxide or niobium halide is more preferable. Examples of the niobium
halides include niobium fluoride, niobium chloride, niobium
bromide, and niobium iodide. In view of handleability and
reactivity, niobium chloride is preferable among the niobium
halide. Niobium compounds may be used alone or in combination of
two or more of these.
[0075] Solvents to be contained in the above acidic liquid solvent
are not particularly limited. Examples thereof include water,
alcohols such as methyl alcohol and ethyl alcohol, and polyols such
as ethylene glycol (EG), glycerol, and polyethylene glycol (PEG).
Of these, water, ethylene glycol, and polyethylene glycol, as well
as a mixture of these, are preferable in view of relatively high
boiling points and applicability to solvothermal reaction. Water is
particularly preferable.
[0076] The acid to be contained in the above acidic liquid solvent
is not particularly limited. Examples thereof include inorganic
acids such as hydrochloric acid, sulfuric acid, and nitric acid,
and organic acids such as trifluoroacetic acid. Of these,
hydrochloric acid and nitric acid are preferable in that they are
easily removable after the reaction. Hydrochloric acid is
particularly preferable.
[0077] Next, the alkaline solution to be used in the step (a) is
described.
[0078] The alkaline solution according to the present invention
includes both Na.sup.+ ion and K.sup.+ ion. Alkali compound to be
contained in the alkaline solution are not particularly limited,
and may be a mixture of KOH and NaOH. The mixture of KOH and NaOH
is preferable because the mixture is favorable to prepare a
high-concentration alkaline solution which is necessary for
achieving the present invention.
[0079] The solvent to be contained in the alkaline solution is not
particularly limited, and may be water, alcohol, diol, triol, and
acetone. Of these, water is preferred.
[0080] The alkaline solution to be used in the present invention
has such a high concentration as 0.1 to 30 mol/L. The concentration
is equivalent to that of a very-high-concentration alkaline
solution having a pH of about 13 or higher. That is, assuming that
the degree of ionization of a strong base (such as NaOH and KOH) is
1 irrespective of the concentration of the alkaline solution, the
pH of a "0.1 mol/L" alkaline solution corresponds to 13, as
follows:
[OH.sup.-]=1.0.times.10.sup.-1 mol/L,
[H.sup.+][OH.sup.-]=1.0.times.10.sup.-14,
and thus,
[H.sup.+]=1.0.times.10.sup.-13,
pH=-log [H.sup.+]=13
[0081] An alkaline solution having a concentration of less than 0.1
mol/L is undesirable because particles may not grow sufficiently,
and thus particles with a desired size and shape may not be
produced. In contrast, if the concentration exceeds 30 mol/L, an
alkaline solution usually reaches saturation. Thus, the upper limit
of the concentration of the alkaline solution herein actually means
a saturation concentration of the alkaline solution, and this upper
limit may vary depending on the nature of the alkali. The lower
limit of the concentration of the alkaline solution is preferably 1
mol/L, and more preferably 2 mol/L. The alkaline solution used
herein is a fairly high concentration solution. Therefore, much
attention is required to handle the solution. The reaction vessel
for step (a) is preferably, but is not limited to, a
corrosion-resistant vessel made of, for example, Teflon.TM..
[0082] The ratio of Na.sup.+ ion relative to K.sup.+ ion (Na:K) in
the alkaline solution is preferably in the range of (1:17) to
(17:1), and more preferably in the range of (4.5:13.5) to
(6.5:12.5). Such specific ion ratio enables to provide secondary
particles of particulate sodium-potassium niobate having unique
shapes as mentioned below, such as substantially spheroidal
particles like a rugby ball, or substantially octahedral particles
(see FIGS. 5 to 8).
