CN102149653A - 电介体陶瓷组合物及层叠陶瓷电容器 - Google Patents
电介体陶瓷组合物及层叠陶瓷电容器 Download PDFInfo
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- 229910052691 Erbium Inorganic materials 0.000 claims abstract description 7
- 229910052693 Europium Inorganic materials 0.000 claims abstract description 7
- 229910052688 Gadolinium Inorganic materials 0.000 claims abstract description 7
- 229910052689 Holmium Inorganic materials 0.000 claims abstract description 7
- 229910052772 Samarium Inorganic materials 0.000 claims abstract description 7
- 229910052771 Terbium Inorganic materials 0.000 claims abstract description 7
- 229910052775 Thulium Inorganic materials 0.000 claims abstract description 7
- 229910052746 lanthanum Inorganic materials 0.000 claims abstract description 7
- 229910052727 yttrium Inorganic materials 0.000 claims abstract description 7
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- 239000003990 capacitor Substances 0.000 claims description 23
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Abstract
本发明提供一种适合用于例如在车载用那样的高温环境下使用的层叠陶瓷电容器的电介体陶瓷组合物。其中,所述电介体陶瓷组合物用组成式:100(Ba1-xCax)mTiO3+aMgO+bV2O5+cSiO2+dR2O3(其中,R为选自Y、La、Sm、Eu、Gd、Tb、Dy、Ho、Er、Tm及Yb中的至少1种金属元素,a、b、c及d表示摩尔比。)表示,且满足0.03≤x≤0.20、0.99≤m≤1.03、0.10≤a≤5.0、0.025≤b≤2.5、0.20≤c≤8.0、及2.5≤d<3.5的各条件。由该电介体陶瓷组合物的烧结体构成层叠陶瓷电容器(1)的电介体陶瓷层(3)。
Description
技术领域
本发明涉及电介体陶瓷组合物及层叠陶瓷电容器,尤其涉及适合用于例如在车载用那样的高温环境下使用的层叠陶瓷电容器的电介体陶瓷组合物、及使用其构成的层叠陶瓷电容器。
背景技术
在层叠陶瓷电容器中,作为构成内部电极的导电性材料,可以使用Ni或Ni合金那样的卑金属,因此,作为构成电介体陶瓷层的电介体陶瓷组合物,要求即使在低氧分压下烧成也不会半导体化的电介体陶瓷组合物。进而,作为电介体陶瓷组合物,要求相对介电常数的温度特性平稳的电介体陶瓷组合物。而且,提出了各种可以满足这些要求的电介体陶瓷组合物。
作为对于本发明有兴趣的电介体陶瓷组合物,例如有在日本特开2005-194138号公报(专利文献1)中记载的电介体陶瓷组合物。在专利文献1中,记载有一种电介体陶瓷组合物,其用组成式:100(Ba1-xCax)mTiO3+aMnO+bV2O5+cSiO2+dRe2O3(其中,Re为选自Y、La、Sm、Eu、Gd、Tb、Dy、Ho、Er、Tm及Yb中的至少1种金属元素,a、b、c及d表示摩尔比。)表示,且满足0.030≤x≤0.20、0.990≤m≤1.030、0.010≤a≤5.0、0.050≤b≤2.5、0.20≤c≤8.0、及0.050≤d≤2.5的各条件。
