CN101679123A - 电介质陶瓷组合物和层叠陶瓷电容器 - Google Patents

电介质陶瓷组合物和层叠陶瓷电容器 Download PDF

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CN101679123A
CN101679123A CN200880020309A CN200880020309A CN101679123A CN 101679123 A CN101679123 A CN 101679123A CN 200880020309 A CN200880020309 A CN 200880020309A CN 200880020309 A CN200880020309 A CN 200880020309A CN 101679123 A CN101679123 A CN 101679123A
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dielectric
ceramic composition
dielectric ceramic
composition
ceramic capacitor
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CN101679123B (zh
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竹田敏和
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Murata Manufacturing Co Ltd
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Abstract

本发明提供层叠陶瓷电容器中使用的电介质陶瓷材料，其能在1300℃以下的温度下与主要成分为Ni的内部电极一起烧结，不仅能确保高介电常数，而且在－55～175℃的范围内的静电容量温度特性良好，在175℃下的电阻率ρ高。电介质陶瓷组合物以组成式(1－a)(K1－xNax)(Sr1－y－zBayCaz)2Nb5O15－a(Ba1－bCab)TiO3(a、b、x、y、z均表示摩尔比，满足0.3≤a≤0.8、0≤b≤0.2、0≤x＜0.2、0.1≤y≤0.5、0.1≤z≤0.5、0.2≤y+z≤0.7)所示的电介质陶瓷组合物为主要成分，并且相对于上述主要成分100摩尔份，含有0.1～40摩尔份的M(M是选自V、Mn、Cr、Fe、Co、Ni、Zn、Mg、Si中的至少1种)作为辅助成分。