[0083] The niobium-containing solution and the alkali solution
prepared separately in the above-mentioned manner are mixed
together to prepare a suspension. The way of addition of the
solutions is not particularly limited. For example, the
niobium-containing solution may be added to the alkaline solution,
or the alkaline solution may be added to the niobium-containing
solution. In view of safety, it is preferable to slowly add a
niobium-containing solution dropwise into the alkaline solution
over a sufficient period of time. Temperature and pressure during
the mixing are not particularly limited. Usually, the mixing may be
carried out at an ordinary temperature (15.degree. C. to 30.degree.
C.) under an ordinary pressure (about 1 atm).
[0084] Next, the step (b) is described.
[0085] The step (b) is a step of heating the suspension at a
relatively low temperature over a long period of time. The method
of the present invention is characterized by including two separate
steps, namely, a step of heating the suspension at a relatively low
temperature over a long period of time, and a step of performing
solvothermal reaction at a high temperature for a short period of
time. If the step (b) is omitted, aggregates are normally
generated, so in many cases the particle size cannot be
sufficiently controlled. Also, if the step (b) is omitted, it may
be in many cases hard to provide particles having a substantially
spheroidal or substantially octahedral shape, which impairs the
characteristics of the present invention.
[0086] In the step (b), the suspension is heated to a temperature
of 80.degree. C. to 150.degree. C. Keeping this temperature
constant for a certain period of time can prevent the particles
from aggregating, and encourages growth of the particles into a
desired shape. The temperature is preferably 80.degree. C. to
120.degree. C., more preferably 90.degree. C. to 110.degree. C.,
and still more preferably the boiling point of a solvent. If water
is used as the solvent, the suspension is preferably heated to
100.degree. C.
[0087] The step (b) is characterized by allowing the suspension to
still stand at a specific temperature for 12 to 48 hours. Such
still standing step for a while can prevent the particles from
aggregating, and promote growth of the particles into a desired
shape. If the period for still standing is too short, the particles
do not sufficiently grow. In contrast, if the period is too long,
the effects may be saturated and the step is unfavorable from an
economical viewpoint. Therefore, an appropriate period of still
standing is 12 to 48 hours. The period of still standing is
preferably 15 to 36 hours, more preferably 18 to 30 hours, and
still more preferably 20 to 26 hours.
[0088] While the pressure during the step (b) is not particularly
limited, the step is usually performed under an ordinary pressure
(about 1 atm (=about 0.10 MPa)).
[0089] Next, the step (c) is described.
[0090] The step (c) is a step of subjecting the suspension having
been heated at a relatively low temperature in the step (b) to
solvothermal reaction at a high temperature.
[0091] The solvothermal reaction is a reaction performed under a
moderate to high degree of pressure (normally 1 to 10,000 atm
(=0.10 to 1,000 MPa)) and temperature (normally 100.degree. C. to
1000.degree. C.). When water is used as a solvent, the solvothermal
reaction is specially referred to as "hydrothermal reaction". By
performing this process, the particles can be stabilized and the
shape of the particles can be controlled.
[0092] In the present invention, the solvothermal reaction is
performed at a temperature of between 150.degree. C. and
300.degree. C. While not particularly limited, the temperature is
preferably 150.degree. C. to 250.degree. C.
[0093] The period for the solvothermal reaction is not particularly
limited, and is usually 1 to 12 hours, preferably 1 to 8 hours, and
more preferably 2 to 5 hours.
[0094] The pressure in the solvothermal reaction is not
particularly limited, and is usually 0.10 to 4.0 MPa.
[0095] Next, the step (d) is described.
[0096] The step (d) is a step to separate the particulate alkali
metal niobate from the reaction product of the solvothermal
reaction.
[0097] The method to separate the particulate alkali metal niobate
is not particularly limited. Desired particulate alkali metal
niobate can be separated through normal processes such as
filtration, washing, and drying. The number of times of washing,
solvents to be used for washing, and other conditions are not
particularly limited, and may be appropriately selected.
<Particulate Sodium-Potassium Niobate>
[0098] Particulate alkali metal niobate, which is the second aspect
of the present invention, is described. The particulate alkali
metal niobate of the invention is particulate sodium-potassium
niobate represented by the formula (1):
Na.sub.xK.sub.(1-x)NbO.sub.3 (1).
