CN105693243A - 一种中介电常数高性能微波介质陶瓷的制备方法 - Google Patents
一种中介电常数高性能微波介质陶瓷的制备方法 Download PDFInfo
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Abstract
本发明公开了一种中介电常数高性能微波介质陶瓷的制备方法,该材料的组成式为:xRO-(1-x)Ln2O3-(1-x)Al2O3-xTiO2,0.65≤x≤0.75;其中R为Ca或Sr;Ln为La或Sm;将分析纯Ln2O3和硝酸铝、RCO3按上述组成称量并倒入硝酸溶液中,搅拌后,将溶于乙醇的钛酸四丁酯和第一沉淀剂滴入搅拌,均匀沉淀,再将第二沉淀剂滴入搅拌,滴定结束将沉淀清洗,得到白色沉淀,加入无水乙醇超声分散、烘干,得到前驱体;经预烧得到的粉体通过球磨、干燥、造粒、干压成型、等静压,烧结得高性能中介电常数微波介质陶瓷材料。本方法制备的粉体颗粒细、活性高、分散好,其介电性能:εr=40~50,Q·f=42000~45000GHz,τf=2~8ppm/℃,适用于现代通讯技术中基站用的介质谐振器、滤波器、介质天线等微波元器件。
Description
技术领域
本发明涉及一种中介电常数(εr=40~50)高性能的微波介质陶瓷的制备方法,属于微波介质陶瓷制备技术领域。
背景技术
微波介质陶瓷的运用十分广泛,主要运用在卫星通讯、移动基站、雷达等,在3G、4G通讯时代起着重要的作用。它是介质谐振器、滤波器、介质天线等微波元器件的关键性材料。
就目前微波介质陶瓷领域,国外的研究与生产都已相当成熟,特别是美国、日本和欧洲,各种体系的微波介质陶瓷都已实现系列化生产,而我国对微波介质陶瓷的研究起步比较晚,开始于80年代,由于开始理论水平低、工艺水平也低、没有好的测试性能的仪器,我们一直都是重复和追踪国外的研究成果。直到21世纪我国在研究高性能微波介质陶瓷方向才有比较快速的发展。
目前研究共沉淀法制备陶瓷的中国专利CN101234892A,名称:一种采用共沉淀法制备镧铝酸钛陶瓷材料的方法,其制备方法是采用共沉淀法制备粉体,其制备的粉体为LaTi2Al9O19,采用氨水为沉淀剂,一步完成沉淀,不控制pH容易让Al3+变为AlO2 -。中国专利CN104844204A,名称:一种高介微波陶瓷介质材料、制备方法及用途,采用共沉淀法制备x(Ba1/2Li)(Mg1/3Ta2/3)O3-(1-x)SrTiO3粉体,以氯化物为原料,氯化钛属高毒类,危害人体健康。以碳酸氢铵或碳酸氢钠为沉淀剂,不控制沉淀的pH。陈向楠等采用共沉淀法合成NdAlO3粉体,以氨水为沉淀剂硝酸盐为原料制备出NdAlO3粉体,其沉淀产物只有Nd(OH)3、Al(OH)3,沉淀离子少,反应简单。研究中介电常数(εr=35~50)微波介质陶瓷有中国专利CN101830697A,名称为:一种中温烧结高Q中介微波陶瓷的制备方法,介电常数(εr=43~46),采用传统固相法制备粉体,采用氧化物预烧分别得到LaAlO3和CaTiO3粉体,烧结后其品质因数Q.f≈40000GHz,品质因数比较低、能耗高、烧结温度高。中国专利CN101565300A,名称为:一种低损耗微波介质陶瓷,介电常数为18~25,Q.f=80000~200000GHz。中国专利CN102603287A、CN102765934A、CN103145412A等,都是运用传统固相法制备的粉体,烧结温度高。常用添烧结助剂的方法来降低烧结温度,但会恶化陶瓷的介电性能。
发明内容
本发明的目的是为了解决传统固相法制备的介质陶瓷烧结温度高、品质因数低等问题,而提供一种中介电常数高性能微波介质陶瓷的制备方法。
