CN110981498A - 提高压电陶瓷蜂鸣片质量的方法 - Google Patents
提高压电陶瓷蜂鸣片质量的方法 Download PDFInfo
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- 239000000919 ceramic Substances 0.000 title claims abstract description 88
- 238000000034 method Methods 0.000 title claims abstract description 42
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 claims abstract description 25
- 229910052709 silver Inorganic materials 0.000 claims abstract description 25
- 239000004332 silver Substances 0.000 claims abstract description 25
- 239000000843 powder Substances 0.000 claims abstract description 15
- 238000005245 sintering Methods 0.000 claims abstract description 14
- 238000001035 drying Methods 0.000 claims abstract description 13
- 229910052751 metal Inorganic materials 0.000 claims abstract description 13
- 239000002184 metal Substances 0.000 claims abstract description 13
- 239000008187 granular material Substances 0.000 claims abstract description 10
- 239000002002 slurry Substances 0.000 claims abstract description 9
- 239000004372 Polyvinyl alcohol Substances 0.000 claims abstract description 7
- 239000000084 colloidal system Substances 0.000 claims abstract description 7
- 238000002156 mixing Methods 0.000 claims abstract description 7
- 229920002451 polyvinyl alcohol Polymers 0.000 claims abstract description 7
- 239000011248 coating agent Substances 0.000 claims abstract description 6
- 238000000576 coating method Methods 0.000 claims abstract description 6
- 238000000227 grinding Methods 0.000 claims abstract description 6
- 238000000462 isostatic pressing Methods 0.000 claims abstract description 6
- 238000007639 printing Methods 0.000 claims abstract description 6
- 238000005520 cutting process Methods 0.000 claims abstract description 5
- 238000003825 pressing Methods 0.000 claims abstract description 4
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- 239000002245 particle Substances 0.000 claims description 6
- 239000011267 electrode slurry Substances 0.000 claims description 5
- 238000000889 atomisation Methods 0.000 claims description 3