[0099] The maximum diameter of each of the particles is 0.05 to 20
.mu.m, and the aspect ratio of each of the particles is 1 to 5.
[0100] The meanings of the "maximum diameter," "aspect ratio," and
"longitudinal axis" used herein are described below with reference
to drawings.
[0101] The "maximum diameter" is a distance between two points on
the outline of the particle when the two points are taken in a
manner that the distance is maximized. FIG. 1 shows a cross-section
of a particle of the particulate sodium-potassium niobate according
to a first aspect of the present invention. The particle is cut so
that the cross-section includes the maximum diameter represented by
L1. Here, an axis including a straight line, which corresponds to
the maximum diameter connecting two points on the particle outline,
is referred to as a "longitudinal axis." In FIG. 1, the
longitudinal axis is a y-axis.
[0102] Assuming that the particle is surrounded by a rectangle
(generally called a circumscribed rectangle), the ratio of the long
side length to the short side length (long side/short side) of the
smallest rectangle is referred to as an aspect ratio. In FIG. 1,
the circumscribed rectangle is shown by a dashed line. The long
side is parallel to the longitudinal axis (y-axis direction in FIG.
1), and the length of the long side is equal to the maximum
diameter L1. The short side is perpendicular to the longitudinal
axis (x-axis direction in FIG. 1), and the length is represented by
L2 in FIG. 1. The length of the short side refers to the longest
length among the particle diameters which are perpendicular to the
longitudinal axis. In FIG. 1, the aspect ratio is represented by
L1/L2.
[0103] In the present invention, the length of each of the
particles in the longitudinal axis direction is 0.05 to 20 .mu.m,
preferably 0.5 to 10 .mu.m, and more preferably 1 to 5 .mu.m. The
particle length in the longitudinal axis direction within the above
range leads to highly uniform size and shape, which is advantageous
when applied to a fine-shape molded body, or the like.
[0104] The aspect ratio of each of the particles is 1 to 5,
preferably 1 to 3, and more preferably 1 to 2. For example, a
typical particle shown at the center of FIG. 6 has an aspect ratio
of 1 to 1.5.
[0105] The particulate sodium-potassium niobate of the present
invention has unique shapes such as rugby ball-like substantially
spheroidal and substantially octahedral shapes (see FIGS. 5 and 6).
In order to achieve such unique shapes, the x in the formula (1) is
preferably in the range of 0.05.ltoreq.x.ltoreq.0.8, and more
preferably in the range of 0.25.ltoreq.x.ltoreq.0.36.
[0106] Preferable embodiments of the present invention relate to
the particulate sodium-potassium niobate having such unique shapes
as mentioned earlier. Some of the preferable embodiments will be
described below with reference to drawings.
[0107] The schematic diagrams shown in FIGS. 1 and 2, and the SEM
image shown in FIG. 6 relate to the particulate sodium-potassium
niobate having an octahedral shape, which is one of the preferable
embodiments of the present invention.
[0108] As mentioned earlier, FIG. 1 illustrates a schematic diagram
of a cross-section (cross-section in the xy-plane) parallel to the
longitudinal axis of the particle. FIG. 2 illustrates a schematic
diagram of a cross-section (cross-section in the xz-plane) cut
perpendicular to the longitudinal axis of the particle.
[0109] A cross-sectional plane in a direction parallel to the
longitudinal axis, the plane including the longitudinal axis
(corresponding to y-axis in FIG. 1), of the particulate
sodium-potassium niobate having an octahedral shape is
substantially line-symmetrical with respect to the longitudinal
axis (a substantially rhombus shape) as shown in FIG. 1. Further,
in FIG. 1, the length from the longitudinal axis to the outline of
the particle (L3 in FIG. 1) decreases towards the end of the
particle along the longitudinal axis.