另一方面,对于层叠陶瓷电容器,除通常的民生机械用以外,例如有车载用等用途。相对层叠陶瓷电容器所要求的特性不一定与通常民生机械用的情况和车载用的情况相同。
例如,对于静电电容温度特性,在通常民生机械用的情况下,要求满足EIA规格的X7R特性(以25℃为基准,-55℃~125℃的范围内的静电电容的温度变化率为±15%以内),与之相对,在车载用的情况下,要求满足同规格的X8R特性(以25℃为基准,-55℃~150℃的范围内的静电电容的温度变化率为±15%以内)。
另外,对于高温负荷可靠性,在通常民生机械用的情况下,在150℃的温度条件下进行评价,在车载用的情况下,在175℃的温度条件下进行评价。需要说明的是,负荷电压根据面向作为制品的层叠陶瓷电容器的用途而决定。
在这样的背景下,前述的专利文献1中记载的电介体陶瓷组合物不一定适合用于构成车载用的层叠陶瓷电容器中的电介体陶瓷层。
即,确认了在专利文献1中记载的电介体陶瓷组合物的在150℃下施加电场强度10V/μm的直流电压时的高温负荷可靠性,以平均故障时间计为100时间以上时是优异的,在175℃下施加电场强度10V/μm的直流电压时的高温负荷可靠性在专利文献1中没有记载。
在专利文献1中记载的电介体陶瓷组合物中,为了提高可靠性而增大Re添加量的情况下,相对介电常数的温度变化率变差,因此,不能兼备高可靠性和相对介电常数的平稳的温度变化率。
另外,已知关于在专利文献1中记载的电介体陶瓷组合物的相对介电常数的温度变化率,在-55℃~125℃的范围可以满足绝对值15%以内但在-55℃~150℃的范围不能满足15%以内。
先行技术文献
专利文献
专利文献1:日本特开2005-194138号公报
发明内容
本发明所要解决的技术问题
因此,本发明的目的在于提供一种可以解决上述那样的问题的电介体陶瓷组合物,即、可以提供一种适合用于在例如车载用那样的高温环境下使用的层叠陶瓷电容器的电介体陶瓷组合物。
本发明的其它的目的在于提供一种使用上述的电介体陶瓷组合物而构成的层叠陶瓷电容器。
解决技术问题的手段
为了解决上述的技术课题,本发明的电介体陶瓷组合物的特征在于,用组成式:100(Ba1-xCax)mTiO3+aMgO+bV2O5+cSiO2+dR2O3(其中,R为选自Y、La、Sm、Eu、Gd、Tb、Dy、Ho、Er、Tm及Yb中的至少1种金属元素,a、b、c及d表示摩尔比。)表示,且满足0.03≤x≤0.20、0.99≤m≤1.03、0.10≤a≤5.0、0.025≤b≤2.5、0.20≤c≤8.0、及2.5≤d<3.5的各条件。
在本发明的电介体陶瓷组合物中,相对于所述(Ba1-xCax)mTiO3表示的化合物100摩尔份,优选进一步含有0.005~5.0摩尔份的MnO。
本发明提供层叠陶瓷电容器,其具备:具有层叠的多个电介体陶瓷层、及沿所述电介体陶瓷层间的特定的界面形成的多个内部电极的电容器主体;以及形成于电容器主体的外表面上的彼此不同的位置且电连接于所述内部电极的多个外部电极。本发明的层叠陶瓷电容器的特征在于,电介体陶瓷层由上述的本发明的电介体陶瓷组合物的烧结体构成。
在本发明的层叠陶瓷电容器中,构成电极的电性材料优选以选自Ni、Ni合金、Cu及Cu合金中的至少1种作为主成分。
发明效果
根据本发明的电介体陶瓷组合物,由于添加有Mg,因此,伴随R添加量的增加,可以使高温中的可靠性变高,且可以使到150℃为止的相对介电常数的温度变化率变小。
更具体而言,根据本发明,可以得到一种电介体陶瓷组合物:相对介电常数为1500以上,并且满足EIA规格的X8R特性地相对介电常数的温度特性平稳,对绝缘电阻而言,以在25℃下的电阻率计,高至1011Ω·m以上,另外,对高温负荷可靠性而言,以在175℃下施加电场强度10V/μm的直流电压时的平均故障寿命计,高至200小时以上。
因此,通过将本发明的电介体陶瓷组合物应用于层叠陶瓷电容器,由于电子机械的高功能化及高集成化,从而即使使用条件变得苛刻,也能够确保优异的高温负荷可靠性。因此,可以将层叠陶瓷电容器设为适用于车载用的层叠陶瓷电容器。
另外,本发明的电介体陶瓷组合物,由于即使在低氧分压下烧成也不能半导体化,因此,在层叠陶瓷电容器中,作为构成内部电极的导电性材料,可以有利地使用以选自Ni、Ni合金、Cu及Cu合金中的至少1种等卑金属作为主成分的导电性材料。