本发明目的技术方案为:本发明采用化学式为xRO-(1-x)Ln2O3-(1-x)Al2O3-xTiO2,0.65≤x≤0.75;R为Ca或Sr;Ln为La或Sm,本文采用共沉淀法(两步沉淀)制备xRO-(1-x)Ln2O3-(1-x)Al2O3-xTiO2粉体,粉体活性高,经过不同温度预烧得到所需粉体,粉体晶粒细小、活性高、团聚现象比较严重,在球磨时添加分散剂可使粉体颗粒分散更加均匀,不易团聚,粉体表面活性大,不添加烧结助剂就能降低陶瓷的烧结温度,能在1380~1440℃下烧结成瓷,制备出工艺稳定且性能较优异的微波介质陶瓷:εr=40~50,Q·f=42000~45000,频率温度系数接近于零,已经能够满足制造现代通信技术中基站用的介质腔体滤波器、双工器等微波频率器件。
本发明的具体技术方案为:一种中介电常数高性能微波介质陶瓷的制备方法,其特征在于该微波介质陶瓷材料的组成式为:xRO-(1-x)Ln2O3-(1-x)Al2O3-xTiO2,0.65≤x≤0.75;其中R为Ca或Sr;Ln为La或Sm;其具体步骤如下:
①将浓硝酸稀释后,将分析纯Ln2O3和硝酸铝、RCO3按上述组成称量并倒入硝酸溶液中,在30~60℃温度下用磁力搅拌器搅拌后,得到硝酸盐溶液;
②将溶于乙醇的钛酸四丁酯和第一沉淀剂同时滴入硝酸盐溶液中,并不断搅拌,均匀沉淀,滴定结束后调节pH值为6~8;其中所述第一沉淀剂为稀氨水或氢氧化钠;
③将第二沉淀剂滴入沉淀R(钙或锶)离子,并不断搅拌,滴定结束后调节pH值至7~8,陈腐6~24h;所述第二沉淀剂为碳酸铵或碳酸钠;
④将沉淀反复过滤清洗至上层清液无其它离子,再用离心机或抽滤得到白色沉淀,加入乙醇,烘干,得到前驱体;
⑤将前驱体在预烧保温得到所需混合粉体,添加分散剂球磨,烘干,添加粘结剂造粒,干压成型,等静压(压力为100~300MPa),烧结保温,制得中介电常数高性能微波介质陶瓷。
本发明所制得中介电常数高性能微波介质陶瓷的介电性能:εr=40~50,Q·f=42000~45000GHz,τf=2~8ppm/℃。
所用原料为碳酸锶、碳酸钙、氧化镧、氧化钐、硝酸铝,其纯度≥99.7%,钛酸四丁酯纯度≥99.5%,浓硝酸、氨水、碳酸铵、氢氧化钠、碳酸钠。
优选步骤①制得的硝酸盐溶液的浓度为1~2mol/L。优选溶于乙醇的钛酸四丁酯的浓度为1~2mol/L;所述稀硝酸的摩尔浓度为1~4mol/L。
优选第一沉淀剂与Al3+和Ln3+(Sm3+或La3+)离子的总摩尔比为3~4:1。优选第二沉淀剂与R离子的摩尔比为1~1.1:1。
本发明分为两步沉淀,沉淀过程中先沉淀Ti4+、Al3+、Sm3+(或La3+)离子,待以上离子沉淀结束后再用CO3 2-沉淀Ca2+(或Sr2+)离子。
优选步骤④中无水乙醇加入清洗后的沉淀中,再超声、分散、干燥。且沉淀与乙醇的质量比为1:(2~5)。
优选上述分散剂为PEG、聚乙二醇、聚甲基丙烯酸铵中的一种或多种;加入质量为球磨粉体质量的0.25%~1%。所述的粘结剂优选聚乙烯醇,常规加入量即可。
优选前驱体预烧温度为1000℃~1150℃,保温时间2~6h。预烧后粉体颗粒粒径在50nm~100nm之间。
优选所述的烧结温度为1380~1440℃,保温时间为2~6小时。
球磨介质为ZrO2球或玛瑙球,考虑成本问题本发明采用ZrO2球;
球磨溶剂常为水或酒精,考虑成本问题本发明采用水作为溶剂。
有益效果:
本发明的制备方法为液相法制备粉体,通过共沉淀法制备前驱体,在较低的预烧温度下合成所需粉体,用固相法制备xRO-(1-x)Ln2O3-(1-x)Al2O3-xTiO2粉体的预烧温度高达1250℃,但采用本方法制备的粉体在1000℃预烧就能合成所需粉体,相比以前的工艺,采用共沉淀法能够降低能耗。陶瓷的烧结采用固相反应法,由于共沉淀法制备的粉体颗粒分布均匀、颗粒粒径小对后期陶瓷的烧结也有明显的促进作用,烧结更加致密,烧结温度从1500℃降低到1380℃~1440℃,同时陶瓷的品质因数也有一定的提高。
附图说明
附图1为0.7CaO-0.3Sm2O3-0.3Al2O3-0.7TiO2陶瓷的XRD图;
附图2为0.69CaO-0.31La2O3-0.31Al2O3-0.69TiO2粉体电镜图。
具体实施方式
为了进一步理解发明,下面结合实施例对本发明优选实施方案进行描述,但是应当理解这些描述只是为了进一步说明本发明的特征和优点,而不是对本发明权利要求的限制。
实施例1~3
第一步:按式xCaO-(1-x)La2O3-(1-x)Al2O3-xTiO2(x=0.69、0.71、0.74)配比进行取料。计算所需各分析纯原料的质量;准确称取适量浓硝酸(质量百分数65%),倒入适量去离子水中搅拌制成2mol/L的稀硝酸,再准确称取氧化镧、九水硝酸铝、碳酸钙倒入硝酸溶液中,在30℃下用磁力搅拌器搅拌30分钟后,并配制成2mol/L的第一溶液。按比例称量钛酸四丁酯并加入适量乙醇形成1mol/L的第二溶液,将浓氨水稀释3倍,氨水与La3+、Al3+离子总摩尔比为3:1。称取适量的碳酸铵并配制成2mol/L的沉淀剂。
第二步:将第二溶液和稀氨水滴入第一溶液中,同时不断用搅拌器搅拌,在反应即将结束时用pH计测量液体的pH值,调节pH=7。继续搅拌30分钟。再将碳酸铵溶液匀速滴入,碳酸铵与Ca2+的摩尔比为1:1,不断搅拌,待反应即将结束时用pH计调节pH=7,继续搅拌30分钟。沉淀陈腐6h。
第三步:将沉淀经过4次离心洗涤,通过离心得到白色沉淀,加入无水乙醇(沉淀与乙醇的质量比1:2)超声30分钟并搅拌,在80℃烘箱中烘干。碾磨成粉在1050℃下预烧得到CaTiO3和LaAlO3粉体。
第四步:称取适量的粉体以锆球为球磨介质,水为溶剂,添加PEG200(质量为粉体质量的0.5%)为分散剂,料球比为1:2,转速为200r/min混合球磨6小时后在100℃烘箱里烘干。加入PVA(8wt.%)造粒、压片(Ф12mm×6mm)、等静压,在1440℃烧结,保温3h。
第六步:采用美国安捷仑网络分析仪(型号为HP8722ET),测试介电常数、品质因素及频率温度系数。
图2为0.69CaO-0.31La2O3-0.31Al2O3-0.69TiO2粉体的扫描电镜图(SEM),从图中可以看出通过1050℃预烧后的前驱体,颗粒比较均匀,粒度在50nm~100nm之间,但粉体团聚现象较严重,因此本发明在后期球磨时添加了分散剂使颗粒分散均匀,促进烧结。
表1:陶瓷不同预烧温度、不同x值与性能表
实施例4~9
第一步:按式0.7CaO-0.3Sm2O3-0.3Al2O3-0.7TiO2配比进行取料。计算所需各分析纯原料的质量;准确称取浓硝酸47.5g(质量百分数68%),倒入适量去离子水中搅拌,再准确称取11.209g氧化钐、24.115g九水硝酸铝倒入2mol/L的稀硝酸溶液中搅拌,再称取15g碳酸钙倒入硝酸溶液中,在60℃下用磁力搅拌器搅拌30分钟后,并配制成1mol/L的第一反应液。取适量的乙醇,称量51.048g钛酸四丁酯倒入乙醇中,搅拌制成2mol/L的第二反应液。称取108g氨水将浓氨水稀释4倍为第三反应液。称取碳酸铵并配成0.5mol/L的第四反应液。