[0110] Moreover, as shown in FIG. 2, a cross-section perpendicular
to the longitudinal axis is in a cross shape.
[0111] It is not clear why the particles having such unique shapes
are produced. As indicated by the SEM image shown in FIG. 6 or FIG.
8, the particles of the embodiments of the present invention are
supposedly aggregates each formed of assembled finer particles (so
called primary particles). The lattices in FIGS. 1 and 2 are
intended to express the primary particles. Variation in the sodium
and potassium ratio in the high-concentration alkaline solution may
affect the crystalline conditions and the like during formation of
aggregates from the primary particles. As a result, the particulate
sodium-potassium niobate having novel shapes never known before is
supposedly generated. The particles of the embodiments of the
present invention can be provided when, for example, the Na:K ratio
is 5:13, although the ratio is not particularly limited
thereto.
[0112] The diameter of the primary particles in the embodiment of
the present invention is about 10 to 500 nm. Since the particle of
the embodiment of the present invention is an aggregate of the
primary particles mentioned above, the maximum diameter is 3 to 20
.mu.m, preferably 3 to 10 .mu.m, and more preferably 3 to 5 .mu.m,
as is to be understood from the SEM image shown in FIG. 6. The
particle length in the longitudinal axis direction within the above
ranges is advantageous when applied to a fine-shape molded body or
the like.
[0113] According to the embodiment of the present invention, the
aspect ratio of the particle (L1/L2 in FIG. 1) is 1 to 5,
preferably 1 to 3, and more preferably 1 to 2. Typical particles
shown in FIG. 6 have an aspect ratio of 1 to 1.5.
[0114] Particulate sodium-potassium niobate having a substantially
spheroidal shape (so-called rugby ball-like shape), which is
another preferable embodiment of the present invention, will be
described below with reference to the schematic diagrams shown in
FIGS. 3 and 4, and the SEM image shown in FIG. 5.
[0115] As mentioned earlier, FIG. 3 illustrates a schematic diagram
of a cross-section (cross-section in the xy-plane) parallel to the
longitudinal axis of the particle. FIG. 4 illustrates a schematic
diagram of a cross-section (cross-section in the xz-plane)
perpendicular to the longitudinal axis of the particle. In FIG. 3,
the meanings of L1, L2, and L3 are the same as those in FIG. 1.
[0116] A cross-sectional plane in a direction parallel to the
longitudinal axis, the plane including the longitudinal axis
(corresponding to y-axis in FIG. 1), of the particulate
sodium-potassium niobate having an octahedral shape is
substantially line-symmetrical with respect to the longitudinal
axis (substantially elliptical shape) as shown in FIG. 3. Further,
in FIG. 3, the length from the longitudinal axis to the outline of
the particle (L3 in FIG. 1) decreases towards the end of the
particle along the longitudinal axis.
[0117] Moreover, as shown in FIG. 4, the cross-section
perpendicular to the longitudinal axis is in a substantially
circular shape. Namely, this particle has a shape filled with a
larger amount of the primary particles than the particle having an
octahedral shape.
[0118] As is understood from the SEM images shown in FIGS. 5 to 8,
the maximum diameter of each of the particles according to the
embodiment of the present invention is 0.05 to 20 .mu.m, and
preferably 3 to 10 .mu.m. The particle length in the above ranges
in the longitudinal axis direction is advantageous when applied to
a fine-shape molded body or the like.
[0119] According to the embodiment of the present invention, the
aspect ratio (L1/L2 in FIG. 3) of the particle is 1 to 5,
preferably 1 to 3, and more preferably 1 to 2. A typical particle
shown in the upper left in FIG. 5 has an aspect ratio of 1 to
1.5.