Description

电介质陶瓷组合物和层叠陶瓷电容器
技术领域
本发明涉及电介质陶瓷组合物和层叠陶瓷电容器，尤其是涉及以具有钨青铜结构的KSr2Nb5O15类化合物和具有钙钛矿结构的BaTiO3类化合物的混晶系为基本组成的电介质陶瓷组合物、以及使用了该电介质陶瓷组合物的层叠陶瓷电容器。
背景技术
作为本发明的主要用途的层叠陶瓷电容器一般如下所述来制造。
首先，准备陶瓷坯片，该陶瓷坯片在其表面按所需的图案赋予了成为内部电极的导电材料，且含有电介质陶瓷原料。
接着，将包含上述赋予了导电材料的陶瓷坯片的多张陶瓷坯片层叠，热压接，从而制作一体化的未烧结层叠体。
然后，该未烧结层叠体通过烧结，得到烧结后的层叠体。在该层叠体的内部形成了由上述导电材料构成的内部电极。
接着，以与特定的内部电极电连接的方式，在层叠体的外表面上形成外部电极。外部电极例如可以通过如下方法来形成：在层叠体的外表面上赋予含有导电性金属粉末和玻璃粉的导电性糊，通过烧结来形成外部电极。如此操作，即可制成层叠陶瓷电容器。
为了降低层叠陶瓷电容器的制造成本，优选采用廉价的Ni作为其内部电极的材料。当采用Ni作为内部电极的材料时，由于Ni为贫金属，因此为了防止在层叠体烧结时Ni的氧化，必须使烧结时的氛围气为还原氛围气。
为了在还原氛围气下烧结，要求电介质陶瓷材料具有耐还原性。作为具有耐还原性且具有优异的电特性的材料，在国际公开第WO2006/114914号小册子(以下称为专利文献1)中公开了KSr2Nb5O15类陶瓷组合物。
专利文献1：国际公开第WO2006/114914号小册子
发明内容
专利文献1的KSr2Nb5O15类陶瓷组合物在具有主要成分为Ni的内部电极的层叠陶瓷电容器中显示出优异的介电常数。
但是，专利文献1的KSr2Nb5O15类陶瓷组合物虽然介电常数高，但存在静电容量的温度特性不理想这一缺点。特别是近年来，要求在175℃左右的高温下具有温度稳定性，作为静电容量温度特性，要求在以25℃的静电容量为基准的-55～175℃的范围内的静电容量的温度变化率为±15％以下。这确保温度直至比EIA规格的X8R特性的温度范围(-55～150℃)更高的稳定性。
作为高温下的温度稳定性的指标，希望175℃下的绝缘电阻的电阻率ρ要高，但专利文献1的陶瓷组合物在这点上也不理想。
本发明是鉴于上述问题而完成的发明，目的在于提供不仅显示足够的介电常数、而且即使在175℃左右的高温下也能得到稳定的静电容量温度特性和高电阻率ρ的电介质陶瓷组合物、以及使用该电介质陶瓷组合物得到的层叠陶瓷电容器。
即，本发明的电介质陶瓷组合物以组成式(1-a)(K1-xNax)(Sr1-y-zBayCaz)2Nb5O15-a(Ba1-bCab)TiO3(a、b、x、y、z均表示摩尔比，满足0.3≤a≤0.8、0≤b≤0.2、0≤x＜0.2、0.1≤y≤0.5、0.1≤z≤0.5、0.2≤y+z≤0.7)所示的电介质陶瓷组合物为主要成分，并且相对于上述主要成分100摩尔份，含有0.1～40摩尔份的M(M是选自V、Mn、Cr、Fe、Co、Ni、Zn、Mg、Si中的至少1种)作为辅助成分。
另外，本发明的层叠陶瓷电容器具备层叠的多层电介质陶瓷层和配置于该多层电介质陶瓷层之间的多个内部电极以及与该多个内部电极电连接的外部电极，上述电介质陶瓷层由上述电介质陶瓷组合物形成。
在本发明的层叠陶瓷电容器中，内部电极的主要成分优选为Ni。
根据本发明的电介质陶瓷组合物，不仅能确保高介电常数，而且在-55～175℃的范围内的静电容量温度特性良好，并且在175℃下能得到足够高的电阻率ρ。因此，能得到即使在高温的使用环境下也具有稳定特性的层叠陶瓷电容器。
附图说明
图1是示意地表示本发明的一实施方式的层叠陶瓷电容器的截面图。
(符号说明)
1：层叠陶瓷电容器、2：陶瓷层叠体、3：电介质陶瓷层、4，5：内部电极、8，9：外部电极
具体实施方式
首先，对作为本发明的电介质陶瓷的主要用途的层叠陶瓷电容器进行说明。图1是表示一般层叠陶瓷电容器1的截面图。
层叠陶瓷电容器1具备长方体形的陶瓷层叠体2。陶瓷层叠体2具备多层层叠而成的电介质陶瓷层3和沿多层电介质陶瓷层3之间的界面形成的多个内部电极4和5。内部电极4和5以抵达陶瓷层叠体2的外表面的方式形成。抵达陶瓷层叠体2的一侧的端面6的内部电极4和抵达另一侧的端面7的内部电极5，在陶瓷层叠体2的内部按照隔着电介质陶瓷层3而能获得静电容量的方式交替配置。
内部电极4和5的导电材料从降低成本的观点出发优选为镍或镍合金。
