Abstract:
A piezoelectric transformer includes a single crystal relaxor ferroelectric element poled along a [0  1 1] direction and selected from the group consisting of PZN-PT, PMN-PZT, PZN-PT and PMN-PT. The element has two opposed surfaces substantially perpendicular to the [0  1 1] direction with an input electrode and an output electrode positioned on one surface. The output electrode is isolated from electrical communication with the input electrode. A ground electrode is positioned on the second, opposed surface. Input electrical energy results in piezoelectric change in the element that is mechanically coupled through the element to generate piezoelectric output energy.

Description:
STATEMENT OF GOVERNMENT INTEREST 
     The invention described herein may be manufactured and used by or for the Government of the United States of America for governmental purposes without the payment of any royalties thereon or therefor. 
    
    
     CROSS REFERENCE TO OTHER PATENT APPLICATIONS 
     None. 
     BACKGROUND OF THE INVENTION 
     (1) Field of the Invention 
     The present invention is directed generally towards piezoelectric transformers, and in particular, to improvements in efficiency and power density for high power single crystal piezoelectric transformers. Naval and commercial applications of the present invention include compact AC/DC or DC/DC adaptor/chargers for personal computers, communication devices, and portable x-ray units. The transformer can be combined to drive ultrasonic motors and motion devices for integration with unmanned autonomous vehicles in lieu of electromagnetic devices, thereby eliminating electromagnetic radiation and interference problems with navigation devices. 
     (2) Description of the Prior Art 
     A piezoelectric transformer is a two-port element that steps up or steps down AC voltages or current via converse and direct piezoelectric effects. These devices were developed in the late 1950&#39;s, and described for example, in C. Rosen&#39;s U.S. Pat. No. 2,974,296 incorporated by reference herein in its entirety for background information only. 
     The first commercial realization for piezoelectric transformers was in the early 1990s as a voltage step-up to ignite the cold cathode fluorescent tube “CCFT” for backlighting flat screens in displays and notebook computers. 
     Compared with the conventional transformer, which uses magnetic coupling between input and output, the piezoelectric transformer uses acoustic coupling. Generally, the input and output parts of the piezoelectric transformer have separate electrodes. An input voltage is applied to drive the device at the resonance frequency, and the mechanical vibration is transformed to the electrical output through the piezoelectric effect. 
     Piezoelectric transformers exhibit many advantages over electromagnetic transformers. They possess higher power density, no electromagnetic noise, better efficiency at resonance, easier miniaturization, and simpler fabrication. 
     Virtually all current piezoelectric transformers are fabricated from piezoelectric ceramics such as lead zirconate titanate, Pb(Zr,Ti)03 (PZT) and its derivatives. Transformer geometries and polarization patterns that are suitable for piezoelectric ceramic processes are discussed in the Rosen patent. Mainly, two polarization schemes have been in use for piezoelectric transformers, and they are still in use to date: transversely polarized regions for input and output, or a continuously polarized element. 
     Subsequent advances on the original Rosen patent include: multilayer transformers given in S. Priya et al., Multilayered Unipoled Piezoelectric Transformers, Japanese Journal of Applied Physics Vol. 43, No. 6A, 2004, pp. 3503-3510 (2004); R. Bishop et al., U.S. Pat. No. 5,834,882; a thickness mode vibration piezoelectric transformer, by T. Inoue et al., U.S. Pat. No. 5,118,982; and a multimode adjustable piezoelectric transformer by Y. Lee et al., U.S. Pat. No. 5,504,384. Each of the above patents is herein incorporated by reference in their entirety for background information only. 
     Ferroelectric single crystals, such as Pb(Zn 1/3 Nb 2/3 ), 0 3 -PbTi0 3 (PZN-PT) and Pb(Mg 1/3 Nb 2/3 )0 3 -PbTi0 3  (PMN-PT), exhibit large electromechanical coupling coefficients and high electric field induced strains. Due to these advantages compared to traditional polycrystalline piezoelectric ceramics, single crystals are a promising alternative to develop new generation devices. 
     U.S. Pat. No. 6,674,222 to Masters et al., herein incorporated by reference in its entirety for background information only, describes a Rosen-type single crystal PZN-PT transformer design. First, the noted low mechanical Q m  of single crystal PZN-PT is a serious drawback and limits the transformer to low power applications. As is well-known, low mechanical Q m  piezoelectric materials cannot sustain high power levels because of overheating. Second, the transformer designs presented in the Masters patent, with the exception of one type are suitable for piezoelectric ceramic elements but not for single crystals for the following fundamental reasons. 
     The crystallographic symmetry of an unpolarized body is consistent with the spherical Curie group ∞/∞ (mm). Therefore, Rosen-type transformers (plates, discs, etc.) with two orthogonally polarized regions each possessing the symmetry of ∞ (mm) can be easily fabricated. 
     Nonetheless, this is not true for the relaxor-ferroelectric single crystals such as PZN-PT. (In relaxor ferroelectric materials the dielectric constant decreases when the material is subjected to an increasing electrical frequency.) In this case, there exists definite directions in the crystals where the polarization vector is allowed. Other directions are forbidden and this fact must be considered as an integral part of any single crystal transformer design rules and the selection of the vibration modes. 