在本发明的电介体陶瓷组合物中,如果添加Mn,则可以得到更高的可靠性。
附图说明
图1是图解表示使用本发明的电介体陶瓷组合物而构成的层叠陶瓷电容器1的剖面图。
具体实施方式
图1是图解表示使用本发明的电介体陶瓷组合物而构成的层叠陶瓷电容器1的剖面图。
层叠陶瓷电容器1具备电容器主体2。电容器主体2具备层叠的多个电介体陶瓷层3、和沿多个电介体陶瓷层3间的特定的多个界面分别形成的多个内部电极4及5而构成。内部电极4及5以到达至电容器主体2的外表面的方式形成,引出至电容器主体2的一端面6的内部电极4和引出至另一端面7的内部电极5在电容器主体2的内部交替配置。
在电容器主体2的外表面上、即端面6及7上分别形成有外部电极8及9。另外,根据需要,在外部电极8及9上分别形成有由Ni、Cu等构成的第一镀敷层10及11,进而在其上分别形成有由锡焊、Sn等构成的第二镀敷层12及13。
接着,对上述那样的层叠陶瓷电容器1的制造方法按照制造工序的顺序进行说明。
首先,准备用于电介体陶瓷组合物的原料粉末,将其浆液化,将该浆液成形为片状,得到用于电介体陶瓷层3的生片。在此,作为电介体陶瓷原料粉末,如后面详细说明,使用用于本发明的电介体陶瓷组合物的原料粉末。
接着,在生片的特定的各一个主面上形成内部电极4及5。构成内部电极4及5的导电性材料优选以选自Ni、Ni合金、Cu、及Cu合金中的至少1种作为主成分,特别优选以Ni或Ni合金作为主成分。这些内部电极4及5通常使用包含上述那样的导电性材料的导电性浆膏,通过丝网印刷法或转印法形成,但不限于这些,也可以通过任意的方法形成。
接着,层叠必要数量的用于形成有内部电极4或5的电介体陶瓷层3的生片,并且,使这些生片处于利用没有形成内部电极的适当数量的生片夹持的状态,通过将其热压接,得到生的电容器主体。
接着,将该生的电容器主体在规定的还原性气氛中在规定的温度下烧成,由此得到图1所示的烧结后的电容器主体2。
然后,在电容器主体2的两端面6及7上以分别与内部电极4及5电连接的方式形成外部电极8及9。作为这些外部电极8及9的材料,可以使用Ni、Ni合金、Cu、Cu合金、Ag或Ag合金等。通常将在金属粉末中添加玻璃粉而得到的导电性浆膏涂布在电容器主体2的两端面6及7上,通过将其烧结而形成外部电极8及9。
需要说明的是,应成为外部电极8及9的导电性浆膏通常如上所述涂布于烧结后的电容器主体2上并烧结,但也可以预先涂布于烧成前的生的电容器主体上,与用于得到电容器主体2的烧成同时进行烧结。
接着,在外部电极8及9上实施Ni、Cu等镀敷,形成第一镀敷层10及11。最后,在这些第一镀敷层10及11上实施焊锡、Sn等镀敷,形成第二镀敷层12及13,完成层叠陶瓷电容器1。
在这样的层叠陶瓷电容器1中,电介体陶瓷层3由用组成式:100(Ba1-xCax)mTiO3+aMgO+bV2O5+cSiO2+dR2O3(其中,R为选自Y、La、Sm、Eu、Gd、Tb、Dy、Ho、Er、Tm及Yb中的至少1种的金属元素,a、b、c及d表示摩尔比。)表示的电介体陶瓷组合物的烧结体构成。
其中,在上述组成式中,x、m、a、b、c及d分别满足0.03≤x≤0.20、0.99≤m≤1.03、0.10≤a≤5.0、0.025≤b≤2.5、0.20≤c≤8.0、及2.5≤d<3.5的各条件。
该电介体陶瓷组合物即使在还原性气氛那样的低氧分压下烧成也可以不半导体化地使其烧结。
另外,如果使用该电介体陶瓷组合物构成层叠陶瓷电容器1中的电介体陶瓷层3,则可以使相对介电常数为1500以上,并且,使相对介电常数的温度特性平稳以满足EIA规格的X8R特性,使绝缘电阻以在25℃下的电阻率计高至1011Ω·m以上,另外,可以使高温负荷可靠性以在175℃下施加了电场强度10V/μm的直流电压时的平均故障寿命计高至200小时以上。
这样的电介体陶瓷组合物的起始原料含有(Ba1-xCax)mTiO3表示的化合物、Mg化合物、V化合物、Si化合物及R化合物(其中,R为选自Y、La、Sm、Eu、Gd、Tb、Dy、Ho、Er、Tm及Yb中的至少1种金属元素),但作为电介体陶瓷组合物的原料粉末的制造方法,只要能够实现(Ba1-xCax)mTiO3表示的化合物,则可以使用任意的方法。