为了取出上述静电容量，在陶瓷层叠体2的外表面上的端面6和7上，以与内部电极4和5中的任一特定一方电连接的方式，分别形成外部电极8和9。作为外部电极8和9中含有的导电材料，可以使用与内部电极4和5相同的导电材料，还可以使用银、钯、银-钯合金等。外部电极8和9通过如下方法来形成：赋予在上述金属或合金的粉末中添加玻璃粉而得到的导电性糊，并通过烧结来形成外部电极。
在外部电极8和9上，根据需要分别形成由镍、铜等形成的第1镀敷层10和11，再在其上分别形成由焊锡、锡等形成的第2镀敷层12和13。
接着，对本发明的电介质陶瓷组合物的详细情况进行说明。
本发明的电介质陶瓷组合物以具有钨青铜结构的KSr2Nb5O15类化合物和具有钙钛矿结构的BaTiO3类化合物的混晶系为主要成分。
混晶的一方(K1-xNax)(Sr1-y-zBayCaz)2Nb5O15具有钨青铜型的结晶结构。各K位点、Sr位点、Nb位点、O位点的摩尔比基本上为1∶2∶5∶15，在能保持钨青铜结构的前提下，可以有所增减。但是，当组成式为(KSr2)mNb5O15时，若m大于1.16或小于0.96，则烧结性会变差，因而不优选。
K可以被Na取代，其取代摩尔比x必须不足0.2。若x为0.2以上，则介电常数会下降。
另外，Sr可以被Ba和Ca取代。其取代摩尔比y和z满足0.1≤y≤0.5、0.1≤z≤0.5、0.2≤y+z≤0.7的三个关系式。若y和/或z过小，则电阻率ρ会下降，若取代量y和/或z过大，则烧结性会变差。
混晶的另一方(Ba1-bCab)TiO3具有钙钛矿型的结晶结构。各Ba位点、Ti位点、O位点的摩尔比为1∶1∶3，在能保持钙钛矿结构且没有异常粒子生长或异常析出等不良现象的前提下，可以有所增减。
另外，Ba可以被Ca取代。但是，Ca的取代摩尔比b为0.2以下。若b大于0.2，则异相成分增加，因而不优选。
使(K1-xNax)(Sr1-y-zBayCaz)2Nb5O15和(Ba1-bCab)TiO3按(1-a)∶a(0.3≤a≤0.8)的摩尔比构成混晶系，不仅能确保高介电常数，而且在-55～175℃的范围内的静电容量的温度变化率在±15％以内，并且在175℃下的电阻率ρ按log(ρ/Ωm)计为8.0以上。若a在上述范围外，则静电容量温度特性以及电阻率ρ会下降。
作为相对于上述主要成分100摩尔份的辅助成分，含有0.1～40摩尔份的M(M是选自V、Mn、Cr、Fe、Co、Ni、Zn、Mg、Si中的至少1种)，因此即使在1300℃以下的温度下也能获得足够的烧结性。假设不含M的话，则即使在1400℃下也得不到足够的烧结性。反之，当M的添加量超过40摩尔份时，得不到足够的绝缘性。
本发明的电介质陶瓷组合物的制造方法可以采用公知的方法。例如，本发明的电介质陶瓷组合物可以采用固相法来得到：将氧化物粉末或碳酸化物等初始原料混合，将得到的混合粉体进行热处理合成。
钨青铜型化合物中，初始原料有K2CO3、SrCO3、Nb2O5等，钙钛矿型化合物中，初始原料有BaCO3、TiO2等。可以将这些初始原料先全部混合，临时烧结，生成由(1-a)(K1-xNax)(Sr1-y-zBayCaz)2Nb5O15-a(Ba1-bCab)TiO3构成的混晶系。另外，也可以分别先生成钨青铜化合物的粉末和钙钛矿型化合物的粉末，然后使这2种粉末混合，烧结，生成由(1-a)(K1-xNax)(Sr1-y-zBayCaz)2Nb5O15-a(Ba1-bCab)TiO3构成的混晶系。
关于辅助成分M，可以事先与上述主要成分的初始原料的混合时同时混合，也可以以添加到生成的主要成分的粉末中的方式来混合。
实施例
以下，对本发明的电介质陶瓷组合物以及使用该电介质陶瓷组合物的层叠陶瓷电容器的实施例进行说明。
本实施例通过改变构成主要成分的元素的含量以及辅助成分的元素种类和含量来分析对电特性的影响。制得的样品的样品号为1～27，各样品的组成如表1所示，各样品的烧结温度和电特性的测定结果如表2所示。下面进行详细说明。
首先，作为主要成分的初始原料，准备K2CO3、Na2CO3、SrCO3、CaCO3、BaCO3、Nb2O5、TiO2，在组成式：(1-a)(K1-xNax)(Sr1-y-zBayCaz)2Nb5O15-a(Ba1-bCab)TiO3中，满足表1的各样品号中记载的a、b、x、y、z进行称量。作为辅助成分的初始原料，满足表1的各样品号中记载的M的合计值(相对于主要成分100摩尔份的摩尔份)称量V2O3、MnCO3、Cr2O3、CoCO3、Fe2O3、、NiO、ZnO、MgCO3、SiO2。