     The two major problems with the Masters relaxor-ferroelectric PZN-PT single crystal patent are: in high power applications, the low mechanical Q m , leads to device overheating and eventual destruction of the transformer; and, most of the proposed designs are not commensurate with the allowed polarization directions in the crystal. This latter deficiency makes it impossible to reduce the design to practice. 
     SUMMARY OF THE INVENTION 
     Accordingly it is an object of the present invention to provide a piezoelectric transformer to overcome the above and other shortcomings in the prior art. 
     The inventive piezoelectric transformer includes a single crystal relaxor ferroelectric element poled along a [0  1 1] direction and selected from the group consisting of PZN-PT, PMN-PZT, PZN-PT and PMN-PT. The element has two opposed surfaces substantially perpendicular to the [0  1 1] direction with an input electrode and an output electrode positioned on one surface. The output electrode is isolated from electrical communication with the input electrode. A ground electrode is positioned on the second, opposed surface. Input electrical energy results in piezoelectric change in the element that is mechanically coupled through the element to generate piezoelectric output energy. 
     Other objects and advantages of the present invention will become apparent from the following description, drawings and claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following drawings are not drawn to scale. 
         FIG. 1A  is a prospective view of a first crystal orientation of a rectangular transformer plate; 
         FIG. 1B  is a prospective view of a second crystal orientation of a rectangular transformer plate; 
         FIG. 1C  is a prospective view of a third crystal orientation of a rectangular transformer plate; 
         FIG. 2  is a perspective view of a rectangular piezoelectric plate transformer with segmented electrodes; 
         FIG. 3A  is a graph of experimental results of output power in watts and temperature rise in degrees Celsius versus frequency in KHz for a transformer sample using Mn doped PMN-PT (L[0  1 1],w[100],t[011]) in accordance with the principles of the present invention; 
         FIG. 3B  is a graph of experimental results of efficiency and voltage gain versus frequency in KHz for a transformer sample using Mn doped PMN-PT (L[0  1 1]w[100]t[011]) in accordance with the principles of the present invention; 
         FIG. 4A  is a top view of a uni-poled disk shaped piezoelectric transformer having a ring-dot electrode pattern; 
         FIG. 4B  is a cross-sectional view of the disk shaped piezoelectric transformer of  FIG. 4A , illustrating a poling direction; 
         FIG. 5A  is a cross-sectional layout view of a multilayer disk shaped transformer having a common ground; and 
         FIG. 5B  is a cross-sectional layout view of a multilayer disk shaped transformer having separated or floating type grounds. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The key advances of the present invention over the single crystal PZN-PT and piezoceramic PZT materials previously used in transformers have been experimentally verified. The following advances have been shown. 
     Two incongruent crystallographic orientations have been shown to exist that are suitable for high power transformers as shown in  FIG. 1B , sample 5, k 32  and  FIG. 1C  sample 6, k 31 . 
     Acceptor-doping with manganese into the k 31  and k 32  crystallographic orientations has been shown, whereby the mechanical Q m  (see Table I, below) was enhanced to levels approaching six times of the reported value in the prior art for single crystal PZN-PT. This occurred without affecting the high electromechanical coupling. The power density of piezoelectric transformer is related with the mechanical quality factor Q m , and the electromechanical coupling coefficient k. 
     Fabrication of a thermally stable high power density single crystal transformer is shown with up to five times the power density of hard PZT piezoceramics and 45% higher efficiency (see the results in Table I). This can result in either an 80% size and weight reduction of current PZT transformers for the same power output, or a five-fold increase in the power output for the same size transformer. 
     Alternate, easily polarized and manufactured transformer designs (see  FIGS. 4A ,  4 B,  5 A and  5 B) have also been developed that do not violate the crystallographic design rules. 
     Table I below lists empirically derived data of various materials tested for use in a piezoelectric transformer, including maximum power densities and efficiencies, mechanical quality factors, and electromechanical coupling coefficients for each material. 
     Specifically, the six samples tested with results provided in Table I are composed of well known single crystal materials. The APC 841 is a conventional PZT ceramic material used for transformers. Each of the PMN-PT samples were derived with different orientations as shown in  FIGS. 1A ,  1 B and  1 C. Notice that samples 4 and 5 were doped with manganese. Testing was also performed on samples doped with indium and iron, however, the best results were obtained by doping with manganese. 
     For each sample, the maximum power density was measured in watts per cubic centimeter, maximum efficiency was calculated using the input and output power, the mechanical quality factor Q m  was measured, and the electromechanical coupling coefficient k 31  was measured. 
     