例如,在将(Ba1-xCax)mTiO3表示的化合物称为主成分、其以外的成分称为副成分的情况下,通过具备以下工序的制造方法,可以得到电介体陶瓷组合物的原料粉末,所述制造方法包括:混合BaCO3、CaCO3及TiO2的工序;为了合成主成分而将该混合物进行热处理的工序;以及在得到的主成分中加入副成分进行混合的工序。
另外,也可以通过具备利用水热合成法、水解法、或溶胶-凝胶法等湿式合成法合成主成分的工序、和在得到的主成分中加入副成分进行混合的工序的制造方法得到电介体陶瓷组合物的原料粉末。
另外,作为副成分即Mg化合物、V化合物、Si化合物及R化合物,只要为可以构成电介体陶瓷组合物的化合物,则不限定于氧化物粉末,也可以使用醇盐或有机金属等溶液,这些所使用的副成分的形态不会损害得到的电介体陶瓷组合物的特性。
另外,上述那样的电介体陶瓷组合物被烧成,成为图1所示的层叠陶瓷电容器1的电介体陶瓷层3,但在这样的烧成工序中,确认了包含于内部电极4及5的Ni、Ni合金、Cu或Cu合金那样的金属也有时扩散至电介体陶瓷层3中,根据上述的电介体陶瓷组合物,即使这样的金属成分扩散,也不会对其电特性带来实质上的影响。
接着,基于本发明的实验例更具体地进行说明。该实验例是用于赋予本发明的电介体陶瓷组合物的组成范围的限定的依据的实验例。
在该实验例中,作为试样,制作图1所示的层叠陶瓷电容器。
首先,作为主成分即(Ba1-xCax)mTiO3的起始原料,准备高纯度的BaCO3、CaCO3及TiO2的各粉末,以得到示于表1的Ca的含量、即“Ca改性量:x”、及“(Ba、Ca)/Ti比:m”的方式配制这些起始原料粉末。
接着,将该配制原料粉末使用球磨机进行湿式混合,使其均匀分散后,实施干燥处理得到调整粉末。
接着,将得到的調整粉末在1000℃~1200℃的温度下预烧,得到平均粒径0.20μm且为示于表1的x及m即主成分粉末。需要说明的是,利用扫描型电子显微镜观察粉末,测定300个粒子的粒径求得平均粒径。
另外,作为副成分的起始原料,准备MgCO3、V2O5、SiO2及R2O3(其中,R为选自Y、La、Sm、Eu、Gd、Tb、Dy、Ho、Er、Tm及Yb中的任一种)的各粉末,以得到示于表1的x、m、a、b、c及d中分别选择的、由组成式:100(Ba1-xCax)mTiO3+aMgO+bV2O5+cSiO2+dR2O3表示的组成的方式配制上述主成分粉末和各副成分的起始原料粉末。
[表1]
接着,将该配制粉末使用球磨机进行湿式混合,使其均匀分散后,实施干燥处理,得到电介体陶瓷组合物的原料粉末。
接着,在该电介体陶瓷原料粉末中加入聚乙烯醇丁缩醛系粘合剂、增塑剂及乙醇等有机溶剂,使用球磨机进行湿式混合,得到含有电介体陶瓷组合物的浆液。
接着,将该浆液在由聚对苯二甲酸乙二醇酯构成的载体膜上成形为片状,得到含有电介体陶瓷组合物的生片。得到的生片的厚度为1.4μm。
接着,在得到的生片上,使用以Ni为主成分的导电性浆膏印刷内部电极图案后,以彼此对向并构成多个静电电容的方式层叠6层,进而在其上下面层叠适当数目的没有形成内部电极图案的陶瓷生片进行热压接,得到生的电容器主体。
接着,将该生的电容器主体在N2气氛中,在350℃的温度下保持3小时进行脱粘合剂,然后,使用N2-H2-H2O的混合气体,在设定为包含于内部电极的Ni没有氧化的氧分压10-12~10-9Mpa的还原性气氛中,在示于表2的温度下分别保持2小时进行烧成,得到烧结的电容器主体。
接着,在得到的电容器主体的两端面上涂布以Ag为主成分、含有B2O3-SiO2-BaO系玻璃粉的导电性浆膏,将其在N2气氛中在600℃的温度下烧结,由此形成与内部电极电连接的外部电极。
接着,在外部电极上,通过公知的方法实施Ni镀敷处理,形成第一镀敷层,在其上实施Sn镀敷处理,形成第二镀敷层。
这样得到的各试样的层叠陶瓷电容器的外形尺寸的宽度为5.0mm、长度为5.7mm、及厚度为2.4mm。另外,有效的电介体陶瓷层数为5,每1层的对向电极面积为16.3mm2,电介体陶瓷层的厚度为1.0μm。
使用自动电桥式测定器在25℃下施加1Vrms、1kHz的交流电压对这些得到的各试样的层叠陶瓷电容器测定静电电容(C)及介电损失(tanδ),根据得到的C和内部电极面积及电介体陶瓷层的厚度算出相对介电常数(εr)。