- 238000004140 cleaning Methods 0.000 claims description 3
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- 230000003179 granulation Effects 0.000 claims description 3
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- 238000002360 preparation method Methods 0.000 abstract description 6
- 238000011031 large-scale manufacturing process Methods 0.000 abstract 1
- 238000004506 ultrasonic cleaning Methods 0.000 abstract 1
- 230000007547 defect Effects 0.000 description 12
- 238000007796 conventional method Methods 0.000 description 11
- 230000010287 polarization Effects 0.000 description 8
- 238000000498 ball milling Methods 0.000 description 6
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- 238000005336 cracking Methods 0.000 description 3
- 229910052573 porcelain Inorganic materials 0.000 description 3
- 238000005096 rolling process Methods 0.000 description 3
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- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 2
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 2
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 2
- 230000001788 irregular Effects 0.000 description 2
- 238000003475 lamination Methods 0.000 description 2
- ZKATWMILCYLAPD-UHFFFAOYSA-N niobium pentoxide Chemical compound O=[Nb](=O)O[Nb](=O)=O ZKATWMILCYLAPD-UHFFFAOYSA-N 0.000 description 2
- 238000012797 qualification Methods 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 229910052726 zirconium Inorganic materials 0.000 description 2
- 229920000297 Rayon Polymers 0.000 description 1
- GHPGOEFPKIHBNM-UHFFFAOYSA-N antimony(3+);oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[Sb+3].[Sb+3] GHPGOEFPKIHBNM-UHFFFAOYSA-N 0.000 description 1
- 238000001354 calcination Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 229910003460 diamond Inorganic materials 0.000 description 1
- 239000010432 diamond Substances 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
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- XMFOQHDPRMAJNU-UHFFFAOYSA-N lead(II,IV) oxide Inorganic materials O1[Pb]O[Pb]11O[Pb]O1 XMFOQHDPRMAJNU-UHFFFAOYSA-N 0.000 description 1