[0120] The method of preparing particulate sodium-potassium niobate
is not particularly limited. The method described above, which is a
first aspect of the present invention, is preferable as the method
of preparing the particulate sodium-potassium niobate. The method
is innovative in that the particle size can be controlled simply by
chemical processes, and no physical processes such as grinding are
necessary. Thus, the method is advantageous in that production
processes can be simplified as compared to conventional methods. In
addition, the method according to a first aspect of the present
invention can control the size of particles, and prevent
agglomeration of the particles, while it is generally difficult to
control variation in particle size in physical grinding or the like
conventional method. As a result, particles with highly-controlled
size can be obtained by the method according to a first aspect of
the present invention. Because of these reasons, the method of the
first aspect of the present invention is preferable as the method
for preparing particulate sodium-potassium niobate.
<Piezoelectric Ceramic Materials>
[0121] A third aspect of the present invention relates to a
piezoelectric ceramic material including the particulate
sodium-potassium niobate.
[0122] A method of producing the piezoelectric ceramic material is
not particularly limited. Generally, the piezoelectric ceramic
material may be produced by mixing dried particulate
sodium-potassium niobate with required additives such as an organic
binder, a dispersant, a plasticizer, and a solvent, to prepare a
composition. Then, an article is molded from the composition
through a known molding method, and the article is sintered at a
high temperature (about 1,000.degree. C.). Examples of such a known
molding method include press molding and molding using a mold.
[0123] Then, by forming electrodes on a molded body obtained from
the piezoelectric ceramic material, piezoelectric elements such as
a piezoelectric buzzer and a piezoelectric transducer can be
produced.
EXAMPLES
[0124] The present invention will be described in more detail based
on the following examples. It is to be noted that the present
invention is not limited to these examples. In the examples and
comparative examples below, the unit "M", which is used to refer to
a concentration of an alkali or acid solution, means mol/L unless
otherwise indicated.
Example 1
Synthesis 1 of Na.sub.xK.sub.(1-x)NbO.sub.3 Particles
[0125] A portion of 27.02 g (=100 mmol) of niobium chloride was
completely dissolved in 150 mL of a 0.10-M aqueous HCl solution.
The solution was transferred into a 200-mL volumetric flask, and a
0.10-M aqueous HCl solution was further added to the flask for
adjusting the total volume of the solution to be 200 mL. A 0.50-M
aqueous NbCl.sub.5 solution in 0.10-M HCl was thus prepared. Then,
6.0 mL of the 0.50-M aqueous NbCl.sub.5 solution in 0.10 M HCl was
slowly added to 6.0 mL of a mixed solution of sodium hydroxide and
potassium hydroxide (NaOH:KOH=6:12 (mol/mol)) having a total 18.0 M
alkaline concentration in a 30-mL Teflon.TM. vessel at room
temperature under stirring. The resulting white suspension was
allowed to still stand with heating in the Teflon.TM. vessel for 24
hours at 100.degree. C. Then, the content was transferred to an
autoclave whose inner chamber wall was made of Teflon.TM., and
allowed to stand for 3 hours with heating at 250.degree. C. to
perform hydrothermal reaction. The solid matter was separated from
the resulting suspension by centrifugation, and then the solid was
dispersed in water under ultrasonic dispersing. The solid matter
was separated again by centrifugation and dried to separate
particulate sodium-potassium niobate. The size and shape of the
obtained solid particles were observed by a scanning electron
microscope (SEM, manufactured by HITACHI, Ltd., S-4800), and the
crystal structure of the solid particles was evaluated by X-ray
diffraction (XRD, manufactured by Rigaku Corporation, Ultima-IV, 40
kV, 40 mA). The resulting particles had a unique rugby ball-like
shape (FIG. 5).
Example 2
[0126] Particulate sodium-potassium niobate was obtained in the
same manner as in Example 1, except that the molar ratio of the
sodium hydroxide and potassium hydroxide (NaOH:KOH) in the mixed
solution having a total 18.0-M alkaline concentration was changed
to 5:13 (mol/mol). The resulting particles had a unique shape with
a substantially octahedral structure (FIG. 6).