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE I 
               
               
                   
               
               
                   
                   
                 Max. 
                   
                   
                   
               
               
                   
                   
                 Power 
                   
                   
                   
               
               
                 Sample 
                   
                 Density 
                 Max. 
                   
                 k 31  or 
               
               
                 No. 
                 Material 
                 (W/cm 3 ) 
                 Efficiency 
                 Q m   
                 k 32   
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 1 
                 APC 841 
                 7.7 
                 0.66 
                 1100  
                 0.30 
               
               
                   
                 hard PZT ceramic 
                   
                   
                   
                   
               
               
                 2 
                 PMN-PT 
                 1.1 
                 0.33 
                 150 
                 0.40 
               
               
                   
                 (L[100] w[010] t[001]) 
                   
                   
                   
                 (k 31 ) 
               
               
                 3 
                 PMN-PT 
                 11.8  
                 0.86 
                 150 
                 0.88 
               
               
                   
                 (L[0  1 1] w[100] t[011]) 
                   
                   
                   
                 (k 31 ) 
               
               
                 4 
                 Mn-PMN-PT 
                 5.2 
                 0.88 
                 250 
                 0.50 
               
               
                   
                 (L[100] w[010] t[001]) 
                   
                   
                   
                 (k 31 ) 
               
               
                 5 
                 Mn-PMN-PT 
                 30.1  
                 0.96 
                 320 
                 0.61 
               
               
                   
                 (L[100] w[0  1 1] t[011]) 
                   
                   
                   
                 (k 32 ) 
               
               
                 6 
                 Mn-PMN-PT 
                 38.1  
                 0.93 
                 220 
                 0.83 
               
               
                   
                 (L[0  1 1] w[100] t[011]) 
                   
                   
                   
                 (k 31 ) 
               
               
                   
               
             
          
         
       
     