将这些称好的粉末在溶剂中通过球磨机混合后，干燥，然后在1100℃下热处理合成2小时，得到样品号1～27的陶瓷原料粉末。
[表1]
Figure G200880020309XD00061
接着，在样品号1～27的陶瓷原料粉末中添加聚乙烯醇缩丁醛类粘合剂和乙醇后，用球磨机进行湿式混合，分别制备陶瓷浆料。然后，将各陶瓷浆料通过刮刀法成形成薄片状，得到厚8μm的矩形陶瓷坯片后，在每个样品的陶瓷坯片上印刷以Ni为主要成分的导电性糊，形成内部电极用的导电性糊膜。
接着，对于各样品的陶瓷坯片，如图1所示那样以导电性糊膜被拉出而暴露于外部的端部分别不同的方式层叠多层，得到未烧结层叠体。将这些未烧结层叠体在氮气氛围气下加热至350℃的温度，使粘合剂分解、燃烧后，在由氧分压为10-9～10-12MPa的H2-N2-H2O气体形成的还原性氛围气中，在表2所示的温度下烧结2小时，得到陶瓷层叠体。然后，在各样品的层叠体的两端面分别涂布含有B2O3-SiO2-BaO系的玻璃粉的Ag糊，在氮气氛围气中于800℃的温度下烧结，形成与内部电极电连接的外部电极。
如此得到样品号1～27的层叠陶瓷电容器的样品。这些层叠陶瓷电容器的外径尺寸为宽3.2mm、长4.5mm、厚0.5mm，内部电极间存在的电介质陶瓷层的厚度为6μm。另外，有效电介质陶瓷层的层数为5，每层的相对电极的面积为2.5×10-6m2。
对上述各样品，使用自动桥式测定仪，在25℃、频率1kHz、1Vrms的条件下测定静电容量和介质损失，由得到的静电容量算出介电常数。其结果如表2所示。
接着，使温度在-55℃～175℃的范围内改变，测定以25℃的静电容量为基准的静电容量的温度变化率(％)。作为该测定结果，在表2示出-55℃和175℃下的静电容量的温度变化率(％)。
另外，对各样品，使用绝缘电阻计，在175℃下施加1分钟30V的直流电压，测定绝缘电阻R，由得到的绝缘电阻R算出电阻率ρ。该算出的的ρ的log(ρ/Ωm)值如表2所示。
[表2]
由表2所示的结果可知，样品号1～27中，本发明的范围内的样品能在还原性氛围气中于1300℃以下的温度下将内部电极与电介质陶瓷层同时烧结，得到2000以上的介电常数，-55～175℃的范围内的静电容量的温度变化率为±15％以内，175℃下的电阻率ρ的log(ρ/Ωm)为8.0以上。
与此相对，样品号1由于不含辅助成分M，因此即使在1400℃下烧结也得不到足够的绝缘性，介电常数低，为1000左右。
另外，样品号2和27由于主要成分的钙钛矿化合物的比例a在0.3～0.8的范围外，因此静电容量的温度变化率在±15％以内的范围之外，且log(ρ/Ωm)也不足8.0。
样品号23由于钨青铜型化合物中K的Na取代量x为0.2以上，因此介电常数低为700。
样品号24和25由于钨青铜型化合物中的Sr的Ba取代量y或Ca取代量z过多，因此烧结性差。
另外，样品号26由于辅助成分M的含量相对于主要成分100摩尔份超过40摩尔份，因此绝缘性下降，介质损失高。
这次公开的实施方式和实施例均为例示，而非限制。本发明的范围以权利要求书为准，而非以上的实施方式和实施例，包括与权利要求书相同意思以及在权利要求范围内的所有修改或变形。
工业上利用的可能性
本发明的电介质陶瓷组合物不仅能确保高介电常数，而且在-55～175℃的范围内的静电容量温度特性良好，并且在175℃下具有足够高的电阻率ρ，因此适合用作在高温环境下使用的层叠陶瓷电容器的电介质陶瓷层的材料。

Claims (3)

1.一种电介质陶瓷组合物，其以组成式(1-a)(K1-xNax)(Sr1-y-zBayCaz)2Nb5O15-a(Ba1-bCab)TiO3(a、b、x、y、z均表示摩尔比，满足0.3≤a≤0.8、0≤b≤0.2、0≤x＜0.2、0.1≤y≤0.5、0.1≤z≤0.5、0.2≤y+z≤0.7)所示的电介质陶瓷组合物为主要成分，相对于所述主要成分100摩尔份，含有0.1～40摩尔份的M(M是选自V、Mn、Cr、Fe、Co、Ni、Zn、Mg、Si中的至少1种)作为辅助成分。
2.一种层叠陶瓷电容器，其具备层叠的多层电介质陶瓷层和配置于所述多层电介质陶瓷层之间的多个内部电极以及与所述多个内部电极电连接的外部电极，所述电介质陶瓷层由权利要求1所述的电介质陶瓷组合物形成。
3.根据权利要求2所述的层叠陶瓷电容器，其中，所述内部电极的主要成分为Ni。
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