Example 3
Synthesis 2 of Na.sub.xK.sub.(1-x)NbO.sub.3 Particles
[0127] An aqueous alkaline solution (6.0 mL) containing NaOH and
KOH (the final NaOH concentration was 12 mol/L and the final KOH
concentration was 24 mol/L in the aqueous alkaline solution) was
added to 0.40 g (=3.0 mmol) of niobium pentoxide put in a 30-mL
Teflon.TM. vessel. Ion-exchange water was further added to the
vessel under stirring to adjust the total volume of the mixture to
12 mL. Then, the Teflon.TM. vessel was sealed and allowed to still
stand with heating for 24 hours at 100.degree. C. Then, the content
was transferred to an autoclave whose inner chamber wall was made
of Teflon.TM., and allowed to stand for 3 hours with heating at
250.degree. C. to perform hydrothermal reaction. The solid matter
was separated from the resulting suspension by centrifugation, and
then the solid was dispersed in water under ultrasonic dispersing.
The solid was separated again by centrifugation and dried to
separate NaNbO.sub.3 particles. Evaluation of the obtained
particles was performed in the same manner as that described in
Example 1. It is to be noted that, by adjusting the initial NaOH
concentration, the initial KOH concentration, and the total
alkaline concentration to 1 to 17 M, 17 to 1 M, and 18 M,
respectively, Na.sub.xK.sub.(1-x)NbO.sub.3 particles can be
provided while the x in the Na.sub.xK.sub.(1-x)NbO.sub.3 particles
is controlled in a range of 0.05 to 0.8, and the particle diameter
is controlled in a range of 0.5 to 30 Moreover,
Na.sub.xK.sub.(1-x)NbO.sub.3 particles having unique shapes can be
produced as well.
Example 4
Synthesis 3 of Na.sub.xK.sub.(1-x)NbO.sub.3 Particles
[0128] An aqueous alkaline solution (185 mL) containing NaOH and
KOH (the final NaOH concentration was 12 mol/L and the final KOH
concentration was 24 mol/L in the aqueous alkaline solution) was
prepared in a Teflon.TM. beaker, and then stirred at room
temperature. Niobium chloride in an amount of 25 g (=92.5 mmol) was
added to 185 mL of a 0.10-M aqueous HCl solution to prepare a
0.50-M aqueous NbCl.sub.5 solution in 0.10 M HCl. The resulting
niobium chloride solution was added at a rate of 15 mL/min to the
alkaline solution under stirring, and then stirred at room
temperature for 10 minutes. The suspension thus obtained was
transferred into an autoclave whose inner chamber wall made of
Teflon.TM.. The suspension was heated to 100.degree. C. over 30
minutes under stirring, and was kept stirred at 100.degree. C. for
24 hours. Thereafter, the suspension was heated to 200.degree. C.
over two and a half hours, followed by further heating at
200.degree. C. for three hours under stirring to perform
hydrothermal reaction. The heated suspension was cooled by natural
cooling. The solid matter was separated from the resulting
suspension by centrifugation. The collected solid matter was
dispersed in water under ultrasonic dispersing, and separated by
centrifugal segmentation. This washing process including ultrasonic
dispersing and centrifugal segmentation was repeated six times.
Washing by centrifugation was further made three times using
acetone as a washing liquid, followed by drying in a desiccator.
Thereby, particulate sodium-potassium niobate was obtained. The
size and shape of the obtained solid particles were observed by a
scanning electron microscope, and the crystal structure of the
solid particles was evaluated by X-ray diffraction. FIGS. 7 and 8
show the SEM images, and FIG. 9 shows the results of the XRD
analysis of the obtained particles. The results found that the
particles were particles having a unique octahedral shape. The
diffraction pattern indicated that the particles were tetragonal
KNbO.sub.3. Further, the condition inside the crystal and the
elemental composition inside the particle were checked by cutting
the particle with a cross-section polisher and performing EDS
analysis thereon (FIGS. 10 to 12). It is to be noted that stirring
on heating was effective to equalize particle shapes.