另外,在-55℃~150℃的范围内,边使温度变化边测定静电电容,以在25℃下的静电电容(C25)为基准,基于ΔCTC={(CTC-C25)/C25}的式算出变化的绝对值成为最大的静电电容(CTC)的温度变化率(ΔCTC)。
另外,使用绝缘电阻计,在25℃下施加120秒的25V的直流电压测定绝缘电阻(IR),基于得到的IR与层叠陶瓷电容器的结构算出电阻率(ρ)。
另外,作为高温负荷可靠性试验,在温度175℃下施加10V的直流电压,测定其绝缘电阻的经时变化,以各试样的绝缘电阻值成为105Ω以下的时刻为故障,求得这些的平均故障时间(MTTF)。
将以上的电特性的评价结果示于表2。
[表2]
关于表2所示的各电特性的优选的范围,εr为1500以上,tanδ为7.5%以下,ΔCTC的绝对值为15%以下,对于ρ,在将其用logρ(ρ的单位:Ω·m)表示的情况下,为11以上,MTTF为200小时以上。
在表1及表2中,在试样编号中带*的试样为本发明的组成范围外的试样。
下面,本发明中,说明对前述那样的组成范围限定的理由。
首先,在x<0.03的情况下,如试样1,ΔCTC的绝对值超过15%,MTTF不足200小时。另一方面,x>0.20的情况下,如试样2,εr不足1500,tanδ超过7.5%,MTTF不足200小时。
接着,m<0.99的情况下,如试样3,logρ不足11,另外,MTTF显著变短。另一方面,m>1.03的情况下,如试样4,εr不足1500,logρ不足11。
接着,a<0.10的情况下,如试样5,logρ不足11,ΔCTC的绝对值为15%以下。另一方面,a>5.0的情况下,如试样6,logρ不足11,MTTF不足200小时。
另外,b<0.025的情况下,如试样7,ΔCTC的绝对值超过15%,MTTF不足200小时。另一方面,b>2.5的情况下,如试样8,εr不足1500,logρ不足11。
另外,c<0.20的情况下,如试样9,εr不足1500,logρ不足11,MTTF不足200小时。另一方面,c>8.0的情况下,如试样10,ΔCTC的绝对值超过15%,logρ不足11。
另外,d<2.5的情况下,如试样11,ΔCTC的绝对值超过15%,MTTF不足200小时。另一方面,d≥3.5的情况下,如试样12,εr不足1500,logρ不足11,MTTF不足200小时。
与之相对,根据在本发明的范围内的试样13~50,可以使εr变大至1500以上,使tanδ变小至5%以下,使ΔCTC的绝对值小至15%以下,对于logρ,使其高至11以上,进而,对于MTTF,使其长至200小时以上。
另外,在本发明的范围内的试样13~50中,相对于(Ba1-xCax)mTiO3所示的化合物100摩尔份,关于MnO在0.005~5.0摩尔份的含量的范围的试样34~50,可以使MTTF进一步长至300小时以上。
符号说明
1层叠陶瓷电容器
2电容器主体
3电介体陶瓷层
4,5内部电极
8,9外部电极
Claims (4)
1.一种电介体陶瓷组合物,其用组成式:100(Ba1-xCax)mTiO3+aMgO+bV2O5+cSiO2+dR2O3表示,且满足0.03≤x≤0.20、0.99≤m≤1.03、0.10≤a≤5.0、0.025≤b≤2.5、0.20≤c≤8.0、及2.5≤d<3.5的各条件,式中,R为选自Y、La、Sm、Eu、Gd、Tb、Dy、Ho、Er、Tm及Yb中的至少1种金属元素,a、b、c及d表示摩尔比。
2.如权利要求1所述的电介体陶瓷组合物,其中,相对于所述(Ba1-xCax)mTiO3表示的化合物100摩尔份,进一步包含0.005~5.0摩尔份的MnO。
3.一种层叠陶瓷电容器,其具备:
具有层叠的多个电介体陶瓷层及沿所述电介体陶瓷层间的特定的界面形成的多个内部电极的电容器主体;以及
形成于所述电容器主体的外表面上的彼此不同的位置且与所述内部电极电连接的多个外部电极,
其中,所述电介体陶瓷层是由权利要求1或2所述的电介体陶瓷组合物的烧结体构成的。
4.如权利要求3所述的层叠陶瓷电容器,其中,构成所述内部电极的导电性材料以选自Ni、Ni合金、Cu及Cu合金中的至少1种作为主成分。
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