     We have experimentally proven that the single crystal piezoelectric transformer of the present invention exhibits much better performance in terms of power density than the conventional hard piezoceramic PZT transformers, if the poling direction, cutting orientation, and dopant type are selected properly. The advantage is significant for the devices of power density larger than 10 W/cm 3  as is evident when examining the results of Table I. Generally, various types and configurations of transformers can be improved by using single crystal materials, such as Pb(Mg 1-x Nb x )0 3 -PbTi0 3  (PMN-PT) and Pb(Zr 1-x Nb x )0 3 -PbTi0 3  (PZN-PT) . 
       FIG. 1A  is a perspective view of a rectangular transformer plate  10  having a length L, a width w, and a thickness t and having a crystal orientation of L[100],w[010],t[001].  FIG. 1B  shows a rectangular transformer plate  12  with a second crystal orientation of L[100],w[0  1 1],t[011], and  FIG. 1C  shows a rectangular transformer plate  14  with third crystal orientation of L[0  1 1],w[100],t[011]. 
       FIG. 2  is a perspective view of a piezoelectric plate transformer  50  for a first embodiment having a length L, a width w, and a thickness t. Transformer  50  is made from relaxor ferroelectric single crystal piezoelectric material  52  poled in the thickness direction t as shown by arrows  54 . The transformer  50  includes two input electrodes  56 ,  58 , an output electrode  60 , and a ground electrode  62 . 
     It should be noted that the configuration with uni-directional poling is preferred in the sense of simplicity and production cost, considering the manufacturing process of relaxor-based piezoelectric single crystals. Initially 17×3×31 mm plates of lead zirconate titanate (PZT) ceramics, undoped and manganese-doped PMN-PT single crystals were manufactured. Properties of these materials are listed in Table I. 
     Specifically, hard PZT APC84 I (a product of APC International) was utilized, and the 0.79 Pb(Mg 1/3 Nb 2/3 )0 3 -0.21PbTi0 3  single crystal samples were fabricated using a solid-state crystal growth (SSCG) technique such as that taught in U.S. Patent Application Publication No. 2009/0211515. Other techniques can be used for this. The single crystals were cut in three orientations (see  FIGS. 1A ,  1 B,  1 C):
     L[100],w[010], t[001],   L[100],w[0  1 1],t[011], and   L[0  1 1], w[100], t[011].   