- 229910052808 lithium carbonate Inorganic materials 0.000 description 1
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Abstract
本发明公开了一种提高压电陶瓷蜂鸣片质量的方法，属于压电陶瓷蜂鸣片制备方法；旨在提供一种既能满足大规模生产的需求、又可提高产品质量的压电陶瓷蜂鸣片制备方法。它包括制备浆料、生坯成型、生坯烧结、银电极被覆、贴片：将压电陶瓷粉体与聚乙烯醇胶体混合均匀，喷雾、干燥，得到团粒；团粒装入模具中，采用等静压工艺压制成棒料生坯，烧结；磨削压电陶瓷棒体外圆，然后将其切割成薄片；超声清洗、烘干，表面印刷银浆，烧银；被覆银电极压电陶瓷片与金属片粘合，烘干固化。本发明方法制备的蜂鸣片具有阻抗小、容量大频率飘逸量小等优点，是一种至制备压电陶瓷蜂鸣片的方法。
Description
技术领域
本发明涉及一种频率精度范围在±0.2KHz以内的压电陶瓷蜂鸣片的制备方法，尤其涉及一种提高压电陶瓷蜂鸣片质量的方法；属于电子元器件的制备方法。
背景技术
压电陶瓷蜂鸣片因其具有体积小、重量轻、功耗低、可靠性高、寿命长，以及可以适应恶劣工作环境等特点，被广泛应用于环境工程、医疗器械、汽车工业、安防﹑工业报警设备﹑家用电器以及军用元件等领域。
目前，压电陶瓷蜂鸣片制备工艺流程通常是：配料-球磨-煅烧-二次球磨-生坯成型（流延或轧膜制备成膜带、冲压成薄片）-叠片烧结-瓷片外观分选-印刷银电极-烧银-极化-银片外观分选-金属片粘贴。整个制备工艺过程存在以下问题：
1﹑生坯成型过程：流延工艺虽然比较简单，可制备厚度为5-25μm的薄带，但烧结成瓷后收缩率大（约20%）、形状不规则、密度低等缺陷。而轧膜工艺虽然密度高，适合生产厚度为0.05mm~1mm薄带；但烧结成瓷后同样存在横向收缩大、易产生变形（一般为不规则椭圆形）等缺陷，且易开裂，效率较低。
2、生坯烧结过程：采用多片叠堆的方式烧结，容易产生变形、翘曲、开裂、片与片之间粘黏等现象；需要大量的人工进行剥片和分选，合格率低、人工成本高。
3﹑被覆银电极过程：由于压电陶瓷片存在变形、翘曲和不平整等缺陷，不仅容易造成印刷电极与瓷片不同心，而且丝网印刷银电极浆料时刮板容易压碎翘曲的瓷片。
4﹑极化过程：由于压电陶瓷片存在翘曲、不平整等缺陷，堆叠施加高电压时容易在瓷片之间产生电弧而将瓷片击穿或造成极化不充分等缺陷。
5、金属片粘贴过程：由于压电陶瓷片存在不规则、翘曲等缺陷，因此难以保证压电陶瓷片与金属片同心贴合，产品性能一致差。
发明内容
为了克服现有技术中存在的上述缺陷，本发明旨在提供一种提高压电陶瓷蜂鸣片质量的方法；利用该方法制备频率精度高（±0.2KHz）的压电陶瓷蜂鸣片时，可有效克服传统方法制备瓷片生坯致密度一致性差，烧结易变形、易粘连、易开裂，银电极被覆质量差，极化合格率低，贴片质量差等诸多缺陷。
为了实现上述目的，本发明方法所采用的技术方案包括制备陶瓷浆料、陶瓷生坯成型、生坯排胶烧结、银电极被覆、贴片，具体方法如下：
1）将压电陶瓷粉体与聚乙烯醇胶体按100:1-6的重量比混合均匀，得陶瓷浆料；
2）通过喷雾器把所述陶瓷浆料喷入造粒塔中进行雾化、干燥，得到粒径为2-8μm的团粒；
3）将所述团粒装入模具中，采用等静压工艺压制成圆柱形棒料生坯，等静压压力为100-300Mpa；
4）将所述棒料生坯在1260℃条件下烧结18小时，得压电陶瓷棒体；
5）磨削所述压电陶瓷棒体外圆至所需尺寸，然后将其切割成所需厚度的薄片，得压电陶瓷片；
6）超声清洗所述压电陶瓷片，烘干；
7）在经过清洗的压电陶瓷片表面印刷银电极浆料，然后在830℃条件下烧银，得被覆银电极压电陶瓷片；
8）用粘胶将所述被覆银电极压电陶瓷片与金属片粘合，然后在90℃条件下烘干固化6小时。
与现有技术比较，本发明采用上述技术方案，因此具有以下优点：
1、利用静压工艺形成棒料状生坯，不仅提高了生坯的密度、保证生坯个部分的致密度均匀，而且还提高了生产效率；既克服了流延工艺膜坯密度小、易产生气孔的缺陷，又克服了轧膜工艺生产率低的缺陷。试验表明，采用本发明方法制备的压电陶瓷密度可达7.6g/cm3左右。
2、由于棒料生坯烧制成为瓷棒料后要进行外圆磨削，因此不仅可以磨削消除传统工艺烧结过程中易产生收缩变形、翘曲变形等缺陷，而且还能提高陶瓷片的几何尺寸精度（直径精度可达±0.005mm）。
3、由于先将棒料生坯烧制成瓷棒后再进行切割，因此既可彻底避免传统堆叠烧结工艺容易产生变形、翘曲、开裂、片与片之间粘黏等现象，又能提高陶瓷片的几何尺寸精度（厚度尺寸精度可达±0.003mm）。