第二步:将第二和第三反应液匀速滴入第一反应液中,氨水与Sm3+、Al3+离子总摩尔比为4:1,同时不断用搅拌器搅拌,在反应即将结束时用pH计测量液体的pH值,调节pH=8。继续搅拌30分钟,再将第四反应液匀速滴入,并不断搅拌,碳酸铵与Ca2+的摩尔比为1:1.1,调节pH=8,将沉淀陈腐24h。
第三步:将沉淀经过4~6次离心洗涤,再用离心机得到白色沉淀,加入无水乙醇(沉淀与乙醇的质量比1:5)超声30分钟并搅拌,在80℃烘箱中烘干。碾磨成粉,在1050℃、1100℃下预烧得到SmAlO3和CaTiO3混合粉体。
第四步:取已预烧好的混合粉体,添加聚甲基丙烯酸铵(质量为粉体质量的1%)为分散剂,以水为溶剂球磨6小时,干燥、加入PVA(8wt.%)造粒、压片(Ф12mm×6mm)、等静压,分别在1380℃、1410℃、1440℃烧结,保温3h。
第六步:采用美国安捷仑网络分析仪(型号为HP8722ET),测试介电常数、品质因素及频率温度系数。
图1为具体实施例80.7CaO-0.3Sm2O3-0.3Al2O3-0.7TiO2陶瓷的XRD图,从图中可以看出制备出的样品没有出现杂相,表明陶瓷样品为纯净的0.7CaO-0.3Sm2O3-0.3Al2O3-0.7TiO2陶瓷,具体实施例1~9均能合成纯净的xRO-(1-x)Ln2O3-(1-x)Al2O3-xTiO2固溶体陶瓷。
表2:预烧温度与性能表
Claims (9)
1.一种中介电常数高性能微波介质陶瓷的制备方法,其特征在于该微波介质陶瓷材料的组成式为:xRO-(1-x)Ln2O3-(1-x)Al2O3-xTiO2,0.65≤x≤0.75;其中R为Ca或Sr;Ln为La或Sm;其具体步骤如下:
①将浓硝酸稀释后,将分析纯Ln2O3和硝酸铝、RCO3按上述组成称量并倒入硝酸溶液中,在30~60℃温度下用磁力搅拌器搅拌后,得到硝酸盐溶液;
②将溶于乙醇的钛酸四丁酯和第一沉淀剂同时滴入硝酸盐溶液中,并不断搅拌,均匀沉淀,滴定结束后调节pH值为6~8;其中所述第一沉淀剂为稀氨水或氢氧化钠;
③将第二沉淀剂滴入沉淀R离子,并不断搅拌,滴定结束后调节pH值至7~8,陈腐6~24h;所述第二沉淀剂为碳酸铵或碳酸钠;
④将沉淀反复过滤清洗至上层清液无其它离子,再用离心机或抽滤得到白色沉淀,加入乙醇,烘干,得到前驱体;
⑤将前驱体在预烧保温得到所需混合粉体,添加分散剂球磨,烘干,添加粘结剂造粒,干压成型,等静压(压力为100~300MPa),烧结保温,制得中介电常数高性能微波介质陶瓷。
2.根据权利要求1所述的制备方法,其特征在于:制得中介电常数高性能微波介质陶瓷的介电性能:εr=40~50,Q·f=42000~45000GHz,τf=2~8ppm/℃。
3.根据权利要求1所述的制备方法,其特征在于:步骤①制得的硝酸盐溶液的浓度为1~2mol/L。
4.根据权利要求1所述的制备方法,其特征在于:所述第一沉淀剂与Al3+和Ln3+离子的总摩尔比为3~4:1。
5.根据权利要求1所述的制备方法,其特征在于:所述第二沉淀剂与R离子的摩尔比为1~1.1:1。
6.根据权利要求1所述的制备方法,其特征在于:步骤④中沉淀与乙醇的质量比为1:(2~5)。
7.根据权利要求1所述的制备方法,其特征在于:所述分散剂为PEG、聚乙二醇、聚甲基丙烯酸铵中的一种或多种;加入质量为球磨粉体质量的0.25%~1%。
8.根据权利要求1所述的制备方法,其特征在于:前驱体预烧温度为1000℃~1150℃,保温时间2~6h。
9.根据权利要求1所述的制备方法,其特征在于:所述的烧结温度为1380~1440℃,保温时间为2~6小时。
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