     Next the top electrode was separated into three parts  56 ,  58 , and  60  (each 5 mm in length in the current embodiment), and the bottom electrode  62  was left as the common ground. In this embodiment, the center portion  60  of the top electrode was used for output as an output electrode, and portions  56  and  58  were used for input as input electrodes. Under the input and output configuration of  FIG. 2 , the transformer worked as a voltage booster (step-up transformer). The experimental results and material properties are also summarized in Table I. 
     The maximum power density is defined as the output power per unit specimen volume when the temperature of the sample&#39;s nodal point rises by 10° C. above room temperature. For single crystals, Q m  and k 31  varied with poling direction and cutting orientation. The mechanical quality factors were enhanced by hard doping (with manganese in the preferred embodiment) during the crystal formulation process. The efficiency and power density are generally related with the product of Q m  and K 2 . 
     Materials with high mechanical quality factor and coupling coefficient are preferred in the transformer application. Compared to PZT ceramics, single crystals have a relatively small mechanical quality factor Q m , but significantly higher coupling coefficients k. Therefore, as shown by the results of Table I, fabrication and testing of several single crystal samples showed better high power performances than ceramics, and the power density of 38 W/cm3 was observed for Sample 6 in Table I, which was 5 times that of the PZT Sample 1 of Table I, also shown in  FIG. 3 . Single crystal elements were tested using manganese, indium and iron as dopants. While indium and iron had some beneficial effect, the best results were obtained using manganese. 
     Empirical test prove that hard doping is essential to increase the mechanical quality factor and the power density of the single crystal. Poling along the [0  1 1] direction exhibits higher power density than the [001] direction. 
     In the experiment, sinusoidal signals were produced by a function generator and amplified by a power amplifier. Each sample was driven in the k 31  vibration mode around the second resonant frequency. A 1.5 kΩ resistor was connected to the output as the load, which is close to the matching impedance, and the output power was kept constant throughout one frequency sweep. An infrared spot thermometer was used to monitor the temperature rise at the center of the plate, i.e., the nodal point of the sample with the maximum heat generation. Each sample was run for several sweeps with different output power levels, while all the data including voltages, currents, and temperatures were logged. The maximum power density is defined as the output power per unit volume when the temperature of the sample&#39;s nodal point rises by 10° C. above room temperature. Furthermore, the voltage gain and efficiency were simultaneously calculated using the input and output data. 
       FIGS. 3A and 3B  give generalized test results for Sample 6 Mn-PMN-PT L[0  1 1],w[100],t[011], the sample having the best measured power density. In  FIG. 3A  the output power versus frequency measurements were plotted as shown by the dotted line  64 A, and the temperature rise versus frequency measurements were plotted as shown by the solid line  64 B. In  FIG. 3B  the efficiency versus frequency measurements were plotted as shown by the dotted line  66 A, and the voltage gain versus frequency measurements were plotted as shown by the solid line  66 B. 
     A second embodiment and suitable configuration for the application of a single crystal transformer is illustrated in  FIGS. 4A and 4B .  FIG. 4A  is a top view of a uni-poled transformer  70  having a ring-dot electrode pattern. Ring-dot electrode pattern has an inner electrode  72  and an outer electrode  74  formed on one surface of a single crystal piezoelectric element  76 . Section line  4 B indicates the section line for  FIG. 4B .  FIG. 4B  shows uni-poled transformer  70  in section. Inner electrode  72  and outer electrode  74  are shown in section on top of single crystal piezoelectric element  76 . Element  76  is poled in the direction shown by arrows  78 . A ground electrode  80  is positioned on an opposite surface of element  76  from the inner electrode  72  and outer electrode  74 . Inner electrode  72  has an inner electrode diameter  82 , and an outer electrode  74  has an outer electrode diameter  84 . A distance  86  separates the top and bottom surfaces of element  76 . The areas of inner and outer electrodes  72  and  74  determine the step-up ratio, efficiency, and impedance characteristics. The disk-shaped transformer of this embodiment exhibited better performance than the rectangular plate-shape in terms of power density. 
     Many other embodiments of the present invention are available such as multilayer structures, i.e., stacking of layers, which can be utilized to further improve the power level. A multi-layer design as in  FIGS. 5A and 5B  can provide high gain and high power at a lower cost. These multi-layer designs use an electrode pattern similar to that shown in  FIG. 4A  and  FIG. 4B  wherein an input electrode surrounds an output electrode and appears in two places because of the cross-sectional view. 
       FIG. 5A  is a cross-sectional view of a multi-layer disk-shaped transformer  100  having a first configuration. In this embodiment, there are multiple single crystal piezoelectric elements  102 , each element  102  having two faces perpendicular to a poling direction  104 . Elements  102  are stacked with opposing poling directions  104 . An input electrode  106  and an output electrode  108  are in electrical communication with one face of element  102 . A ground electrode  110  is in electrical communication with the other face of element  102 . Ground electrodes  110  are joined to a ground  112 . Adjacent elements  102  share either the input electrode  106  and output electrode  108  or ground electrode  110  with the adjacent element. Input electrodes  106  on different layers are joined by a conductor  114 . Output electrodes  108  on different elements  102  are electrically joined by, for example, a hidden conductor  116 . 
       FIG. 5B  is a cross-sectional view of a multi-layer disk-shaped transformer  150  having a second configuration. This embodiment also has multiple single crystal piezoelectric elements  152 . Each element  152  has two opposed faces perpendicular to a poling direction  154 . Elements  152  are stacked with opposing poling directions  154 . Input electrodes  156  and output electrodes  158  are in electrical communication with one face of each element  152 . An input ground electrode  160  and an output ground electrode  162  are in electrical communication with the other face of element  152 . Input ground electrodes  160  are joined to an input ground  164 . Output ground electrodes  162  are joined to an output ground  166 . Adjacent elements  152  share either input electrodes  156  and output electrodes  158  or ground electrodes  160  and  162  with the adjacent element. Input electrodes  156  on different layers are electrically joined by hidden conductors  168 . Output electrodes  158  are also joined by hidden conductors  168 . Input ground electrodes  160  are joined to each other, as are output ground electrodes  162  by hidden conductors  168 . In this embodiment, through isolating the input ground and the output ground, it is believed that an output signal free of interference from the input signal will result. 
     It will be understood that additional variations and alternatives in the details, materials, steps and arrangement of parts, which have been herein described and illustrated in order to explain the nature of the invention, may be made as understood by those skilled in the art within the principles and scope of the invention as expressed in the appended claims. 
     The foregoing description of the preferred embodiments of the invention has been presented for purposes of illustration and description only. It is not intended to be exhaustive nor to limit the invention to the precise form disclosed; and obviously many modifications and variations are possible in light of the above teaching. Such modifications and variations that may be apparent to a person skilled in the art are intended to be included within the scope of this invention as defined by the accompanying claims.