[0129] As shown in FIG. 12, sodium ion and potassium ion were
uniformly incorporated inside the particle, which proved that
Na.sub.xK.sub.(1-x)NbO.sub.3 particles were obtained.
Examples 5 to 8
[0130] Particulate sodium-potassium niobate was obtained in the
same manner as in Example 1, except that the NaOH: KOH molar ratio
was changed to 4:14 (Example 5), 3:15 (Example 6), 2:16 (Example
7), and 1:17 (Example 8). The SEM images of the respective
particles thus obtained were shown in FIGS. 13 to 16.
Comparative Example 1
[0131] Particulate sodium niobate was obtained in the same manner
as in Example 1, except that a 12.0-M aqueous NaOH solution (6.0
mL) was used as an alkaline solution. The resulting particles were
fine particles having a substantially rectangular cuboid structure
(FIG. 17).
Comparative Example 2
[0132] Particle potassium niobate was obtained in the same manner
as in Example 1, except that a 12.0-M aqueous KOH solution (6.0 mL)
was used as an alkaline solution. The resulting particles were fine
particles having a substantially rectangular cuboid structure (FIG.
18).
[0133] As is recognized by comparing the results of Comparative
Examples 1 and 2 with the results of Examples, in the case where
only NaOH or only KOH was used as an aqueous alkaline solution, the
resulting particles were normally fine particles having a
substantially rectangular cuboid structure. In contrast, in the
case where NaOH and KOH were used in combination, the resulting
particles had a unique, substantially octahedral shape, as shown,
for example, in FIG. 7 and FIG. 8. It would be very difficult to
expect based on the ordinary technical knowledge that the particles
having such unique shapes can be obtained.
Example 9
Preparation of Na.sub.xK.sub.(1-x)NbO.sub.3 Ceramics by Sintering
and Evaluation of Piezoelectric Properties
[0134] The Na.sub.xK.sub.(1-x)NbO.sub.3 particles prepared in
Example 4 were pelletized and then sintered at a temperature of
1,025.degree. C. The piezoelectric properties of the obtained
ceramics were evaluated. FIGS. 19 and 20 show the SEM images of the
resulting sintered body, and Table 1 shows values of the
properties.
[0135] In Table, the "kp" refers to an electromechanical coupling
coefficient, which was calculated based on values of resonance
frequency and antiresonance frequency measured with an impedance
analyzer. The ".di-elect cons..sub.33.sup.T/.di-elect cons..sub.0"
refers to a dielectric constant measured with an impedance
analyzer. The "Np" refers to frequency constant calculated based on
values of resonance frequency measured with an impedance analyzer
and element size. The "tan .delta." refers to a dielectric loss
measured with an impedance analyzer. The "d33" refers to a
piezoelectric constant measured with a d33 meter.
TABLE-US-00001 TABLE 1 kp Np tan .delta. d33 (%)
.epsilon..sub.33.sup.T/.epsilon..sub.0 (Hz m) (%) (pC/N) 24.1 445
2240 16.3 84
[0136] As shown in Table 1, the Na.sub.xK.sub.(1-x)NbO.sub.3
ceramics obtained in the present invention have high piezoelectric
properties, as d.sub.33 of 84. Accordingly, the particulate
sodium-potassium niobate of the present invention can be suitably
used also as a piezoelectric material.
INDUSTRIAL APPLICABILITY
[0137] The production method of the present invention is a method
to provide particulate sodium-potassium niobate having unique
shapes directly only by chemical processes, which does not need any
physical processes such as grinding. The particles thus obtained
are micrometer-order-size particles having a highly uniform size
and shape with excellent handleability, and such particles can be
suitably used as a piezoelectric material.
EXPLANATION OF SYMBOLS
[0138] L1: Maximum diameter, or length of a long side of the
circumscribed rectangle of the particle [0139] L2: Length of a
short side of the circumscribed rectangle of the particle [0140]
L3: Length from the longitudinal axis to the outline of the
particle
* * * * *