4、在被覆银电极过程中，由于压电陶瓷片不存在外圆变形、表面翘曲和不平整等常见缺陷，因此彻底避免了传统工艺在印刷电极浆料时电极面与瓷片不同心、翘曲瓷片易被压碎等缺陷。
5、在极化过程中，由于压电陶瓷片表面比较平整，因此堆叠施加高电压时，压电陶瓷片之间不会产生电弧，极化处理均匀、充分。
6、在金属片粘贴过程中，由于瓷片几何尺寸好，因此能够利用自动贴片机实现瓷片与金属片同心贴合；既提高了贴片效率、又能够保证产品性能一致。
具体实施方式
下面结合具体的实施例对本发明作进一步说明：
实施例1，制备蜂鸣片规格：金属片规格为Φ27mm×0.18mm，压电陶瓷片规格为Φ20mm×0.15mm，两者贴合后蜂鸣片的频率要求3.2KHz±0.5KHz。
1）按常规方法制备压电陶瓷粉体：
1.1）一次球磨：将Pb3O4、ZrO2、TiO2、Sb2O3、Nb2O5、NiO、MgO、Li2CO3等原料粉体按常规方法混合，然后再与无水乙醇、锆球按常规方法混合、球磨，按常规方法烘干、过筛，得生瓷粉；
1.2）预烧：将所述生瓷粉按常规方法烧结，冷却后过筛，得瓷粉；
1.3）二次球磨：将所述瓷粉按常规方法与无水乙醇、锆球混合、球磨，然后烘干、过筛，得压电陶瓷粉体；
2）将所述压电陶瓷粉体与聚乙烯醇胶体按100:1的重量比混合均匀，得陶瓷浆料；
3）通过喷雾器把所述陶瓷浆料喷入造粒塔中进行雾化、干燥，得到粒径为2μm的团粒；
4）将所述团粒装入模具中，采用等静压工艺将其压制成Φ23.2mm×130mm的棒料生坯；保证等静压压力100Mpa，保压10min；
5）将所述棒料生坯在1260℃条件下烧结18小时，得压电陶瓷棒体；
6）磨削所述压电陶瓷棒体外圆至Φ20mm，然后利用金刚石线锯切割机将其切割成0.15mm厚的薄片，得压电陶瓷片；
7）按常规方法超声清洗所述压电陶瓷片，烘干；
8）按常规方法在经过清洗的压电陶瓷片表面印刷银电极浆料，然后在830℃的隧道式炉中按常规方法烧银，得被覆银电极压电陶瓷片；
9）按常规方法将所述被覆银电极压电陶瓷片进行叠片极化处理；
10）按常规方法用粘胶将经过极化处理的压电陶瓷片与金属片粘合，然后在90℃条件下烘干固化6小时。
随机抽取本实施例制备的蜂鸣片以及传统工艺制备的蜂鸣片各50片，对谐振频率﹑谐振阻抗﹑容量范围等性能进行测试，测试数据件表1。
表1：本发明与传统方法制备的蜂鸣片电性能指标对照表
实施例2，制备蜂鸣片规格：金属片规格为Φ34.7mm×0.30mm，压电陶瓷片规格为Φ25mm×0.246mm，两者贴合后蜂鸣片的频率要求3.45KHz±0.5KHz。
各步骤同实施例1。其中，步骤2）中的压电陶瓷粉体与聚乙烯醇胶体的重量比为100:6；步骤3）中的团粒粒径为8μm；步骤4）中的棒料生坯的外形尺寸为Φ29.0mm×130mm，等静压压力300Mpa；步骤6）中压电陶瓷棒体的外圆直径为Φ25mm，压电陶瓷片的厚度为0.30mm。
随机抽取本实施例制备的蜂鸣片以及传统工艺制备的蜂鸣片各50片，对谐振频率﹑谐振阻抗﹑容量范围等性能进行测试，测试数据件表2。
表2：本发明与传统方法制备的蜂鸣片电性能指标对照表
实施例3，制备实施例1中蜂鸣片。
各步骤同实施例1。其中，步骤2）中的压电陶瓷粉体与聚乙烯醇胶体的重量比为100:3；步骤3）中的团粒粒径为5μm；步骤4）中的等静压压力200Mpa。
实施例4，制备实施例2中蜂鸣片。
各步骤同实施例1。其中，步骤2）中的压电陶瓷粉体与聚乙烯醇胶体的重量比为100:4；步骤3）中的团粒粒径为4μm；步骤4）中的等静压压力150Mpa。
从表1-2可以看出：本发明方法制备的蜂鸣片，其谐振阻抗明显小于传统方法制备的蜂鸣片、其容量大于或等于传统方法制备的蜂鸣片；其谐振频率范围小于额定指标，因此频率飘逸量小、稳定性好。
Claims (1)
1.一种提高压电陶瓷蜂鸣片质量的方法，包括制备陶瓷浆料、陶瓷生坯成型、生坯排胶烧结、银电极被覆、贴片，其特征在于方法如下：
1）将压电陶瓷粉体与聚乙烯醇胶体按100:1-6的重量比混合均匀，得陶瓷浆料；
2）通过喷雾器把所述陶瓷浆料喷入造粒塔中进行雾化、干燥，得到粒径为2-8μm的团粒；
3）将所述团粒装入模具中，采用等静压工艺压制成圆柱形棒料生坯，等静压压力为100-300Mpa；
4）将所述棒料生坯在1260℃条件下烧结18小时，得压电陶瓷棒体；
5）磨削所述压电陶瓷棒体外圆至所需尺寸，然后将其切割成所需厚度的薄片，得压电陶瓷片；
6）超声清洗所述压电陶瓷片，烘干；
7）在经过清洗的压电陶瓷片表面印刷银电极浆料，然后在830℃条件下烧银，得被覆银电极压电陶瓷片；
8）用粘胶将所述被覆银电极压电陶瓷片与金属片粘合，然后在90℃条件下烘干固化6小时。
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